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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Insulation Activation and Contamination in Low-Power Experiments

Among the diverse advanced nuclear reactor concepts being developed are designs that expect to operate at much higher temperatures than conventional light-water reactors, and therefore require alternative materials for components capable of withstanding these extreme temperatures. Insulation is one such component where alternative high-temperature industrial composites are being considered. Low-power experiments can provide an opportunity for advancing our understanding of material behavior under irradiation; however, these experiments are not without occupational hazards. The focus of this paper is the potential for activation of insulating composites when exposed to neutron fluence during reactor experiments, and to discuss the subsequent contamination of the testing area. This paper will also discuss practical measures for preventing the creation and inhalation of activated particulate matter (i.e., dust), such as engineering and administrative controls and personal protective equipment. This paper evaluates the suitability of several insulation materials for use in reactor experiments based on their activation from neutron irradiation. The materials considered are Pyrogel XTE by Aspen Aerogel, Cerablanket and Kaowool by Morgan Advanced Materials, Thermo-12 Gold by Johns Manville, and Maxsil CF6-2000 by McAllister Mills. Although these materials are not yet widely used in the nuclear industry, they are common in other industries due to their thermal insulating properties. These materials produce dust while handling that can pose health and safety hazards, which could be further exacerbated by activation. The analysis presented in this paper utilizes a deterministic method developed to predict the activation source term of the provided insulation materials. The method calculates the atomic density of each element within the composites and simulates their exposure to a specified neutron flux density representative of low power experimental conditions. During the irradiation phase and throughout the extensive cooling period, neutron absorptions and nuclear decays are tracked for relevant isotopes. The residual activity within each composite is then assessed to identify the material with the lowest potential radiological hazard to workers. Dust will be created during installation and removal of insulating materials and may also be generated during the experiment. Contamination of surrounding surfaces due to dispersion is highly likely unless preventative measures are taken. The results of this analysis are used to estimate an internal dose from inhalation of activated dust, which is significantly lower than the allowable whole-body dose. However, the risk of internal exposure may increase if the dust becomes a transport vector for nuclear material. The goals of this paper are to enhance the understanding of the potential activation and contamination hazards from the use of these insulating materials in low-power nuclear experiments and to foster safer work environments through informed decision-making and strategic planning. This work ultimately contributes to a broader understanding of how new non-nuclear materials for advanced reactors impact the radiological safety of co-located workers, helping to ensure the responsible management of radioactive materials during installation and decommissioning activities.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗
DOE OSTI2018

Structural and metal-insulator transitions in rhenium-based double perovskites via orbital ordering

Re-based double perovskites (DPs) have garnered substantial attention due to their high Curie temperatures (T C ) and display of complex interplay of structural and metal-insulator transitions (MIT). In this report we systematically study the ground-state electronic and structural properties for a family of Re-based DPs A 2 BReO 6 (A=Sr, Ca and B=Cr, Fe), which are related by a common low-energy Hamiltonian, using density functional theory +U calculations. We show that the on-site interaction U of Re induces orbital ordering (denoted C-OO), with each Re site having an occupied d xy orbital and a C-type alternation among d xz /d yz , resulting in an insulating state consistent with experimentally determined insulators Sr 2 CrReO 6 , Ca 2 CrReO 6 , and Ca 2 FeReO 6 . The threshold value of U Re for orbital ordering is reduced by inducing E g octahedral distortions of the same C-type wavelength (denoted C-OD), which serves as a structural signature of the orbital ordering; octahedral tilting also reduces the threshold. The C-OO and the concomitant C-OD are a spontaneously broken symmetry for the Sr-based materials (i.e., a 0 a 0 c - tilt pattern), while not for the Ca-based systems (i.e., a - a - b + tilt pattern). Spin-orbit coupling does not qualitatively change the physics of the C-OO/C-OD, but can induce relevant quantitative changes. We prove that a single set of U Cr , U Fe , U Re capture the experimentally observed metallic state in Sr 2 FeReO 6 and insulating states in other three systems. We predict that the C-OO is the origin of the insulating state in Sr 2 CrReO 6 , and that the concomitant C-OD may be experimentally observed at sufficiently low temperatures (i.e., space group P4 2 /m) in pure samples. Additionally, given our prescribed values of U, we show that the C-OO induced insulating state in Ca 2 CrReO 6 will survive even if the C-OD amplitude is suppressed (e.g., due to thermal fluctuations). The role of the C-OO/C-OD in the discontinuous, temperature driven MIT in Ca 2 FeReO 6 is discussed.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Cryogenic Insulation Solutions for the Surface of Mars with Its Unique Environments

