SBIR-STTR Award

Thermal Management Technologies (TMT), a newly formed small business with strategic ties to the Space Dynamics Laboratory (SDL) at Utah State University, is proposing to determine the feasibility of fabricating isothermal panels and inter-panel connections that will meet the thermal performance requirements as outlined in AF083-217.  These panels are based on Channel Panel technology that has been under development at SDL for the past decade. Recent advancements in manufacturing processes allow the fabrication of Channel Panel units using a variety of materials including metals, plastics and carbon-based composites. These panels may be fabricated into strong, light-weight sandwich-like panels that serve as the mechanical structure as well as the thermal management system. Electrical and electronic components may be molded into or attached directly to the panels making them truly multifunctional modules.  TMT has already demonstrated functioning isothermal Channel Panels in a 1-g laboratory environment. The Phase I objectives are: (1) develop modular satellite architecture that is compatible with Channel Panel technology; (2) design inter-panel connections that minimize temperature gradients between panels; (3) analyze mass and thermal capacitance parameters for the modular multifunctional panels and connections; (4) investigate space environment compatibility of Channel Panel and inter-panel connections.

Benefit:
Development of modular structural panels that accept component heat, convey that heat to energy rejection surfaces, and remain essentially isothermal will provide the Air Force with low-cost, low-risk, plug and play thermal management solution. If the connections between modular panels can be shown to exhibit low thermal impedance and change-out of modular panels can be quickly and efficiently accomplished, the rapid response objectives can be realized. Any aerospace firm competing for contracts to build rapid response spacecraft will also have serious interest in demonstrable and feasible technologies capable of meeting deployment time constraints. These companies will provide a very substantial commercial market for the use of this technology.

Keywords:
Rapid Response, Spacecraft, Six-Day-Satellite, Multifunctional Panels, Isothermal Panels, Low-Thermal Impedance Connections, Channel Panels, Operationally Responsive Spacecraf

Thermal Management Technologies (TMT) will team with Utah State University’s Space Dynamics Laboratory to design, model, build, test, and demonstrate a full scale engineering prototype of an isothermal satellite bus enabled by TMT’s proprietary Channel Panel™ heat spreader technology and high performance inter-panel connections. The proposed work, to be carried out over two years, is based on a very successful Phase I feasibility study by the same team. It is anticipated that the modular isothermal panels will be fabricated from high performance carbon fiber composite material designed for low thermal expansion, low mass, and high structural integrity. A simple “pegboard” configuration will allow payload components to be bolted directly to the panels and facilitate simple bolted connections between panels. The proposed schedule includes subjecting both the prototype modular panels and assembled prototype satellite bus to appropriate 1-g thermal testing in vacuum chambers and vibration testing. Based on Phase I results, there is a high level of confidence that Phase II technical objectives will be realized.

Benefit:
This project is focused directly on military applications including rapid response spacecraft that may be quickly configured from modular isothermal structural panels. The engineering prototype resulting from the proposed effort will help enable the very aggressive “six day satellite” concept. In addition, the proposed technology will have application in commercial space where small satellites with inherently low thermal mass typically expose sensitive payload components to broad temperature swings. Because the proposed approach greatly simplifies the thermal analysis and thermal control measures required, very sizable markets are anticipated in commercial space. In addition, the proposed effort is complementary to a parallel TMT programs focused on terrestrial applications of the Channel Panel™ heat spreader technology including cooling of: data/server centers, Li-Ion batteries, printed circuit boards, and LED arrays. Another potential military application, for which a white paper has been submitted to the Office of Naval Research, is the cooling of amphibious ships’ decks heated by exhaust plumes of short take-off vertical landing aircraft.

Keywords:
Isothermal , Heat Spreader, Flat Plate Heat Pipe, Channel Panel, Isothermal Radiators, Modular Spacecraft, Operationally Responsive Space, Thermal Management Technologies