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An integrated lightweight structure and thermal insulation has been developed for the Mars Rover Warm Electronics Box (WEB). It combines a low thermal conductivity fiber reinforced composite structure with co-cured thermal control surfaces and an ultralightweight hydrophobic solid silica aerogel which eliminates convection and minimizes conduction and radiation. It provides excellent thermal insulation both at low gas pressures and in vacuum; and meets the structural requirements for spacecraft launch loads and for a 60 g impact landing at Mars without damage to the insulation or structure. The integrated design provides for variable conductance to meet the different thermal requirements for the different phases of operation. The system incorporates heat conduction paths to provide thermal control on the ground and during interplanetary cruise, which are then disconnected for Mars operation.

The Mars Rover has a lightweight integrated structure/insulation that has been environmentally tested and qualified for the 1996 launch for the Pathfinder mission to Mars. The basic structure with insulation, called the Warm Electronics Box (WEB), accounts for only 10% of the total Rover mass. The WEB is a thermal isolating composite structure with co-cured thermal control surfaces and an ultralightweight hydrophobic solid silica aerogel which minimizes conduction and radiation. This design provides excellent thermal insulation at low gas pressures and meets the structural requirements for spacecraft launch loads and for a 60 g impact landing at Mars without damage to the insulation or structure. The Rover design has been thermally qualified in a series of both static and transient thermal-vacuum testing in vacuum and 8 torr wind environments simulating all predicted environmental conditions.