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The Space Suit Water Membrane Evaporator (SWME) is a baseline heat rejection technology that was selected to develop the Constellation Program lunar suit. The Hollow Fiber (HoFi) SWME is being considered for service in the Constellation Space Suit Element Portable Life Support Subsystem to provide cooling to the thermal loop via water evaporation to the vacuum of space. Previous work [1] described the test methodology and planning that are entailed in comparing the test performance of three commercially available HoFi materials as alternatives to the sheet membrane prototype for SWME: (1) porous hydrophobic polypropylene, (2) porous hydrophobic polysulfone, and (3) ion exchange through nonporous hydrophilic-modified Nafion®.

During an ExtraVehicular Activity (EVA), both the heat generated by the astronaut's metabolism and that produced by the Portable Life Support System (PLSS) must be rejected to space. The heat sources include the heat of adsorption of metabolic CO2, the heat of condensation of water, the heat removed from the body by the liquid cooling garment, the load from the electrical components and incident radiation. Although the sublimator hardware to reject this load weighs only 1.58 kg (3.48 lbm), an additional 3.6 kg (8 lbm) of water are loaded into the unit, most of which is sublimated and lost to space, thus becoming the single largest expendable during an eight-hour EVA. Using a radiator to reject heat from the astronaut during an EVA can reduce the amount of expendable water consumed in the sublimator. Radiators have no moving parts and are thus simple and highly reliable. However, past freezable radiators have been too heavy.

The optimum radiator configuration in hot lunar thermal environments is one in which the radiator is parallel to the ground and has no view to the hot lunar surface. However, typical spacecraft configurations have limited real estate available for top-mounted radiators, resulting in a desire to use the spacecraft's vertically oriented sides. Vertically oriented, flat panel radiators will have a large view factor to the lunar surface, and thus will be subjected to significant incident lunar infrared heat. Consequently, radiator fluid temperatures will need to exceed ~325 K (assuming standard spacecraft radiator optical properties) in order to provide positive heat rejection at lunar noon. Such temperatures are too high for crewed spacecraft applications in which a heat pump is to be avoided.

For future lunar extra-vehicular activities (EVA), one method under consideration for rejecting crew and electronics heat involves evaporating water through a hydrophobic, porous Teflon® membrane. A Spacesuit Water Membrane Evaporator (SWME) prototype using the Teflon® membrane was tested successfully by Ungar and Thomas (2001) with predicted performance matching test data well [1]. The above referenced work laid the foundation for the design of the SWME development unit, which is being considered for service in the Constellation System Spacesuit Element (CSSE) Portable Life Support System (PLSS). Multiple PLSS SWME configurations were considered on the basis of thermal performance, mass, volume, and performance and manufacturing risk. All configurations were a variation of an alternating concentric water and vapor channel configuration or a stack of alternating rectangular water and vapor channels.

We have completed preliminary tests that show the feasibility of an innovative concept for a spacesuit thermal control system using a lightweight, flexible heat pump/radiator. The heat pump/radiator is part of a regenerable LiCI/water absorption cooling device that absorbs an astronaut's metabolic heat and rejects it to the environment via thermal radiation at a relatively high temperature. We identified key design specifications for the system, demonstrated that it is feasible to fabricate the flexible radiator, measured the heat rejection capability of the radiator, and assessed the effects on overall mass of the PLSS. We specified system design features that will enable the flexible absorber/radiator to operate in a wide range of space exploration environments. The materials used to fabricate the flexible absorber/radiator samples were all found to be low off-gassing and many have already been qualified for use in space.

The Spacesuit Water Membrane Evaporator (SWME) is the baseline heat rejection technology selected for development for the Constellation lunar suit. The first SWME prototype, designed, built, and tested at Johnson Space Center in 1999 used a Teflon hydrophobic porous membrane sheet shaped into an annulus to provide cooling to the coolant loop through water evaporation to the vacuum of space. This present study describes the test methodology and planning to compare the test performance of three commercially available hollow fiber materials as alternatives to the sheet membrane prototype for SWME, in particular, a porous hydrophobic polypropylene, and two variants that employ ion exchange through non-porous hydrophilic modified Nafion. Contamination tests will be performed to probe for sensitivities of the candidate SWME elements to ordinary constituents that are expected to be found in the potable water provided by the vehicle, the target feedwater source.

