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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Diaphragm with embossed pattern has greater structural rigidity than one with smooth surfaces, but under severe stress, tensile loads will flatten embossing. This provides necessary additional panel stretch needed to prevent rupture of diaphragm material. Hexagonal embossing-configuration allows panel stretch in any direction or in all directions simultaneously.
A microfluidic system has been designed to survive spaceflight and to function autonomously on the Martian surface. It manipulates microscopic quantities of liquid water and performs chemical analyses on these samples to assay for the presence of molecules associated with past or present living processes. This technology lies at the core of the Urey Instrument, which is scheduled for inclusion on the Pasteur Payload of the ESA ExoMars rover mission in 2013. Fabrication processes have been developed to make the microfabricated Teflon-AF microfluidic diaphragm pumps capable of surviving extreme temperature excursions before and after exposure to liquid water. Two glass wafers are etched with features and a continuous Teflon membrane is sandwiched between them (see figure). Single valves are constructed using this geometry. The microfabricated devices are then post processed by heating the assembled device while applying pneumatic pressure to force the Teflon diaphragm against the valve seat while it is softened. After cooling the device, the embossed membrane retains this new shape. This solves previous problems with bubble introduction into the fluid flow where deformations of the membrane at the valve seat occurred during device bonding at elevated temperatures (100-150 C). The use of laminated membranes containing commercial Teflon AF 2400 sheet sandwiched between spun Teflon AF 1600 layers performed best, and were less gas permeable than Teflon AF 1600 membranes on their own. Spinning Teflon AF 1600 solution (6 percent in FLOURINERT(Registered TradeMark) FC40 solvent, 3M Company) at 500 rpm for 1.5 seconds, followed by 1,000 rpm for 3 seconds onto Borofloat glass wafers, results in a 10-micron-thick film of extremely smooth Teflon AF. This spinning process is repeated several times on flat, blank, glass wafers in order to gradually build a thick, smooth membrane. After running this process at least five times, the wafer and Teflon coating are heated under vacuum at 220 C for one hour in order to drive off any residual solvent present in the composite film. After this, a second blank, glass wafer is brought down from above and the stack is held under vacuum at 3 atm mechanical pressure for ten 10 hours.
Multilayer material consisting of embossed, silver-coated Mylar, nylon net, and silk net is useful for thermal-protection systems and cryogenic containers. Embossing serves two purposes: helps separate radiation barriers and controls radiant energy diffusion. Insulation requires no maintenance after installation.
Selective results are presented of laboratory radiation tests of metallic foil tapes, thermal blankets, and thermooptical coatings undertaken as part of the development and qualification of materials for the Galileo spacecraft. Of the two metallic foil tapes used for electrical continuity, the adhesive used on the aluminum embossed foil was superior to the copper embossed foil when exposed to simulated Jovian electrons. Proton-irradiation tests performed on a number of thermal blanket samples showed that black polyester on Kapton proved to be a lower weight loss (i.e., outgassing) material than Fluorglas. In addition, preliminary results concerning the response of thermooptical coatings to simulated Jovian electrons show that the ITO-coated polyester over a Kapton surface gave the lowest absorptance.
Plasteel Products Corporation approached the Industrial Applications Center at the University of Pittsburgh to search for ideas on "rigidized" metal sheeting. Thinner-gage metal with strength of heavier sheeting can be obtained through cold bending, stamping, dimpling, or embossing - referred to as "rigidizing." Pittsburgh came up with 36 reports relevant to Plasteel's needs. On the basis of this search the company purchased an embossing machine with which it hopes to provide thinner gage metal panels where permitted by building codes.
As a dispersing device for spectroscopy, the prism was by 1950 being supplanted by the diffraction grating, which provided broader spectrum coverage, gave higher intrinsic dispersion, and was more flexible to use. Today most gratings are three-dimensional and blazed, being embossed with thousands of identical mirrors. The relative merits of gratings in comparison with new interferometric scanning devices are examined, taking into account Fourier spectroscopy. Problems of grating ruling are discussed together with the status of ruling engines, and questions of ruling with mechanical engines.
Family of polymer formulations, which has limiting oxygen indices from 50 to 100, can be extruded through dies to produce elastic fibers, compression molded, dissolved in solvents as required for coatings, and calendered to produce film and embossed sheeting. Applications include upholstery, paint products, automobile products, and coated fabrics.
Production expenses are decreased by embossing encapsulating plastic film to position and secure cells. Electric circuit is printed on plastic film simultaneously with cell encapsulation process. Procedure can be used with standard-contact and wraparound contact cells.
Electrical connections to solar cells in a module are made at the same time the cells are encapsulated for protection. The encapsulating material is embossed to facilitate the positioning of the cells during assembly.
The design, development, fabrication and testing of a shingle-type terrestrial solar cell module which produces 98 watts/sq m of exposed module area at 1 kW/sq m insolation and 61 C are reported. These modules make it possible to easily incorporate photovoltaic power generation into the sloping roofs of residential or commercial buildings by simply nailing the modules to the plywood roof sheathing. This design consists of nineteen series-connected 53 mm diameter solar cells arranged in a closely packed hexagon configuration. These cells are individually bonded to the embossed surface of a 3 mm thick thermally tempered hexagon-shaped piece of glass. Polyvinyl butyral is used as the laminating adhesive.