The surface of Mars provides unique challenges for cryogenic insulation systems and for cryogenic spacecraft traveling there. In order to store cryogenic fluids for propulsion, life support, and other applications on the surface of Mars one must protect the insulation from the array of unique environmental factors that are present. Travel to Mars is a very energy intensive endeavor and landing on the surface requires launching over 200 kg of propellant and spacecraft per kilogram landed. As such, high performance, lightweight insulations are needed for cryogenic systems to be used on the surface. Traditional spacecraft use multilayer insulation that works well in a vacuum, but Mars has an atmospheric of pressure approximately 7 torr, consisting of approximately 95 % carbon dioxide. Based on analysis and trade studies NASA has shown that the mass savings from the higher performance of multilayer insulation with a vacuum jacket saved several hundred kilograms of mass for a typical human Mars ascent stage. Thus NASA, along with several contractors, have been developing a lightweight vacuum jacketed system for the 7 torr environment. This lightweight vacuum jacketed system must survive launch from earth, travel to Mars, and on the surface for several years. On the surface, it must be able to survive landing, natural environmental occurrences such as dust storms, and temperature cycling with minimal if any human maintenance. The insulation systems under development have been exposed to an array of tests to demonstrate their capability to survive these environments while still providing the high performance required to meet mission needs.

Cryogenic Fluid Management↗
DOE OSTI2025

Structure-property relationships and recyclability of natural fiber insulation

Thermal insulation can significantly decrease the energy required to maintain internal temperatures within buildings, saving money and decreasing environmental impacts. Many industrially available insulation options utilize petroleum-derived materials, such as polyurethane, fiberglass, and polystyrene, which can be detrimental to the environment by emitting greenhouse gases during production. A sustainable alternative to these synthetic insulations is the use of renewable feedstocks to produce comparable insulation products. In this work, natural fibers such as flax and banana were bound with an epoxy system to produce natural-fiber insulation. Key experimental parameters for this study included evaluating the fiber lengths and processing methods while varying the viscosity of the epoxy binder solvent dissolution. Insulation performance was determined by comparing density, thermal conductivity, resilience, and compressive strength; these parameters were tested to further understand and investigate the structure- property relationships within the system and to understand how these composites compare to current commercial materials. Furthermore, from this characterization and optimization, a natural fiber sample with an R/in. >5 was achieved, making these materials competitive with commercial alternatives.

Compressive strength↗
DOE OSTI2021

Performance evaluation of a dynamic wall integrated with active insulation and thermal energy storage systems

Thermal energy storage systems in buildings can store cooling/heating energy during non-peak load hours or when renewable energy sources are available for later use when demanded. Using the building envelope as a thermal battery can help to shave the peak load, reduce the burden in electric grids, and enhance the occupant's thermal comfort. Sensible energy storage on wall systems such as thermally activated building systems can provide an active thermal storage strategy. However, most of the stored energy is used through passive means directed by the thermal lag, which can impede the on-demand release of the stored energy. Integrating active insulation systems with building thermal storage systems can increase the flexibility of charging and discharging time and duration. In this study, a wall system equipped with an active insulation system and thermally activated storage system was designed, and its performance on active cooling energy contribution was studied. The performances of energy storage (charging), release (discharging) of the thermal energy storage energy, and the active insulation system were studied separately and together as an integrated system. Results showed that the thermal properties of the thermal energy storage core material and the pipe spacing of both embedded pipes in the thermal energy storage and hydronic pipes used in the active insulation system affected the wall performance the most out of all the tested wall system parameters. During discharging, the heat flux into the wall was as high as 81.92 W/m 2 . This active insulation system's dynamic R-value varied between less than 1ft 2 •°F•h/BTU (0.18 m 2 •K/W) to 98% of the equally thick foam insulation's R-value.

