Army 17. 1 Small Business Innovation Research (sbir) Proposal Submission Instructions

• Shall accept a premade three-dimensional CAD model of a swatch sample, with actual material properties

• Shall illustrate, in three-dimensional space, the flame propagation on a material swatch sample subjected to a vertical flame test, as discussed in ASTM D6413.

• Shall quantify the heat released as a function of time.

• Shall give the user the flexibility to adjust ignition flame magnitude, direction, and placement relative to the sample under test.

• Shall provide the user environmental parameters to adjust, such as humidity and temperature

• Shall demonstrate the feasibility of further advancements to the software package, to instill confidence in a Phase II award.

The awardee shall also perform market research on existing fire modeling software that may be used in support of this project, in order to avoid a redundant effort. It is desirable for the modeling and simulation software package to be novel, and thereby exhibit other inputs, outputs, capabilities or variables not clearly indicated in this solicitation.

In order to fulfill reporting requirements, the awardee shall report monthly on their progress, in the form of a 4-8 page technical report indicating accomplishments, project progress against schedule, tables, graphics, and any other associated data.

Deliverables:

• Six monthly reports, with each report containing the following:

o Expenditure to date, against proposed schedule

o Technical progress to date, against proposed schedule.

o Technical achievement highlights, as well as problems or decision-points reached.

o Within first two reports, present market research of all existing fire modeling and simulation software and their feasibility in addressing the solicitation requirements.

• A final technical report summarizing the entire effort, submitted within 15 days after contract termination.

• A demonstration of the developed “alpha” version software, to be conducted at NSRDEC and exhibiting the following qualities:

o The ability to simulate an ASTM D6413 vertical flame test. Contractor should have preemptively conducted a video-recorded ASTM D6413 burn test of a sample that is identical in size, shape and material properties of the sample simulated in the software package. A side-by-side comparison of the simulation and the recorded footage will allow for validation of the model. This may not be a preprogrammed, or catered demonstration. Any and all visual depictions presented by the model must be calculated and simulated.

o Software shall also exhibit the aforementioned “alpha” version required capabilities.

PHASE II: Phase II is a significant developmental improvement to the Phase I “alpha” version software, and must result in a more mature and capable “beta” version software package. This effort will not exceed two (2) years or $1M in cost.

Phase II tasks include adding the following capabilities to the “alpha” software package:

• Import a highly detailed three-dimensional model of a soft- and rigid-wall shelter that exhibits complex configurations. Shelter model selected will be at the government agency’s discretion.

• Modify a shelter model’s individual material and component properties (i.e. specific heat, thermal conductivity, melting point, and permeability) and view a corresponding change in the simulation outcome.

• Configurable ignition source location, both inside and outside the shelter model.

• Change internal and external environmental conditions, to allow for specific air flow (i.e. wind direction and magnitude) around and through the shelter material.

• Adjustable mesh setting to augment simulation resolution (likely at the expense of processing time)

• Quantify flame spread, heat release, smoke generation, toxicity produced, thermal variations, material consumption, Oxygen concentration, and other crucial fire safety properties, and allow for applicable visual depictions in real time.

• After the shelter fire simulation, an actual shelter (identical to the one selected for the simulation) may be burned by the government to validate the simulation’s accuracy in predicting a live fire incident.

Phase II deliverables include:

• "Beta” version software demonstration at NSRDEC, validating aforementioned required capabilities.

• Training of two government personnel on delivered software package.

• Submit the following documentation:

o Specification (architecture and framework) for software package

o User manual for software package

o Monthly reports to cover the period-of-performance

o Final report summarizing entire effort

PHASE III DUAL USE APPLICATIONS: The initial use of this technology is for the military expeditionary basing systems, but there is an inherent benefit to other governmental organizations and commercial industry. The product developed under the Phase I and Phase II efforts shall also aim to enhance commercial three-dimensional fire modeling and simulation software. Technology areas that could benefit from commercialization of this software technology are as follows:

• Commercial and residential real estate: Such as mobile homes, temporary housing/shelters, shopping centers, storage facilities and apartment buildings.

• Land, Air, and Sea transportation safety. Such as automobiles, recreational vehicles, shipping containers and tractor trailers.

