The document discusses the concept of a "Chameleon Suit" that aims to revolutionize extra-vehicular activity (EVA) systems through an integrated, multi-functional design approach. It outlines some of the key challenges with current EVA systems and opportunities emerging technologies provide to address issues like mobility, thermal control, life support and energy needs. The concept integrates functions like thermal regulation, gas transport and power generation directly into the suit material through the use of advanced materials like conductive polymers, shape memory alloys and thin film devices. While challenges remain around issues like artificial photosynthesis integration, the document argues the required technologies are advancing and a fully-integrated, lightweight suit that improves upon current systems is achievable.

1. 1
Chameleon Suit –Changing the Outlook for EVA
November 7, 2003
Ed Hodgson
Hamilton Sundstrand

2. 2
Project Basics
•Advanced Extra-Vehicular Activity System Concept
•Phase 2 Study
–March 2002 –January 2004
•Contract #NAS5-03110 Grant #07605-003-001
•HS Project Team –Gail Baker, Allison Bender, JoelGoldfarb, Edward Hodgson, Gregory Quinn, FredSribnik, CatherineThibaud-Erkey
•External Support –NIAC, NASA JSC, NASA HQ, and many, many more.

3. 3
Why a Chameleon Suit?
•History
•Future Needs
•Technology Opportunities

4. 4
Historical EVA Challenges and Issues
•Pressure Suit Mobility & Comfort
•On-Back Weight
•EVA Expendables
•Durability / Maintainability

5. 5
Future Mission NeedsAccessiblePlanetarySurfaceEarth& LEOAnywhere/ AnytimeEarth’sNeighborhood
•Easier
•Lighter
•Cheaper
•Longer
•Adaptable

6. 6
Technology Opportunities –The Shape of Things to Come
•Recursive system evolution•Atomic scale design & manufacture•The imitation of lifeActive, optimal multi-functional materials – unconstrained design integration.

7. 7
The Guiding Concept –A Different System Paradigm
Historic EVA Systems•Functional partition•Environment isolation•Component interfacesChameleon Suit•Functional integration•Environment exploitation•Human interfaces

8. 8
The Many Shapes of the Chameleon – Concept Implementation Options

9. 9
Implementation Options
Technology & Logical Choices
Phase 1 Study
Integrated Passive Thermal Control
Integrated Active Heat TransportEmphasize
Integrated CO2&
Humidity Control
Active Mobility
MCP Suit
Mobility
Mass Savings
& Integration
Active Suit FitTransportArtificialPhotosynthesisEnergy HarvestingDistributed Energy HarvestingO2RecoveryModule
Distributed
O2Recovery
Reactants
Energy

10. 10
Integrated Passive Thermal Control
(Phase 1 Study) LCVG Layers (outer layer, transport tubing, liner) TMG and MEMS louversVariable loft layerswith active polymerspacers and thermallyconductive fiber felt

11. 11
Integrated Active Heat TransportDistributed thin filmmodules or flexiblethermoelectric polymersTMG and MEMS louversVariable loft layerswith active polymerspacers and thermallyconductive fiber felt

12. 12
Integrated CO2& Humidity ControlDistributed thin filmmodules or flexiblethermoelectricpolymersTMG and MEMS louversSelective ChemicalTransport MembranesVariable loft layerswith active polymerspacers and thermallyconductive fiber felt

13. 13
Active Suit FitDistributed thin filmmodules or flexiblethermoelectric polymersTMG and MEMS louversSelective ChemicalTransport MembranesActive Suit Fit MaterialVariable loft layerswith active polymerspacers and thermallyconductive fiber felt

14. 14
Energy HarvestingDistributed thin filmmodules or flexiblethermoelectric polymersTMG and MEMS louversSelective ChemicalTransport MembranesActive Suit Fit MaterialFlexible solar cell arrays/ Photoelectric polymersConcentrated CO2and H2O vented toenvironmentHarvested Energy tobackpack reducesbattery sizeVariable loft layerswith active polymerspacers and thermallyconductive fiber felt