25 ENERGY STORAGE↗
DOE OSTI2022

Condition assessment of cable insulation materials in advanced reactor environments

While existing cable insulation materials are sufficient for use in the current reactor fleet, environmental conditions inside some advanced reactors, such as small modular reactors, will be substantially harsher. The work herein was conducted to assess the performance and overall survivability of several high-temperature, radiation resistant insulation polymers in a simulated small modular reactor environment. The materials evaluated under this research include polyether ether ketone, polyimide, and silicone rubber. These polymers were subjected to 1000 h of environmental stress exposure under two different conditions: 1) high temperature (i.e., 250 °C) in atmospheric pressure and 2) high temperature in a low-pressure vacuum (i.e., less than 2 psia). During the environmental exposure process, each insulation was periodically tested using several materials characterization techniques including Fourier transform infrared spectroscopy, oxidation induction time, and oxidation induction temperature. The objective of this testing was to assess and monitor changes that occurred in the thermal and chemical properties of the materials during the environmental exposures. The overall survivability of each insulation was assessed based on these property changes. The results of this research revealed that the polyimide and polyether ether ketone insulations had significantly better thermal and chemical stability than the silicone rubber during both the high-temperature atmospheric and vacuum exposures. Both polyimide and polyether ether ketone experienced minimal reductions in their chemical and thermal properties over the course of 1000 h in the simulated environments. Finally, based on this research, polyimide and polyether ether ketone show promise as potential base materials for small modular reactor cable insulation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Electric control of a canted-antiferromagnetic Chern insulator

Abstract The interplay between band topology and magnetism can give rise to exotic states of matter. For example, magnetically doped topological insulators can realize a Chern insulator that exhibits quantized Hall resistance at zero magnetic field. While prior works have focused on ferromagnetic systems, little is known about band topology and its manipulation in antiferromagnets. Here, we report that MnBi 2 Te 4 is a rare platform for realizing a canted-antiferromagnetic (cAFM) Chern insulator with electrical control. We show that the Chern insulator state with Chern number C = 1 appears as the AFM to canted-AFM phase transition happens. The Chern insulator state is further confirmed by observing the unusual transition of the C = 1 state in the cAFM phase to the C = 2 orbital quantum Hall states in the magnetic field induced ferromagnetic phase. Near the cAFM-AFM phase boundary, we show that the dissipationless chiral edge transport can be toggled on and off by applying an electric field alone. We attribute this switching effect to the electrical field tuning of the exchange gap alignment between the top and bottom surfaces. Our work paves the way for future studies on topological cAFM spintronics and facilitates the development of proof-of-concept Chern insulator devices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Load responsive multilayer insulation performance testing

Cryogenic insulation designed to operate at various pressures from one atmosphere to vacuum, with high thermal performance and light weight, is needed for cryogenically fueled space launch vehicles and aircraft. Multilayer insulation (MLI) performs well in a high vacuum, but the required vacuum shell for use in the atmosphere is heavy. Spray-on foam insulation (SOFI) is often used in these systems because of its light weight, but can have a higher heat flux than desired. We report on the continued development of Load Responsive Multilayer Insulation (LRMLI), an advanced thermal insulation system that uses dynamic beam discrete spacers that provide high thermal performance both in atmosphere and vacuum. LRMLI consists of layers of thermal radiation barriers separated and supported by micromolded polymer spacers. The spacers have low thermal conductance, and self-support a thin, lightweight vacuum shell that provides internal high vacuum in the insulation. The dynamic load responsive spacers compress to support the external load of a vacuum shell in one atmosphere, and decompress under reduced atmospheric pressure for lower heat leak. Structural load testing was performed on the spacers with various configurations. LRMLI was installed on a 400 liter tank and boil off testing with liquid nitrogen performed at various chamber pressures from one atmosphere to high vacuum. Testing was also performed with an MLI blanket on the outside of the LRMLI.