• Raw materials and composites fire safety predictability.

• In support of the National Fire Protection Association (NFPA) in developing fire safety standards and codes.

• In support of the Underwriters Laboratories (UL) in certifying products for fire-safe operation.

REFERENCES:

1. ASTM D6413 – Standard Test Method for Flame Resistance of Textiles (Vertical Test)
http://www.textileinstruments.net/okit88/UploadFiles/ASTM%20D6413-Vertical%20flammability%20testing.PDF

2. MIL-PRF-444103D – Performance Specification – Cloth, Fire, Water, and Weather Resistance

3. NFPA 251 – (2006 Edition) Standard Method of Tests of Fire Resistance of Building Construction and Materials

4. MIL-STD-1472F – Design Criteria Standard – Human Engineering

KEYWORDS: modeling, simulation, software, fire, heat

TECHNOLOGY AREA(S): Materials/Processes

OBJECTIVE: Investigate and develop lightweight, thin-film solar cells coupled to periodic optical nanostructures that can scale up to large-area, low-cost modules deployed by the military for extended missions. The periodic optical nanostructure should enhance power conversion efficiency by light-trapping, reducing overheating, and/or other mechanisms.

DESCRIPTION: Thin-film solar cells are increasingly relevant to both military and commercial sectors [1]. Thin-film lightweight solar cells form modules (“solar blankets”) that may be folded, placed in a rucksack, and carried by Warfighters (and outdoors enthusiasts). These modules are used to reduce the number of extra batteries carried on long, extended missions. In addition, there is increasing interest in the Shelters and Expeditionary Basing community in deploying photovoltaic panels to reduce the amount of material required for re-supply to small bases and shelters. As production and deployment costs for high-quality but brittle and heavy traditional thick film solar cells increase, there is renewed interest in depositing solar cells, instead of etching from a crystal, onto lightweight substrates for mobile applications. State-of-the-art of solar blankets that have been employed in some cases by the US military conform to the specification sheets in Ref. 2 (power/weight ratio 18-19.5 W/lb and power/area ratio 3-6 W/ft2, with output powers of 62 W or 120 W under “full sun”). Despite having been employed and tested by the US military, these state-of-the-art solar blankets do not meet current US Army solar blanket requirements to produce a minimum of 100 W output power over a maximum of 25 ft2 and with a maximum weight of 4.7 lb. One of the state-of-the-art solar blankets given in Ref. 2 produces 120 W but over 33.4 ft2 and with a weight of 6.5 lbs; the other state-of-the-art solar blanket only produces 62 W, and still does not meet the derived power/weight metric (e.g., is too heavy).

The market for lightweight solar panels in the developing world, much of which lacks infrastructure to transport heavy, bulky panels, is increasing, and there are more applications where solar cells must be able to withstand mechanical shock (e.g., the “hammer test”) – for example, rigid-wall Shelters for expeditionary military units. Thin-film cells can be lightweight and relatively inexpensive, but have absorption limited by the thickness of the active solar absorber, which limit solar cell conversion efficiency and requires the solar blanket’s unfolded area to be tens of square feet to produce sufficient power. A number of technologies, including antireflective coatings, randomly (nano)structured top surfaces, and back reflectors, have been introduced to better trap light inside the solar cell, and have resulted in modest efficiency gains. Lightweight substrates such as plastic sheeting with deposited metal back reflectors, flexible, lightweight thin-film glass, and/or thin metal foils have been introduced to reduce weight.

Periodic optical nanostructures, such as photonic crystals, have demonstrated high-precision control of light, optical bandgaps, ultrahigh reflectivity, selective angle- and polarization-dependent transmission [3] and advanced spectral control for radiative cooling [4,5]. These periodic optical nanostructures have been predicted to enhance solar cell efficiency through both light-management/light-trapping effects and by increasing infrared emission [6], but so far have not been utilized to a great extent (with the exception of References 7-8) for improving the absorption and efficiency of solar cells and modules. One key way in which periodic optical nanostructures could improve solar cells is by spectrally controlling the flow of light into and out of the solar cell [5]. By transmitting only the visible light that generates electron-hole pairs and by emitting only the thermal infrared derived from the solar cell’s temperature (especially into the atmospheric window of 8-13 um), a periodic nanostructure such as a photonic crystal could increase visible-light absorption and yet prevent the solar cell from overheating, thus enhancing efficiency relative to solar cells that overheat due to absorbed infrared light.