15. 15
Artificial PhotosynthesisDistributed thin filmmodules or flexiblethermoelectric polymersTMG and MEMS louversVariable loft layerswith active polymerspacers and thermallyconductive fiber feltSelective ChemicalTransport/CatalysisActive Suit Fit MaterialFlexible solar cell arrays/ Photoelectric polymersHarvested energyfrom photo- & thermoelectrics todrive oxygenrecovery

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Distributed O2RecoveryDistributed thin film modules orflexible thermoelectric polymersTMG and MEMS louversSelective ChemicalTransport MembranesActive Suit Fit MaterialFlexible solar cell arrays/ Photoelectric polymersOxygen Recovery ProcessVariable loft layerswith active polymerspacers and thermallyconductive fiber feltCO2, H20 andO2 Transfer

17. 17
Active Mobility -MCP SuitTMG and MEMS louversActive Suit Fit MaterialVariable loft layerswith active polymerspacers and thermallyconductive fiber felt

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Distributed Energy Harvesting -
O2Recovery ModuleDistributed thin filmmodules or flexiblethermoelectric polymersTMG and MEMS louversActive Suit Fit Material for MCPFlexible solar cell arrays/ Photoelectric polymersHarvested energyfrom photo- & thermoelectrics tobackpackVariable loft layerswith active polymerspacers and thermallyconductive fiber feltSuit atmosphere tobackpack for CO2, H2O removal andO2 recovery

19. 19
Enabling Technologies
•Multi-functional Materials
•Bio-mimetic Processes
•Advanced Manufacturing Technologies
•Information Technologies

20. 20
Multifunctional Materials
•Conductive Polymers
•Shape Change Materials
•Optically Active Materials
•Energy Storage and Conversion
•Chemically Active Materials

21. 21
Polymers andNanocomposites
Engineered Materials Revolution
•Driven by, enabled by, and underlying information revolution
–Microelectronics > massive complexity > ever smaller features > MEMS
–Computational, imaging and modeling tools at atomic and molecular scales
•Ubiquitous in science, industry & society
•Designer molecules
–Multi-functional polymers –conductive, mechanically active, optically active, chemically active
–Biomimetic
•Nano-composites

22. 22
Conductive PolymersAlternatives to Wiring Harnesses, Switches and Liquid Electrolytes•Conductive polymers and composite electro-textiles–Flexibility–Massively parallel interconnection•Polymeric semiconductors–Integrated function, structure & control•Solid polymer electrolytes–Lithium polymer batteries –Fuel cells ~ 1000 W-hr/Kg–Flexible batteries –160W-hr/Kg

23. 23
Shape Change Materials
- -100- 60-80- Medium to fast3807.2Dielectric---20 to 40 20 to 40-150 to150 Temperature range (C) - 0.3 30-35107100200.35 HumanMuscle- 1201105@0.3% strain3240MIT CP 2002NVery low1105Low25-10insulation- >42010636250.5MIT targetY 40201061002540MCP/ assisted mobility20Tensile strength (MPa) Ylow1000Low2520Active fitO2compatibilityEfficiency (%) Life cycleStrain rate (%/s) Strain (%) Force output (MPa) Characteristics- Characteristics

24. 24
Optically Active Materials
•Electrochromicmaterials–Inorganic–Polymers•Electroemissivematerials–OLED•MEMS•Photoelectric materials

25. 25
Energy Storage & Conversion
•Thin film & polymeric devices•Increasing conversion efficiency•Lower cost & more flexible manufacture•Emerging applicationsProgress of Thermoelectic Improvements01234519301950197019902010Year Figure of Merit, ZT Thin Film State of the ArtPolymer state of the artCommercially available materialElectrolytePlastic (PET)Platinum CatalystTransparent Conductor0.010 inchesPlastic (PET)TiO2& DyeTransparent ConductorPhotovoltaicPolymer Batteries
Thermoelectric

26. 26
Chemically Active MaterialsO2CO2H2OCO2e-loadH2OO2H2e-powerH+ CO3= O2CO2H2OCO2e-Porous substrateLiquid containing facilitatorsHydrophilized surfaceVent flowCO2,O2, H2OH2OCO2Vacuumor Sweep gasPassive transport selective membranesActive transport –polymer electrolytes
Chemical conversion –integrated catalysis

