A Super Cooled, Non-toxic, Non-flammable Phase Change Material Thermal Pack for Portable Life Support Systems

The continuation of concept development and test of a water-based, advanced Phase Change Material (PCM) heat sink is proposed. Utilizing a novel material choice for both an expansion diaphragm and the PCM case itself, the PCM can accommodate both the expansion of the freezing water-based material and very low temperature of approximately -250F. The water-based PCM itself would be non-toxic and non-flammable, but additives will be included to preclude deterioration of wither the PCM container or the diaphragm material. The use of a water-based PCM gives the highest heat capacity for the mass. This is highly limited due to the needs for portability as required for an Extra-Vehicular Activity (EVA). The total heat capacity of an operational unit would be for 4 hour duration EVA use. Through a logical progression of tasks including concept of operation formulation, requirements formulation, concept design reviews and detail design reviews that include design and thermal analysis using Thermal DesktopTM models, this effort can progress from the TRL 3 achieved in Phase I to TRL 4-5. The team will continue development by designing a Variable Conductance Interface (VCI) for protecting water in the Liquid Cooling Garment (LCG) from freezing due to the temperature of the heat sink used by the PCM. The team will also develop system improvements identified during Phase I testing. The PCM will be tested to confirm heat input/temperature performance and cycling capability. The test bed will allow for accurate heat input knowledge, temperature monitoring and cycling capability. The results will be compared to the thermal model to ensure accurate prediction capability for the next phase unit and system implementation. The design description and test results would form the basis of the final report.