This SBIR program will investigate innovative ways, based on advanced periodic optical nanostructures, of increasing solar efficiency to reduce solar blanket area and while retaining high output power (100 W or more) to achieve revolutionary advances in the power/area (efficiency) and power/weight derived metrics used to characterize solar blankets. The periodic optical nanostructures will be employed to increase solar cell efficiency by improving light trapping, reducing solar cell temperature, acting as an antireflective layer, and possibly other mechanism(s). Other technical strategies, for example the employment of novel lightweight substrates to reduce solar blanket weight, may be employed as well. A total energy production during a partially sunny day of at least 200 W-hr is desirable, but not a critical goal.

PHASE I: An innovative solution, involving periodic optical nanostructures, is sought to advance performance far beyond current US Army requirements, for a new generation of solar blankets. Research, develop, and evaluate methods for increasing the output power per unit mass (W/kg) by employing new, manufacturable substrates, and introduce a periodic optical nanostructure to improve efficiency such that there is a clear path to achieving 6 W/ft2 over the large areas required to produce output powers of 100 W. Deliverable #1 is a demonstration of a periodic optical nanostructure that yields an output power density of 5 W/ft2 and, if possible, 21.3 W/lb (thus exceeding current requirements). Working solar cells with area 1 square inch must be demonstrated (Deliverable #2). A technical report (Deliverable #3) should be generated with a detailed plan to achieve at least 6 W/ft2 and 30 W/lb; for example, 100 W from a thin–film lightweight solar cell, having a periodic optical nanostructure, over an area of 16.67 ft2 (1.55 m2) or less with total weight less than 3.33 lbs (1.51 kg).

PHASE II: Building on results from Phase I and employing a periodic optical nanostructure, demonstrate (Deliverable #1) thin-film lightweight solar cells with total area of at least 1 ft2, that produce at least 6 W/ft2 output power density (100 W/(16.67 ft2) = 6 W/ft2 = 64.5 W/m2) with specific output power of 100 W/3.33 lb = 30 W/lb = 66.1 W/kg. Detail the research and development activities leading up to Deliverable #1, including the employment of the periodic optical nanostructure, in a technical report, and explain how to scale up to areas of 16.67 ft2 in a manufacturing process (Deliverable #2). A cost model (Deliverable #3) should be presented that shows how this technology would compete with other lightweight thin-film portable solar cells by reducing price to less than $10/Watt).

PHASE III DUAL USE APPLICATIONS: Scale the technology demonstrated in Phase II up to a level that produces lightweight thin-film solar modules with 100 W output, area of 16.67 ft2, and total weight less than 3.33 lbs. The production cost must be low and competitive in the market for thin-film solar cells. This technology would satisfy official requirements for solar blanket power output, size, and weight, needed for dismounted Soldier power and potentially also for small base camps and expeditionary shelters, because of the light weight, low cost, high power output, and flexibility/ease of use. Lightweight thin-film inexpensive solar cells will also impact the enormous personal electronics industry, by enabling civilians (outdoors enthusiasts initially, but extending to anyone living in a sunny climate) to charge personal electronics (e.g., smart phones, electronic textiles) while on the move. It is envisioned that this technology will benefit from large emerging civilian markets by seeing price reductions as demand for portable power increases.

