N102-110 TITLE: Cooling/Thermal Management System Development for Active Denial Technology (ADT) and High-Power Radio-Frequency vehicle Stopper (RF) Systems

TECHNOLOGY AREAS: Ground/Sea Vehicles, Materials/Processes, Electronics, Weapons

ACQUISITION PROGRAM: Joint Non-Lethal Weapons Program - ACAT III

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted." The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: Develop a new novel Cooling/Thermal Management System design that reduces the current size, cost, and weight of the existing thermal management subsystems by a factor of 2 and still meet full system performance specifications. These new Thermal Management designs should be capable of achieving the performance specifications shown below for the following Directed Energy Systems, such as the 95 GHz GaN Solid State Arrays and the the High-Power Radio-Frequency vehicle Stopper (RF) Systems.
Required Thermal Management Performance Specifications:
Vapor Compression System
� 18-200 kW dissipation required
� 12,000 W/ft3 (no condenser)
� 500 W/lb (no condenser)
� 75,000 W/ft3 for condenser
� Operating temperature range: -25 �F to 120 �F
� Operates off DC voltage
� 50/50 ethylene glycol/water (EGW) or propylene glycol/water (PGW) coolant
Radiator System
� 200 kW dissipation required
� 150 �F max into radiator
� 50/50 EGW or PGW coolant
� 2 pass system
� 225 W/lb
� 8,300 W/ft2
� Operating temperature range: -25 �F to 120 �F
� Operates off DC voltage
� Air pressure drop: 0.347 in H2O
� Fluid pressure drop: 9.31 psi

DESCRIPTION: Develop a next-generation Thermal Management system which reduces the current state-of the art for size, wieght, and cost by a factor of 2. The contractor is to consider several special new materials as recently demonstrated in this field of engineering. This light-weight cooling/thermal management system is required for integration into a high-power, solid-state ADT array system, which integrates into small, tactical vehicles and vessels. A variant of this novel next-generation thermal management/cooling system is also needed for integration with mobile, high-power, RF vehicle stopper systems (to cool 1-30 kw magnetron HPM systems). A notional example of such a next-generation cooling system consists of a vapor compression refrigeration system (VCRS), an integrated phase-change material (PCM) heat exchanger to level the cooling load on the VCRS, and an auxiliary cooling loop (ACL) to transport the heat dissipated in the ADT or RF system to the PCM. The objective is to develop new subsystem designs for the systems described above to lead to an overall reductions in size, weight, and cost by a facor of 2 and still meet the system performance requirements shown above.

PHASE I: Develop a next generation Cooling/Thermal Management System design which meets the desired improved system performance specifications provided above. The preliminary next-generation thermal management/cooling system environmental and performance specifications must be established and documented to meet current next-generation Directed Energy Weapon systems, such as the ADT (mm-wave) system and the 30 kW vehicle stopper system. These requirements will be used to define the overall cooling/thermal management system architecture for many programs and will be flowed down to develop requirements and interface specifications for each of these program subsystems. Physical parameters for each USMC/Navy Directed Energy Weapon source will be provided at SBIR award.

PHASE II: Fabricate and test this new novel Cooling/Thermal Management design as integrated on two existing USMC/USN non-lethal Directed Energy Weapons. Conduct system analysis and design tradeoffs. The primary objectives of the system analysis are to assist in developing the specification for the PCM heat exchanger and to verify the sizing of the VCRS and the ACL. The system analysis and design trade studies should include the thermodynamic and heat transport calculations.

PHASE III: Integrate and test this novel design into current PCM heat exchange designs in existing JNLWD-developed non-lethal Directed Energy Weapon systems. Develop a new PCM heat exchanger design for the integrated cooling system including materials specification, fabrication approach, and performance prediction modeling. A method for verifying PCM heat exchanger performance through testing should be developed and documented.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: This technology could be used by any branch of the military or by civilian forces as a subsystem required for a reduced size, highly mobile cooling system.

REFERENCES:
1. Ahuja, A. S., "Augmentation of Heat Transport in Laminar Flow of Polystyrene Suspensions. I. Experiments and Results," Journal of Applied Physics, vol. 46, No. 8, (Aug. 1975), pp. 3408-3416.

2. Ibid, pp. 3417-3425.

3. Charunyakorn, P. et al., "Forced Convection Heat Transfer in Microencapsulated Phase Change Material Slurries: Flow in Circular Ducts," Int J Heat Mass Transfer, vol. 34, No. 3, (1991), pp. 819-833.

4. Charunyakorn, P., et al., "Forced Convection Heat Transfer in Microencapsulated Phase Change Material Slurries: Flow between Parallel Plates," ASME HTD-vol. 129, General Papers: Phase Change and Convective Heat Transfer, ASME, AIAA/ASME Thermophysics and Heat Transfer Conference, Seattle, Washington, (Jun. 18-20, 1990), pp. 55-62.

5. Cho, Keumnam, et al., "Thermal Characteristics of Paraffin in a Spherical Capsule during Freezing and Melting Process", Int J Heat Mass Transfer, vol. 43 (2000), pp. 3183-3196.

6. Cho, Young I., et al., "Development of Advanced Low-Temperature Heat Transfer Fluids for District Heating and Cooling," Report No. DOE/CE/26592-2, prepared for the U.S. Department of Energy, Agreement No. DE-FG01-89CE26592, (Mar. 31, 1999), 10 pgs.

7. Cho, K., et al., "Comparison of Thermal Characteristics of a Test MCM Using Water, PF-5060 and Paraffin Slurry," EEP-vol.26-2, Advances in Electronic Packaging, vol. 2, (199), pp. 1499-1505.

KEYWORDS: non-lethal weapon; Thermal Management System; cooling syste; high-power microwave, heat exchanger, Active Denial System

** TOPIC AUTHOR (TPOC) **

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