42 ENGINEERING↗
DOE OSTI2021

Noncompact atomic insulators

Here we study the conditions for Bloch bands to be spanned by symmetric and strictly compact Wannier states that have zero overlap with all lattice sites beyond a certain range. Similar to the characterization of topological insulators in terms of an algebraic (rather than exponential) localization of Wannier states, we find that there may be impediments to the compact localization even of topologically “trivial” obstructed atomic insulators. These insulators admit exponentially localized Wannier states centered at unoccupied orbitals of the crystalline lattice. First, we establish a sufficient condition for an insulator to have a compact representative. Second, for $\mathscr{C}_2$ rotational symmetry, we prove that the complement of fragile topological bands cannot be compact, even if it is an atomic insulator. Third, for $\mathscr{C}_4$ symmetry, our findings imply that there exist fragile bands with zero correlation length. Fourth, for a $\mathscr{C}_3$-symmetric atomic insulator, we explicitly derive that there are no compact Wannier states overlapping with less than 18 lattice sites. We conjecture that this obstruction generalizes to all finite Wannier sizes. Our results can be regarded as the stepping stone to a generalized theory of Wannier states beyond dipole or quadrupole polarization.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Polymorphous band structure model of gapping in the antiferromagnetic and paramagnetic phases of the Mott insulators MnO, FeO, CoO, and NiO

The existence of band gaps in both the antiferromagnetic (AFM) and paramagnetic (PM) phases of the classic NaCl-structure Mott insulators MnO, FeO, CoO, and NiO is traditionally viewed and taught as a manifestation of strong correlation whereby insulation results from electrons moving across the lattice forming states with doubly occupied d orbitals on certain atomic sites and empty d orbitals on other sites. Within such theories, the gap of the AFM and PM phases of these oxides emerges even in the absence of spatial symmetry breaking. The need for such a correlated picture is partially based on the known failure of the commonly used band models for the PM phase that assume for such a spin disordered state the macroscopically averaged NaCl structure, where all transition metal (TM) sites are symmetry-equivalent (a monomorphous description), producing a gapless PM state with zero magnetic moments, in sharp conflict with experiment. Here, we seek to understand the minimum theoretical description needed to capture the leading descriptors of ground state Mott insulation in the classic, 3d monoxide Mott systems—gapping and moment formation in the AFM and PM phase. As noted by previous authors, the spin-ordered AFM phase in these materials already shows in band theory a significant band gap when one doubles the NaCl unit cell by permitting different potentials for transition-metal atoms with different spins. For the spin-disordered PM phase, we allow analogously larger NaCl-type supercells where each TM site can have different spin direction and local bonding environments (i.e., disordered), yet the total spin is zero. Such a polymorphous description has the flexibility to acquire symmetry-breaking energy-lowering patterns that can lift the degeneracy of the d orbitals and develop large on-site magnetic moments without violating the global, averaged NaCl symmetry. Electrons are exchanged between spin-up and spin-down bands to create closed-shell insulating configurations that lend themselves to a single determinental description. It turns out that such a polymorphous description of the structure within the single-determinant, mean-field, Bloch periodic band structure approach (based on DFT+U) allows large on-site magnetic moments to develop spontaneously, leading to significant (1–3 eV) band gaps and large local moments in the AFM and PM phases of the classic NaCl-structure Mott insulators MnO, FeO, CoO, and NiO in agreement with experiment. We adapt to the spin disordered polymorphous configurations the “special quasirandom structure” (SQS) construct known from the theory of disordered substitutional alloys whereby supercell approximants which represent the best random configuration average (not individual snapshots) for finite (64, 216 atoms, or larger) supercells of a given lattice symmetry are constructed. We conclude that the basic features of these paradigmatic Mott insulators can be approximated by the physics included in energy-lowering symmetry broken DFT.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Delocalization Transition of a Disordered Axion Insulator

