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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Pot-ability Assessment of Litz Wires for High Power Density Electric Motor

An alternative process technique, namely vacuum-assisted axial injection potting (VaAIP), has been developed to pot the Litz wires in the stator winding of high power density electric motors for the future electrified aircrafts. Initial trials of the process showed significant improvement in potting quality with less voids, thus potential improvement in thermal management of the motors. As an initial effort of pot-ability assessment, microstructures, 2-D and 3-D, of the Litz wires including dimensions and distribution of conductor filament, coating, and open spaces; packing patterns; shape/configuration changes of each bundles or the overall cross-sections per degree of twist were determined and quantified successfully. The microstructure analyses were performed not only for effective potting process development but also for more realistic electro-thermal modeling solutions. This paper will present results of the microstructure analyses, potentials of the VaAIP process from the trials, and future plans for scale-up and implementation of the process into a full-scale prototype stator winding.

Electrified aircraft↗
NASA NTRS2021

Improved Potting of Litz Wires for High Power Density Electric Motor

Specific details including selections of process materials, tooling/fixture setups, and a step-by-step procedure for scaling-up demonstrations of the newly developed potting process, namely vacuum-assisted axial injection potting (VaAIP) have been fully developed for the stator winding of high power density electric motors for the future electrified aircrafts. Various essential pre-trial subtasks identified for the full-scale demonstrations were carried out. To date, optimization of cure condition and thermal stability of the coating epoxy and determination of optimum application conditions and thermal stability of the high temperature encapsulant wax were completed successfully and other subtasks were under way. The efforts to enhance thermal conductivity of the selected potting compound by adding conductive nano fillers such as boron nitride nanosheets (BNNS) have also been advanced. Initially, selection of the best mixing method and procedures was attempted via extensive and systematic experimental design.

Litz wire↗
NASA NTRS1977

Potting procedure for electronic components

Potting process is modified to effect a match more closely between embedded electronic components, potting mediums, and thermal environment. Application of room-temperature vulcanizing silicone rubber band cured in modified thermal cycle minimizes coil-to-resin adhesion and thus lowers stresses between transformer and potting compound.

Rubino, A. G.↗
NASA NTRS1988

Silicones As Connector-Potting Compounds

Report evaluates silicone potting materials for electrical connectors. Describes tests of connector specimens made with CV-2510 and DC-6-1104 silicones with dibutyl tin dilaurate catalyst and evaluates test results in light of previously published test results for polyurethanes. Discusses requirements for connector-potting materials, methods used to evaluate silicones, techniques for preparing specimens, and results of tests. Identifies commercial sources of silicone potting materials.

Bouquet, Frank L.↗
NASA NTRS2006

High Voltage Breakdown Levels in Various EPC Potting Materials

This viewgraph presentation reviews exploration activities at JPL into various potting materials. Since high power space-borne microwave transmitters invariably use a vacuum tube as a final power amplifier, and this tube requires high electrode voltages for operation. The associated high voltage insulation typically represents a significant fraction of the mass of the transmitter. Since mass is always a premium resource on board spacecraft, we have been investigating materials with the potential to reduce the mass required for our applications here at JPL. This paper describes electrical breakdown results obtained with various potting materials. Conathane EN-11 (polyurethane) is the traditional HVPS encapsulant at JPL, but due to temperature limitations and durability issues it was deemed inappropriate for the particular application (i.e., CloudSat radar). The choices for the best available materials were epoxies, or silicones. Epoxies are too rigid, and were deemed inadvisable. Two silicones were further investigated (i.e.,ASTM E595- 93e2: GE RTV566(R) and Dow Corning 93-500X(R), another compound was considered (i.e., DC material, Sylgard 184(R)). "Loading" (adding filler materials) the potting compound will frequently alter the final material properties. Powdered alumina and borosilicate glass known as "microballoons" were investigated as possible loading materials. The testing of the materials is described. Each of the two loading materials offers advantages and disadvantages. The advantages and disadvantages are described.