The Block 4 shingle type module makes it possible to apply a photovoltaic array to the sloping roof of a residential building by simply nailing the overlapping hexagon shaped shingles to the plywood roof sheathing. This third-generation shingle module design consists of nineteen series connected 100 mm diameter solar cells which are arranged in a closely packed hexagon configuration to provide in excess of 75 watts/sq m of exposed module area under standard operating conditions. The solar cells are individually bonded to the embossed underside of a 4.4 mm thick thermally tempered piece of glass. An experimental silicone pottant was used as the transparent bonding adhesive between the cells and glass. The semi-flexible portion of each shingle module is a composite laminate construction consisting of an outer layer of FLEXSEAL bonded to an inner core of closed cell polyethylene foam. Silaprene is used as the substrate laminating adhesive. The module design has satisfactorily survived qualification testing program which includes 50 thermal cycles between -40 and +90 C, a seven day temperature-humidity exposure test, and a wind resistance test.
Among several cellular ceramic structures manufactured by various suppliers for regenerator application in a gas turbine engine, three have the best potential for achieving durability and performance objectives for use in gas turbines, Stirling engines, and waste heat recovery systems: (1) an aluminum-silicate sinusoidal flow passage made from a corrugated wate paper process; (2) an extruded isosceles triangle flow passage; and (3) a second generation matrix incorporating a square flow passage formed by an embossing process. Key physical and thermal property data for these configurations presented include: heat transfer and pressure drop characteristics, compressive strength, tensile strength and elasticity, thermal expansion characteristics, chanical attack, and thermal stability.
A test was conducted to determine the solar reflections from the Orbiter radiator panels. A one-tenth scale model of the forward and mid-forward radiator panels in the deployed position was utilized in the test. Test data was obtained to define the reflected one-sun envelope for the embossed silver/Teflon radiator coating. The effects of the double contour on the forward radiator panels were included in the test. Solar concentrations of 2 suns were measured and the one-sun envelope was found to extend approximately 86 inches above the radiator panel. A limited amount of test data was also obtained for the radiator panels with the smooth silver/Teflon coating to support the planned EVA on the Orbiter STS-5 flight. Reflected solar flux concentrations as high as 8 suns were observed with the smooth coating and the one-sun envelope was determined to extend 195 inches above the panel. It is recommended that additional testing be conducted to define the reflected solar environment beyond the one-sun boundary.
Two proposed electromechanical systems for making braille characters produced relatively inexpensively. Similar in operating principle to dotmatrix printers, two methods use electronically actuated pins to reproduce characters from information stored on magnetic tape. First, one or more pins scanned over blank page and energized at intervals to emboss text on paper, one or more dots at time. Second, handheld device containing one or more character-generator cells used by reader to scan lines of text manually.
In testing a stochastic variational principle at high frequencies by using a Kirchhoffean trial function in an idealized model for surface scattering - a randomly embossed plane - we have found not only the predicted high-frequency improvement but also an unexpected low-frequency improvement in the calculated scattering amplitudes. To investigate systematically the all-frequency variational behavior, we consider here the deterministic one-boss case - Rayleigh's classic model whose exact solution is available for comparison - over all wavelengths, polarizations, and configurations of incidence and scattering. We examine analytically in particular the long-wave limit of the variational-Kirchhoff amplitudes; the results demonstrate improvements in both wavelength and angle depedence for horizontal (TM) polarization and some variational improvements for vertical (TE) polarization. This low-frequency behavior in tandem with the foreseen high-frequency improvement leads to good variational-Kirchhoff results through the intermediate resonance-frequency regime for this model.
Embossed plates direct flows of reactants and coolant. Membrane-type fuel-cell battery has improved reactant flow and heat removal. Compact, lightweight battery produces high current and power without drying of membranes.
High efficiency, deep groove, surface relief Diffractive Optical Elements (DOE) with various optical functions can be recorded in a photoresist using conventional interferometric holographic and computer generated photolithographic recording techniques. While photoresist recording media are satisfactory for recording individual surface relief DOE, a reliable and precise method is needed to replicate these diffractive microstructures to maintain the high aspect ratio in each replicated DOE. The term 'high aspect ratio' means that the depth of a groove is substantially greater, i.e. 2, 3, or more times greater, than the width of the groove. A new family of dry photopolymers SURPHEX was developed recently at Du Pont to replicate such highly efficient, deep groove DOE's. SURPHEX photopolymers are being utilized in Du Pont's proprietary Dry Photopolymer Embossing (DPE) technology to replicate with very high degree of precision almost any type of surface relief DOE. Surfaces relief microstructures with width/depth aspect ratio of 1:20 (0.1 micron/2.0 micron) were faithfully replicated by DPE technology. Several types of plastic and glass/quartz optical substrates can be used for economical replication of DOE.
Diffractive lenses have arrived. Literally hundreds of papers have been published and technology impact reports have been written about the exciting addition of a new tool for the lens designer. Sophisticated computer programs have been developed to aid in the optimization of these diffractive phase profiles for a wide variety of applications. Now, several fabrication methods are being pursued to produce these diffractive elements economically. The best known process is the etching of a multi-level relief grating, known as binary optics. This process uses sets of computer generated lithographic masks. Another, more recently developed method is Dry Photopolymer Embossing (DPE). This replication process uses master holograms. And now, diamond turning is being applied for the machining of these elements. Diamond turning is especially well suited for infrared optics. As any process has advantages and limitations, so has diamond turning. These advantages and limitations are discussed and general guidelines are presented to aid the designer and systems engineer in the project predesign stage.