REFERENCES:

1. http://www.renewableenergyfocus.com/view/43425/solar-frontier-achieves-world-record-thin-film-solar-cell-efficiency/

2. See the following two links for state-of-the-art solar blankets:

a) http://www.powerfilmsolar.com/sitevizenterprise/website/cgi-bin/file.pl/powerfilmsolar/ media/products/120_Watt_Foldable_Sales_Sheet_583DA5D4AF047.pdf

3. Shen, Y. et. al., “Optical broadband angular selectivity”, Science 343, 1499 (2014).

4. Rephaeli, E. et. al., “Ultrabroadband Photonic Structures to Achieve High-performance Daytime Radiative Cooling”, Nano Letts. 13, 1457 (2013)
http://web.stanford.edu/group/fan/publication/Rephaeli_NL_13_1451_2013.pdf

5. Raman, A. et. al., “Passive Radiative Cooling Below Ambient Air Temperature under Direct Sunlight”, Nature 515, 540 (2014). http://web.stanford.edu/group/fan/publication/Raman_Nature_515_540_2014.pdf

6. Yu, Z., et. al., “Fundamental limit of light trapping in grating structures”, Optics Express (2010), https://arxiv.org/ftp/arxiv/papers/1006/1006.4331.pdf

7. Li, X., et. al., “Integration of Subwavelength Optical Nanostructures for Improved Antireflection Performance of Mechanically Flexible GaAs solar cells fabricated by epitaxial lift-off”, Solar Energy Mats. Solar Cells 143, 567 (2015).

http://etylab.ece.utexas.edu/pdfpubs/SOLMAT_143_567_2015.pdf

8. Curtin, B., et. al., “Photonic crystal based back reflectors for light management and enhanced absorption in amorphous silicon solar cells, appl. Phys. Lets. 95, 231102 (2009) http://optoelectronics.ece.ucsb.edu/sites/default/files/publications/ApplPhysLett_95_231102.pdf

KEYWORDS: thin film, solar cell, lightweight, optical nanostructure, photonic crystal, portable power

A17-075

TITLE: Fire Retardant Nylon Yarn

TECHNOLOGY AREA(S):

OBJECTIVE: Develop a method to impart flame protection to Nylon 6,6 textile fiber/yarn used to fabricate the Army Combat Uniform (ACU).

DESCRIPTION: The current Army Combat Uniform (ACU) is fabricated from a fabric consisting of a 50:50 blend of cotton and Nylon 6,6. This fabric is not inherently flame retardant, and when soldiers are deployed they are issued Flame Retardant ACUs (FR-ACU). The current FR-ACU is made from very expensive fabric, one of the constituents of which is not Berry Amendment compliant. Along with increased cost, this fabric also has issues with decreased durability and comfort. Emerging threat scenarios, such as subterranean and megacities are necessitating that the Army reassess its current FR-ACU to develop fabrics that are more durable, comfortable and lower cost while having flame protection properties equal to or surpassing the current FR-ACU and not use halogenated or toxic materials that may be released while burning.

One approach to meeting these requirements is to develop a nylon 6,6 fiber/yarn that has flame resistant characteristics that can be used in conjunction with FR cotton thread to construct a novel FR-ACU fabric. Various approaches will be considered, and could consist of additives to nylon polymer or finishes or coatings on the yarn itself, however fabric level coatings will not be considered.

The new FR-ACU fabric (approx. 6.5oz/yd) based on the novel fiber technology developed here should have these properties:

• Must not melt or drip when exposed to heat or flame and must self-extinguish when heat or flame is removed

• Must not introduce health hazards to the wearer if it comes in contact with an open wound and/or inhalation if burned

• Must maintain its flame resistance and system durability and minimize shrinkage through 50 launderings

• Shall resist ripping/tearing, IAW ASTM D1424 (Tear Strength) minimum 30 lbs, and ASTM D5034 (Tensile Strength) minimum 300 lbs

• Shall cost no more than $20/yd at full volume

PHASE I: A successful Phase I program will:

• Design a concept for imparting flame retardant properties for Nylon fiber that could potentially be scaled to meet the price requirement

• Prepare test samples of fiber or compounded polymer in sufficient quantity to perform laboratory-scale testing

• Demonstrate, through laboratory testing, flame retardant behavior that would indicate potential to meet flame requirements of the fabric

• Perform preliminary cost estimate for fiber and fabric

Deliverables will include samples of fiber or compounded polymer for testing at NSRDEC

PHASE II: A successful Phase II program will:

• Prepare enough FR Nylon yarn to prepare FR fabrics of 50:50 NyCo for the testing listed below and to supply to NSRDEC for testing

