4 ways our modernized C-130 insulation system reduces corrosion

Nearly 30% of the maintenance costs for C-130s are corrosion-related, and the lion’s share of those costs are hull/frame-related. One of the key contributors to the corrosion problem is an outdated insulation system. That old system traps moisture between the insulation and the airframe, leading to corrosion, mold, mildew, etc. Additionally, the old system makes inspection of the hull and frame both cumbersome and time-consuming, preventing early detection of corrosion.

After many years of R&D, Cocoon has modernized each element of the system – batting, blankets, and attachment, greatly reducing the risk of corrosion by:

1. Preventing moisture from building up between the insulation and the airframe

The key to the modernized insulation system is the use of advanced technical textiles which are highly air-permeable. What that means is moisture can escape as vapor. Air-permeability is a feature of both the batting and blankets. (For more on air-permeability, click here.)

2. Making hull/frame inspection much easier and far faster

The updated and upgraded attachment system makes the airframe much easier to inspect. There’s no need for using hook & loop strips glued to the hull because the batting compresses between the ribs to stay in place. It’s both secure and easy to remove. Inspections can be done in a fraction of the time it takes with the old system and is much less of a hassle – making it possible for more frequent and thorough inspections of the hull/frame.

3. Making the materials field repairable

Both the batting and blankets are designed to be easily repaired in the field. In the old system, rips and tears in either the batting or blanket results in the use of improper materials (e.g. duct tape), simply living with the defect, or removing the piece entirely. With the new system, a supplied repair kit includes spare fabric which can be easily ironed into place with the provided iron. This prevents moisture or contaminants from entering a rip or tear.

4. Creating documentation and a robust supply chain for replacement parts

Currently, replacing a missing blanket is difficult, if not impossible. There are no drawings or part numbers, which means it’s easier to live with soiled, torn, and degraded components than find new ones. The resulting contaminants contribute to and accelerate corrosion. The new system includes full documentation, including part numbers for each piece of batting and every blanket panel, and a robust supply chain that makes replacement easy – ensuring the integrity of the full system.

It’s fair to say that the C-130 insulation system hasn’t just been modernized, it’s been revolutionized. The result is reduced risk of corrosion, increased readiness, lower maintenance costs, and improved performance.