The axion insulator is a higher-order topological insulator protected by inversion symmetry. We show that, under quenched disorder respecting inversion symmetry on average, the topology of the axion insulator stays robust, and an intermediate metallic phase in which states are delocalized is unavoidable at the transition from an axion insulator to a trivial insulator. We derive this conclusion from general arguments, from classical percolation theory, and from the numerical study of a 3D quantum network model simulating a disordered axion insulator through a layer construction. We find the localization length critical exponent near the delocalization transition to be ν = 1.42 ± 0.12. We further show that this delocalization transition is stable even to weak breaking of the average inversion symmetry, up to a critical strength. Finally, we also quantitatively map our quantum network model to an effective Hamiltonian and we find its low-energy k ∙ p expansion.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Insulation Coordination Design for Grid-Connected Solid-State Transformers

The deployment of solid-state transformers (SSTs) in medium-voltage (MV) distribution systems is facing various challenges, especially the challenge of insulation coordination design against grid-originated lightning impulses. In this article, two challenges in existing insulation coordination designs for grid-connected SSTs are identified. One challenge is the mismatch between metal-oxide varistor (MOV) protective levels and SST insulation strength, the other challenge is the incompatibility of standard impulse test on SST protective structures. To address the MOV selection challenge, a novel lightning protection scheme is designed to protect a single-stage SST where the semiconductor modules are directly exposed to external lightning impulses. Here, the in-lab lightning impulse tests are performed to verify the overvoltage attenuation performance of the prototyped lightning protection scheme. To address the impulse test challenge, the surge withstand capability of the protected SST is comprehensively evaluated with a complete set of insulation coordination design procedures beyond the basic insulation level (BIL) test. After these two challenges are addressed, a discussion is presented on substituting conventional transformers with the protected SSTs into insulation-coordinated distribution systems to facilitate the field deployment of SSTs.

solid-state transformer (SST)↗
DOE OSTI2013

External Insulation of Masonry Walls and Wood Framed Walls

Exterior insulation is an effective means for increasing the overall thermal resistance of wall assemblies. It also has other advantages including improved water management and often increased airtightness of the building. The engineering basis and support work for exterior insulation, however, has not been conducted, resulting in obstacles for building official and building code acceptance. Additionally, water management strategies and integration practices for window systems, door systems, decks, balconies, and roof wall intersections have not been adequately developed. This gap also stands in the way of wider deployment. In this research project, the Building Science Corporation (BSC) developed baseline engineering analysis to support the installation of thick layers of exterior insulation (2 in. to 8 in.) on existing masonry walls and wood framed walls. Wood furring strips (fastened through the insulation back to the structure) were used as a cladding attachment location. Water management details necessary to connect the exterior insulated wall assemblies to roofs, balconies, decks, and windows were created as guidance for integrating exterior insulation strategies with other enclosure elements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2013

Advanced Insulation for High Performance Cost-Effective Wall, Roof, and Foundation Systems Final Report