27. 27
Bio-mimetic Processes
•Membranes
•Bio-catalysts
•Artificial Photosynthesis
•Self-Assembling Systems

28. 28
Membrane Technologies
•Biological membranes
–Self organizing
–Selective transport
–Active transport
•Enzyme membranes
•Biomimeticliquid crystal membranes
–CO2 transport & selectivity comparable to lung tissue

29. 29
Bio-catalysts
BiocatalyticProcesses
•Efficient reactions at useful rates and modest temperatures
•High specificity
•Enzymes -organic - stereochemical
Historical Processes
•Efficient reactions at high rates , high temperatures
•Limited specificity
•Inorganic metals & salts

30. 30
Artificial Photosynthesis
•Find alternate chemicals / chemical sequences to achieve photosynthetic functions recognizing photosynthesis specificity of–Fast kinetics–Highly specific pathways–Molecular level assembly •For example, mimicking chlorophyll’s light conversion process (PSII) –Carotene/Porphyrin/Fullerene sequence (Arizona State University) –Development of Ru-Mncomplexes (Uppsala University, Sweden)

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Self-Assembling Systems•The essence of biology•Complexity (apparently) without cost•Genetic codes –molecular templates•Understanding ÎPractice–Natural systems ÎModes of operation ÎEngineered analogs

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Advanced Manufacturing Technologies
•Photo-Lithography
•Stereo-Lithography
•Self-Assembling Systems

33. 33
Photolithographic Processes
Keys to Practical Complexity at Any Scale
•Design and manufacturing approaches are proven
•Extension to multi- disciplinary systems has been made
•Extension to large scale planar structures
•Further growth in scale and range of materials

34. 34
Stereo-Lithography
•Photo-lithographic process extended to 3D•Direct computer control–Design flexibility–Responsiveness–Small lot economics•Increasing materials possibilities

35. 35
Self-Assembling Systems (again)
•Becoming a practical reality in engineering practice
•One key to mastering massively parallel, repeating systems of very small parts …
Like the Chameleon Suit
Nanolithoeffort harnesses self-assembly PORTLAND, Ore. —Nanoscalepatterning of silicon substrates with regular, repeatable, atomically perfect application-specific templates could enablemanufacturable nanoscalechips within the decade, according to scientists at the University of Wisconsin'sMaterials Research Science and Engineering Center (Madison). By R. Colin Johnson
EE Times
August 5, 2003 (2:54 p.m. ET)

36. 36
Information Technologies
•Underlying Technology
•Information Processing
•Connectivity
•Recursive Design
•Advanced Interfaces

37. 37
Underlying Technology Base
•Silicon as a designer material
–Flexible, easily controlled functionality
–Consistent continuous structure
•Photolithographic manufacturing
–Progressive evolution to smaller scales
–Consistent, local control ofmicroscalecomposition
•Automated design, manufacturing processes

38. 38
Information Processing
•Dealing with massive complexity essential for and enabled by information revolution enables:
–Design of complex structures and networks
–Complex control algorithms and networks
–Practical coordinated interaction of large numbers of sensors and effectors
–Analysis and understanding of complex natural systems –designer molecules &biomimeticdesign
ÎChameleon Suit practicality

39. 39
Connectivity
•Data bus structures and approaches to enable flow of information among large numbers of cooperating devices with practical overhead
–Data bus ÎEthernetÎInternet
•Wireless adaptations Îflexible geometry and topology
•Smaller, lower power access devices Γsmart dust”

40. 40
Recursive & Extensible Processes•N-1th generation capabilities enable Nth generation design•Progressive change in scale (smaller), complexity (greater) •Extensible to additional degrees of freedom & new domains–MEMS–Microchannelsystems

41. 41
Advanced Information Interfaces – Toward Thought Controlled Systems
•Progress in sensors and signal processing Î
Robust research in thought controlled systems
–Military systems &assistivesystems and devices
•Complex spatial and temporal patterns of very low level signals
–Noise, individual variability
•Extensive training, user concentration
•Limited channel bandwidth < 10 Hz
•Continued progress and research interest Î Chameleon Suit applications potential

42. 42
Application Analyses and Results –Is the Concept Real?
•Thermal Control
•Transport
•Mobility
•Mass Reduction
•System Energy Balance
•Implications for System Robustness
•Artificial Photosynthesis Integration

43. 43
Thermal Control Viability – Passive & BeyondCollapsedLayersThermoelectricModulesHeat Spreading LayerCarbon VelvetPlasticHeat Spreading LayerPlasticCarbon VelvetGap (Vacuum)AluminumThreadSkinAmbient EnvironmentPassive heat rejection from suit surface in most environments and at most work rates
Thin film thermoelectric devices in suit walls allow no expendables heat rejection at maximum work rate and lunar noon –worst case thermal environment –250 W power input.