This paper describes the need and solution for minimizing EVA airlock time and depress gas losses using a new method that minimizes EVA out-the-door time for a suited astronaut and reclaims most of the airlock depress gas. This method consists of one or more related concepts that use an evacuated reservoir tank to store and reclaim the airlock depress gas. The evacuated tank can be an inflatable tank, a spent fuel tank from a lunar lander descent stage, or a backup airlock. During EVA airlock operations, the airlock and reservoir would be equalized at some low pressure, and through proper selection of reservoir size, most of the depress gas would be stored in the reservoir for later reclamation. The benefit of this method is directly applicable to long duration lunar and Mars missions that require multiple EVA missions (up to 100, two-person lunar EVAs) and conservation of consumables, including depress pump power and depress gas.

During an ExtraVehicular Activity (EVA), both the heat generated by the astronaut's metabolism and that produced by the Portable Life Support System (PLSS) must be rejected to space. The heat sources include the heat of adsorption of metabolic CO2, the heat of condensation of water, the heat removed from the body by the liquid cooling garment and the load from the electrical components. Although the sublimator hardware to reject this load weighs only 1.58 kg (3.48 lbm), an additional 3.6 kg (8 lbm) of water are loaded into the unit, most of which is sublimated and lost to space, thus becoming the single largest expendable during an eight-hour EVA. Using a radiator to reject heat from the astronaut during an EVA can reduce the amount of expendable water consumed in the sublimator. Last year we reported on the design and initial operational assessment tests of a novel radiator designated the Radiator And Freeze Tolerant heat eXchanger (RAFT-X).

With new direction to return to the Moon, NASA is developing highly efficient and lightweight extravehicular activity (EVA) equipment for working on the rugged lunar terrain. This paper presents results and evaluations of lunar thermal environments and design challenges for the EVA system. The evaluations include a review of basic lunar environment data, a review of metabolic rate predictions, analyses and reviews of spacesuit heat leak effects in past designs, and methods to improve the performance of spacesuit-mounted radiators in a hot lunar environment. In addition to reviewing existing lunar thermal environment data, a simplified thermal model is presented that can simulate the lunar surface temperature variation as a function of latitude and time on the lunar surface. The assumed physical and optical properties of the lunar soil as well as the solar heating on the Earth's Moon are also presented.

This paper presents results of advanced airlock concept studies conducted at the NASA Johnson Space Center in support of exploration surface systems, such as lunar lander airlocks and other advanced vehicle airlocks. The studies include preliminary requirements for advanced airlocks, and rationale for using the rear-entry space suit as the basic advanced suit design to be accommodated by the airlocks. The studies also present rationale for minimum volume airlocks and gas reclamation methods needed for long duration missions. Another study shows conceptual designs for single person airlocks, dual person airlocks, and multi-person airlocks, along with associated benefits and disadvantages of each. A test and selection methodology is also discussed for future airlock development.

This paper describes the effort and accomplishments for developing flexible fabrics with high thermal conductivity (FFHTC) for spacesuits to improve thermal performance, lower weight and reduce complexity. Commercial and additional space exploration applications that require substantial performance enhancements in removal and transport of heat away from equipment as well as from the human body can benefit from this technology. Improvements in thermal conductivity were achieved through the use of modified polymers containing thermally conductive additives. The objective of the FFHTC effort is to significantly improve the thermal conductivity of the liquid cooled ventilation garment by improving the thermal conductivity of the subcomponents (i.e., fabric and plastic tubes).

Flexible fiber-reinforced aerogel composites were studied for use as insulation materials of a future space suit for Moon and Mars exploration. High flexibility and good thermal insulation properties of fiber-reinforced silica aerogel composites at both high and low vacuum conditions make it a promising insulation candidate for the space suit application. This paper first presents the results of a durability (mechanical cycling) study of these aerogels composites in the context of retaining their thermal performance. The study shows that some of these Aerogels materials retained most of their insulation performance after up to 250,000 cycles of mechanical flex cycling. This paper also examines the problem of integrating these flexible aerogel composites into the current space suit elements.

Fiber-reinforced Aerogel composite insulations provide superior thermal insulation protection in both the low-earth orbit (LEO) and near-earth neighborhood planetary environments. The flexible nature and thermal properties of these materials make them the best insulation candidates for advanced space suit application. This paper reviews the properties of various Aerogel composite materials developed for NASA by Aspen Systems, Inc. Previous studies showed that the Aerogel materials retained acceptable thermal performance after some amount of mechanical cycling. The goal of the current work is to reach a complete understanding of the mechanical properties of these materials in the domain of space suit application. Hence, a good knowledge of the durability of the aerogel composites is needed. This paper presents the extensive testing program needed to determine the life of these insulations for advanced space suit application.

