Precursor compositions for a protective article, protective articles comprising a reaction product of the precursor composition, related aerospace structures, and related methods

A protective article, comprising:

• a foamed protective material comprising a reaction product of a precursor composition comprising:
• a primary polymer in an amount of from about 65.0% by weight to about 80.0% by weight based on a total weight of the precursor composition, wherein the primary polymer is an acrylic ethylene monomer (AEM);
• expanded microspheres;
• a strengthening additive in an amount of from about 2% by weight to about 20% by weight based on the total weight of the precursor composition, wherein the strengthening additive comprises one or more of nanotubes, platelets, rods, or disks of one or more of carbon, glass, metal, or ceramic;
• a peroxide curing agent and a peroxide cure accelerator;
• and
• one or more additional additives comprising a thermal ablation additive, a reflectivity additive, or an x-ray absorption additive;
• wherein the precursor composition is free of an amine curing agent;
• and
• wherein the foamed protective material exhibits a density of from about 0.1 g/ml to about 1.0 g/ml.

An aerospace structure comprising:

• a protective article on at least a portion of an external surface of an aerospace structure, the protective article comprising a foamed protective material comprising a reaction product of a precursor composition comprising:
• a primary polymer in an amount of from about 65.0% by weight to about 80.0% by weight based on a total weight of the precursor composition, wherein the primary polymer is an acrylic ethylene monomer (AEM);
• expandable microspheres;
• a strengthening additive in an amount of from about 2% by weight to about 20% by weight based on the total weight of the precursor composition, wherein the strengthening additive comprises one or more of nanotubes, platelets, rods, or disks of one or more of carbon, glass, metal, or ceramic;
• a peroxide curing agent and a peroxide cure accelerator;
• and
• one or more additional additives comprising a thermal ablation additive, a reflectivity additive, or an x-ray absorption additive;
• and
• wherein the precursor composition is free of an amine curing agent.

A method of forming a protective article, comprising:

• forming a precursor composition comprising:
• a primary polymer in an amount of from about 65.0% by weight to about 80.0% by weight based on a total weight of the precursor composition, wherein the primary polymer is an acrylic ethylene monomer (AEM);
• a foaming agent comprising expandable microspheres;
• a strengthening additive in an amount of from about 2% by weight to about 20% by weight based on the total weight of the precursor composition, wherein the strengthening additive comprises one or more of nanotubes, platelets, rods, or disks of one or more of carbon, glass, metal, or ceramic;
• a peroxide curing agent and a peroxide cure accelerator;
• and
• one or more additional additives comprising a thermal ablation additive, a reflectivity additive, or an x-ray absorption additive;
• wherein the precursor composition is free of an amine curing agent;
• and exposing the precursor composition to heat to form a foamed protective article.