encapsulants↗
NASA NTRS2013

Recirculating 1-K-Pot for Pulse-Tube Cryostats

A paper describes a 1-K-pot that works with a commercial pulse tube cooler for astrophysics instrumentation testbeds that require temperatures <1.7 K. Pumped liquid helium-4 cryostats were commonly used to achieve this temperature. However, liquid helium-4 cryostats are being replaced with cryostats using pulse tube coolers. The closed-cycle 1K-pot system for the pulse tube cooler requires a heat exchanger on the pulse tube, a flow restriction, pump-out line, and pump system that recirculates helium-4. The heat exchanger precools and liquefies helium- 4 gas at the 2.5 to 3.5 K pulse tube cold head. This closed-cycle 1-K-pot system was designed to work with commercially available laboratory pulse tube coolers. It was built using common laboratory equipment such as stainless steel tubing and a mechanical pump. The system is self-contained and requires only common wall power to operate. The lift of 15 mW at 1.1 K and base temperature of 0.97 K are provided continuously. The system can be scaled to higher heat lifts of .30 to 50 mW if desired. Ground-based telescopes could use this innovation to improve the efficiency of existing cryo

Paine, Christopher T.↗
NASA NTRS1979

No-warp potted circuits

Sponge inserts compensate for potting-compound expansion and relieve thermal stresses on circuit boards. Technique quality of production runs on PC boards intended for applications in environments less severe than those for aerospace equipment. Pads reduce weight of modules because they weigh far less than potting compound they displace.

Robinson, W. W.↗
NASA NTRS1999

Cerebrovascular regulation in the postural orthostatic tachycardia syndrome (POTS)

Patients with the postural orthostatic tachycardia syndrome (POTS) have symptoms of orthostatic intolerance despite having a normal orthostatic blood pressure (BP), which suggests some impairment of cerebrovascular regulation. Cerebrovascular autoregulation refers to the maintenance of normal cerebral blood flow in spite of changing BP. Mechanisms of autoregulation include myogenic, metabolic and neurogenic vasoregulation. Beat-to-beat recording of blood-flow velocity (BFV) is possible using transcranial Doppler imaging. It is possible to evaluate autoregulation by regressing deltaBFV to deltaBP during head-up tilt. A number of dynamic methods, relating deltaBFV to deltaBP during sudden induced changes in BP by occluding then releasing peripheral arterial flow or by the Valsalva maneuver. The deltaBFV to deltaBP provides an index of autoregulation. In orthostatic hypotension, the autoregulated range is typically expanded. In contrast, paradoxical vasoconstriction occurs in POTS because of an increased depth of respiration, resulting in hypocapnic cerebrovascular constriction, and impaired autoregulation.

Review↗
NASA NTRS2019

Thermal Analysis of Potted Litz Wire for High-Power-Density Aerospace Electric Machines

Increasing the power density and efficiency of electric machines (motors and generators) is integral to bringing Electrified Aircraft (EA) to commercial realization. To that end an effort to create a High Efficiency Megawatt Motor (HEMM) with a goal of exceeding 98% efficiency and 1.46 MW of power has been undertaken at the NASA Glenn Research Center. Of the motor components the resistive losses in the stator windings are by far the largest contributor (34%) to total motor loss. The challenge is the linear relationship between resistivity and temperature, making machine operation sensitive to temperature increases. In order to accurately predict the thermal behavior of the stator the thermal conductivity of the Litz wire-potting-electrical insulation system must be known. Unfortunately, this multi material system has a wide range of thermal conductivities (0.1 W/m-K – 400 W/m-K) and a high anisotropy (axial vs transverse) making the prediction of the transverse thermal conductivity an in turn the hot spot temperatures in the windings is difficult. In order to do this a device that simulates the thermal environment found in the HEMM stator was designed. This device is not unlike the motorettes (little motors) that are described in IEEE standards for testing electrical insulation lifetimes or other electric motor testing. However, because the HEMM motor design includes significant rotor electrical and thermal considerations the term motorette was not deemed appropriate. Instead statorette (or little stator) was adopted as the term for this test device. This paper discussed the design, thermal heat conjugate analysis (thermal model), manufacturing and testing of HEMM's statorette. Analysis of the results is done by thermal resistance network model and micro thermal model and is compared to analytical predictions of thermal conductivity of the insulated and potted Litz wire system.

Motor↗
NASA NTRS1964

Producibility of potting compounds

Effect of environmental temperatures and relative humidities on curing times of polyurethane and polysulfide potting compounds

HUMIDITY MEASUREMENT↗