44. 44
Transport Membrane Integration0.0% 0.5% 1.0% 1.5% 2.0% 2.5% 0.00.10.20.30.40.50.60.70.8Hole Spacing (in) Required Flow Area/Total Suit Area LaminarSharp-Edged Orifice
Analyses show that CO2and humidity transport through suit insulation is consistent with thermal control design0.0E+002.0E-064.0E-066.0E-068.0E-061.0E-051.2E-0500.10.20.30.40.50.60.70.8Hole Spacing (in) Pressure Drop per Suit Layer (psid) Pressure drop component for flow through felt is negligible compared to the pressure drop through the holes in the suit which is ~0.008 psid per layer

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Assisted and Enhanced Mobility
•Active Fit, Assisted Mobility, Mechanical Counter Pressure•Required performance parameters separately demonstrated in active materials•Combined characteristics & environmental tolerance in sight•Energy harvesting essential for assisted mobility & mechanical counter pressureWristBearing
Scye
BearingBearing
Arm

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System Mass Reduction020406080100120140On Back Mass (Kg) basephase123456789 ConceptOn-Back Mass Reduction With Chameleon Suit Concepts

47. 47
System Energy Balance CurrentPhase 1SuitConcept12345678(W-hr)(W-hr)(W-hr)(W-hr)(W-hr)(W-hr)(W-hr)(W-hr)(W-hr)(W-hr) DCM/CWS80808080808080808080Radio90909090909090909090Pump4020N/AN/AN/AN/AN/AN/AN/AN/AFan/Separator Motor Ass'y304304254N/AN/A254N/AN/AN/A254Circulation FanN/AN/AN/A125125N/A125125125N/AElectrochromicsN/A222222222ActuatorsN/A150-300150-300150-300150-300150-300150-300150-300150-300150-300MEMS LouversN/A555555555ThermoelectricsN/AN/A122-80122-81122-82122-83122-84122-85122-86122-87PhotovoltaicsN/AN/AN/AN/AN/AN/A0 to 34560 to 34560 to TBD0 to 3456Oxygen RecoveryN/AN/AN/AN/AN/AN/AN/A2350N/A2350Net Energy Balance - MAX51480185372472485372430747243203Net Energy Balance - MIN5146515013723725013084734TBD605Phase 2 ConceptsENERGY BALANCES FOR CHAMELEON SUIT CONCEPTS

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Implications for System Robustness
•Current reliability and life issues are eliminated: sublimator, gas trap, filters.
•Fewer duration limiting resources
•Massively parallel systems Îgraceful failure responses (gradual performance loss)
•Inherent environmental sensitivity
•Central control or common power failures (design mitigation)
•Local thermal extremes possible with failures

49. 49
Artificial Photosynthesis Integration•Materials and energy transport problem–Energy (light) available outside suit–Materials available (CO2, H2O), and needed (O2), inside suit–Both must be together for O2recovery•Energy transport–As electricity (low efficiency) –As energetic intermediates? •A satisfactory solution path has not been identified yet. Suit Pressurized VolumeUnpressurizedSuitInsulation SpaceWasteCO2, H2OO2NeedAvailableLight EnergyTransport?

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Summary –Vision for the Future
•The seed has been planted and it will grow!
–The path is clear to revolutionary change
–The required technologies are ripening for harvest
–Targeted research is being explored with many investigators
–The vision of possibilities has been shared
–The Chameleon Suit is on our technology roadmap
•Today’s unsolved problems are not insoluble
•Perhaps the Chameleon Suit really will look like those Star Trek images after all
The best possible space suit will be invisible