The objective of this project was to explore and potentially develop high performing insulation with increased R/inch and low impact on climate change that would help design highly insulating building envelope systems with more durable performance and lower overall system cost than envelopes with equivalent performance made with materials available today. The proposed technical approach relied on insulation foams with nanoscale pores (about 100 nm in size) in which heat transfer will be decreased. Through the development of new foaming methods, of new polymer formulations and new analytical techniques, and by advancing the understanding of how cells nucleate, expand and stabilize at the nanoscale, Dow successfully invented and developed methods to produce foams with 100 nm cells and 80% porosity by batch foaming at the laboratory scale. Measurements of the gas conductivity on small nanofoam specimen confirmed quantitatively the benefit of nanoscale cells (Knudsen effect) to increase insulation value, which was the key technical hypotheses of the program. In order to bring this technology closer to a viable semi-continuous/continuous process, the project team modified an existing continuous extrusion foaming process as well as designed and built a custom system to produce 6" x 6" foam panels. Dow demonstrated for the first time that nanofoams can be produced in a both processes. However, due to technical delays, foam characteristics achieved so far fall short of the 100 nm target set for optimal insulation foams. In parallel with the technology development, effort was directed to the determination of most promising applications for nanocellular insulation foam. Voice of Customer (VOC) exercise confirmed that demand for high-R value product will rise due to building code increased requirements in the near future, but that acceptance for novel products by building industry may be slow. Partnerships with green builders, initial launches in smaller markets (e.g. EIFS), and efforts to drive cost down will help acceptance in residential and commercial retrofit and new construction.

36 MATERIALS SCIENCE↗
DOE OSTI2013

External Insulation of Masonry Walls and Wood Framed Walls

The use of exterior insulation on a building is an accepted and effective means to increase the overall thermal resistance of the assembly that also has other advantages of improved water management and often increased air tightness of building assemblies. For thin layers of insulation (1” to 1 ½”), the cladding can typically be attached directly through the insulation back to the structure. For thicker insulation layers, furring strips have been added as a cladding attachment location. This approach has been used in the past on numerous Building America test homes and communities (both new and retrofit applications), and has been proven to be an effective and durable means to provide cladding attachment. However, the lack of engineering data has been a problem for many designers, contractors, and code officials. This research project developed baseline engineering analysis to support the installation of thick layers of exterior insulation on existing masonry and frame walls. Furthermore, water management details necessary to integrate windows, doors, decks, balconies and roofs were created to provide guidance on the integration of exterior insulation strategies with other enclosure elements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Measure Guideline: Deep Energy Enclosure Retrofit for Interior Insulation of Masonry Walls and Flat Roofs

Measure Guideline: Deep Energy Enclosure Retrofit for Zero Energy Ready House Flat Roofs BSC TO5 Task 7.4 Deep Energy Enclosure Retrofit (DEER) for Interior Insulation of Masonry Walls Lawrence, MA 01840 This Measure Guideline describes a deep energy enclosure retrofit solution for insulating mass masonry buildings from the interior. It describes the retrofit assembly, technical details, and installation sequence for retrofitting masonry walls. Interior insulation of masonry retrofits might adversely affect the durability of the wall. This guideline includes a review of decision criteria pertinent to retrofitting masonry walls from the interior and the possible risk of freeze-thaw damage. This Measure Guideline is intended to support contractors who are implementing an interior insulation-based high-performance enclosure retrofit for masonry buildings and designers who are looking to design such retrofits. It may also be helpful to building owners who wish to learn more about strategies that are available for deep energy enclosure retrofit of masonry residential buildings on the interior. This Measure Guideline is important to the high-performance retrofit industry because the solution described here provides an opportunity to retrofit masonry buildings with ambitious energy performance goals by insulating them from the interior without disturbing their exterior appearance. BSC TO5 Task 7.4 Deep Energy Enclosure Retrofit (DEER) for Zero Energy Ready House (ZERH) Flat Roofs House Jamaica Plain, MA 02130 This Measure Guideline provides design and construction information for a deep energy enclosure retrofit solution of a flat roof assembly. It describes the strategies and procedures for an exterior retrofit of a flat wood-framed roof with brick masonry exterior walls using exterior and interior (framing cavity) insulation. The approach supported in this guide could also be adapted for use with flat wood-framed roofs with wood-framed exterior walls. Designers, contractors, and building code officials will benefit from the information contained in this Measure Guideline. The guide may also be helpful to building owners who wish to learn more about strategies for deep energy enclosure retrofit of flat roofs. This Measure Guideline is important to the high-performance retrofit industry because it demonstrates techniques for retrofitting flat roofs from the exterior, which is less disruptive to the living space and allows the structure to remain occupied during the project. It also illustrates a solution for preparing homes to become zero energy ready.