Future spacesuits will require thermal insulation protection in low-earth orbit (LEO), in the near-earth neighborhood and in planetary environments. In order to satisfy all future exploration needs and lower production and maintenance costs, a common thermal insulation is desirable that will perform well in all these environments. A highly promising material is a fiber-reinforced aerogel composite insulation currently being developed at the Johnson Space Center. This paper presents an overview of aerogels and their manufacture, a summary of the development of a flexible fiber-based aerogel for NASA by Aspen Aerogels, Inc., and performance data of aerogels relative to flexible commercial insulation. Finally, future plans are presented of how an aerogel-based insulation may be integrated into a spacesuit for ground testing as well as for a flight configuration.

For planetary exploration, new thermal insulation materials are needed to deal with unique environmental conditions presented to extravehicular activity (EVA). The thermal insulation material and system used in the existing space suit were specifically designed for low orbit environment. They are not adequate for low vacuum condition commonly found in planetary environments with a gas atmosphere. This study attempts to identify the types of lofty nonwoven thermal insulation materials and the construction parameters that yield the best performance for such application. Lofty nonwovens with different construction parameters are evaluated for their thermal conductivity performance. Three different types of fiber material: solid round fiber, hollow fiber, and grooved fiber, with various denier, needling intensity, and web density were evaluated.

For planetary applications, the space suit insulation has unique requirements because it must perform in a dynamic mode to protect humans in the harsh dust, pressure and temperature environments. Since the presence of a gaseous planetary atmosphere adds significant thermal conductance to the suit insulation, the current multi-layer flexible insulation designed for vacuum applications is not suitable in reduced pressure planetary environments such as that of Mars. Therefore a feasibility study has been conducted at NASA to identify the most promising insulation concepts that can be developed to provide an acceptable suit insulation. Insulation concepts surveyed include foams, microspheres, microfibers, and vacuum jackets. The feasibility study includes a literature survey of potential concepts, an evaluation of test results for initial insulation concepts, and a development philosophy to be pursued as a result of the initial testing and conceptual surveys.

The importance of being able to determine the usage rate of life support subsystem consumables was recognized well before the first Apollo Extravehicular Activity (EVA). Since that time, metabolic activity levels have been evaluated and recorded for each EVA crew member. Throughout the history of the United States space program, EVA metabolic rates have been shown to be variable depending upon the mission scenario and the equipment used. Knowing this historic information is invaluable for current EVA planning activities, as well as for the design of future Extravehicular Mobility Unit (EMU) systems. This paper presents an overview of historic metabolic expenditures for Apollo, Skylab, and Shuttle missions, along with a discussion of the types of EVA crew member activities which lead to various metabolic rate levels, and a discussion on how this data is being used to develop advanced EMU systems.

A preliminary evaluation of several portable life support system (PLSS) concepts which could be used during the First Lunar Outpost (FLO) mission extravehicular activities (EVA's) has been performed. The weight, volume and consumables characteristics for the various PLSS concepts were estimated. Thermal effects of day and night EVA's on PLSS consumables usage and hardware requirements were evaluated. The benefit of adding a radiator and the total PLSS weight to be carried by the astronaut were also evaluated for each of the concepts. The results of the evaluation were used to provide baseline weight, volume and consumables characteristics of the PLSS to be used on the 45 day FLO mission. The benefit of radiators was shown to be substantial. Considerable consumables savings were predicted for EVA schedules with a high concentration of nighttime EVA's versus daytime EVA's.

The National Aeronautics and Space Administration (NASA) has accomplished a “return to extravehicular activity (EVA)” on the Space Transportation System 37 (STS-37) mission that flew in April 1991. This first U.S. EVA in almost 6 years included both an unscheduled EVA on mission day 3 and a scheduled EVA on mission day 4. The unscheduled EVA occurred when the high-gain antenna on the Compton Gamma Ray Observatory (GRO) would not deploy when commanded from the ground. Mission specialists Jerry Ross and Jay Apt quickly donned their space suits, went into the Shuttle cargo bay for EVA, and freed the jammed antenna, saving the $617 million scientific spacecraft. During the scheduled EVA, crewmembers Ross and Apt successfully completed the Space Station Freedom (SSF) EVA Development Flight Experiment (EDFE). EDFE evaluated three classes of equipment planned for SSF: Crew and Equipment Translation Aids (CETA), Crew Loads Instrumented Pallet (CLIP), and EVA Translation Evaluation (ETE).

This paper outlines the selection, design, and testing of a prototype nonventing regenerable astronaut cooling system for Extravehicular Activity (EVA) space suit applications, for mission durations of four hours or greater. The selected system consists of the following key elements: a radiator assembly which serves as the exterior shell of the portable life support subsystem (PLSS) backpack; a layer of phase change thermal storage material, n-hexadecane paraffin, which acts as a regenerable thermal capacitor; a thermoelectric heat pump; and an automatic temperature control system. The capability for regeneration of thermal storage capacity with and without the aid of electric power is provided.