• Prepare fabric consisting of FR Nylon with FR cotton in quantities sufficient for testing listed below and to supply to NSRDEC for testing

• Demonstrate the FR properties of a 50:50 NyCo fabric through Vertical Flame Testing (ASTM D6413) of the as-prepared fabric and after 50 wash cycles (AATCC Test Method 135-2014)

• Demonstrate tear strength and tensile strength of the

• Demonstrate the ability to continuously prepare FR Nylon fiber/yarn

• Provide a detailed cost estimate for the proposed FR fabric

PHASE III DUAL USE APPLICATIONS: The initial use for this technology will be to provide soldiers with high performance, cost effective FR uniforms. FR clothing is also used in several commercial industries such as: petrochemical, electrical and gas utilities, and fire response personnel.

REFERENCES:

1. Villa, Kay M and Krasny, John F. Fire Safety Journal 16 (1990) 229-241, “Small-scale Vertical Flammability Testing for Fabrics",http://fire.nist.gov/bfrlpubs/fire90/PDF/f90014.pdf

2. AATCC Test Method TM 124-1996 - Appearance of Fabrics after Repeated Home Laundering. https://law.resource.org/pub/us/cfr/ibr/001/aatcc.tm.124.1996.pdf

3. GL-PD-07-12, REV. 8 - PURCHASE DESCRIPTION CLOTH, FLAME RESISTANT (uploaded in SITIS on 11/30/16).
KEYWORDS: Flame Retardant, Military Uniforms, Nylon 6,6, Textiles, fabric

A17-076

TITLE: Low Profile Strain Measurement System for Parachute Suspension Lines

TECHNOLOGY AREA(S): Materials/Processes

OBJECTIVE: Develop and demonstrate innovative materiel solutions for Army parachutes to measure forces exerted on individual suspension and control lines during the challenging airdrop environment

DESCRIPTION: Presently during military parachute testing, force measurements are taken with one or two load cells attached to a riser that has multiple suspension lines attached. These measurements provide valuable information about the forces exerted on the instrumented suspension line group but there is no current capability to capture the forces on control lines. The cords typically used in parachute systems include PIA-C-5040, PIA-C-2754, and PIA-C-7515. Traditional strain links and/or load cells are too large and bulky to realistically and functionally instrument an individual suspension line or control line without significantly increasing the risk of major damage during parachute deployment. Having the capability to measure force on each of the suspension lines as well as control lines will provide valuable data to support many efforts including evaluation of service life, new parachute development, and computer modeling.

The purpose of this SBIR solicitation is to develop materials and methods that could be used to measure dynamic force and strain on individual parachute suspension and control lines through deployment. The challenge described here is greater than existing electro textile and sensor technologies for two main reasons (See References). First, the sensors need to be small enough to incorporate on every line without significantly increasing the bulk of the parachute system. Second, the smart lines need to be durable to withstand the high shock loads experienced during parachute opening while remaining flexible to withstand the repeated handling, packing of the parachute system.

All sensors should be capable of data capture rates of at least 1000 Hz in order to accurately capture dynamic forces within the lines occurring during canopy deployment and inflation. It is desired to have a sensors solution capable of use with up to 500lb payloads but solutions for any range of payloads from 1-500lbs or a smaller subset of that range (ex 5-20lbs or 100-400lbs) would be acceptable. It is recommended that any sensors used are able to interface with a data processor or recorder that could be located at either attachment point of the line. Analog or digital (I2C, SPI, etc.) interfaces between sensors and data processor are both acceptable The data recorder could be located in the parachute canopy itself or at the payload, AGU, or pack tray depending on system. Sensors that would be able to transmit information across the suspension and control lines are desirable. Guided airdrop systems such as the Joint Precision Airdrop System (JPADS) use a steerable cargo ram air canopy and an airborne guidance unit (AGU) to guide a parachute to its target using GPS. Current research to incorporate and network sensors and actuators into the canopy fabric is ongoing. These systems have used local batteries and wireless data transmission. Incorporating the ability to transmit data and power between the AGU and an in canopy sensor network into the suspension lines is desirable to ensure reliable data transmission. It is desired that the final system shall cost no more than double that of traditional lines, however, it is dependent on the technology used.