Array↗
NASA NTRS2018

Nature-Inspired Motivation for Developing Self-Healable Electrical Insulation

Polymeric aircraft electrical insulation normally degrade by partial discharge with increasing voltage, which causes excessive localized Joule heating in the material and ultimately leads to dielectric failure of the insulator through thermal breakdown. Self-healing insulation may be a viable option to mitigate permanent mechanical degradation, thus increasing the longevity of the material. Instead of relying on catalyst and monomer-filled microcapsules to crack, flow, and cure at the damaged sites described in well-published mechanisms, self-healing through establishment of ionic crosslinks allows for multiple healing events to occur as well as achieving full recovery strength under certain thermal environments. Surlyn®, a commercial ionically-crosslinked material, was investigated as a self-healing insulation candidate based on prior demonstrations of self-healing behavior. Thin films of varying thicknesses were investigated and the effects of thickness on the dielectric strength were evaluated and compared to representative polymer insulators. The effects of thermal conditioning on the recovery strength and healing were observed as a function of time following dielectric breakdown. Moisture absorption was studied to determine if moisture absorption rates in Surlyn® were lower than that of common polyimide insulators. Preliminary data showed that when cut, Surlyn® films lost nearly 60 percent of its original dielectric strength. However, when Surlyn® was cut and subsequently annealed, the films not only re-mended, but also recouped approximately 93 percent of its original dielectric strength, along with 90-97 percent of its mechanical strength.

electrical↗
NASA NTRS2018

Lightweight, Durable, and Multifunctional Electrical Insulation Material Systems for High Voltage Applications

Newly developed multilayer structures of well-known polymer insulation materials significantly improved dielectric breakdown voltage, VB, or dielectric strength, K, if well-bonded, when compared to those of single material insulations or the commercial SOA systems, such as Teflon-Kapton-Teflon (TKT), at the same overall thickness. To date, the greatest improvement of the new structures from a few candidate materials, including various types of Kapton PIs and PFA or PET as bond layer (BL), was about 61% higher than that of the Kapton PI alone films, 40.1 vs. 24.9 kV, which was translated to 86.3% decrease in insulation thickness, thus significant volume and weight reduction of the final system. However, it was of interest to note that most improvements of the multilayer structures occurred at thicker overall thicknesses, above ~ 0.15 mm. Extensive analyses also showed that K of the multilayer structures increased with (i) decreasing individual layer thickness regardless of material type, (ii) increasing total accumulated thickness of PI or overall PI/BL ratio, and (iii) increasing number of interface or total number of layers, but only above the aforementioned overall thickness limit. Increases in VB of the multilayer structures were directly correlated with damage evolution and failure mode. With further material-design-process optimizations of the multilayer structures, it was expected to achieve other multifunctionalities, such as high partial discharge (PD) resistance, improved durability, EMI shielding, and high thermal dissipation in addition to high dielectric strength. These new structures can be used in various high voltage and high temperature applications, such as future hybrid or all electric aircraft wiring and power transmission as well as many other non-aerospace high power cables, electronic parts and components, printed circuit board, and so forth. The multilayer insulation system can be easily processed and manufactured with various conductor types via calendaring, compression-molding, stamping, laminating, vacuum-bagging and autoclaving, or 3D printing, even for complex 3-D components. Based on their unique structural configurations and potential capabilities, the new insulation system was identified as micro-multilayer multifunctional electrical insulation (MMEI). Patent application of the MMEI concept and current design configurations was filed for a 1-year provisional application (OAI-58834, Serial No.: 62/659,234), pending conversion to a U.S. utility application. This paper presents details of the MMEI structures, their dielectric performance analyses, potential mechanisms, and commercial scaleup feasibility assessment.

Electric aircrafts↗