Manufacturing & Prototyping

Improved Blackbody Temperature Sensors for a Vacuum Furnace

Through proper selection of materials, it is possible to satisfy severe requirements. Some improvements have been made in the design and fabrication of blackbody sensors (BBSs) used to measure the temperature of a heater core in a vacuum furnace. Each BBS consists of a ring of thermally conductive, high-melting-temperature material with two tantalum-sheathed thermocouples attached at diametrically opposite points. The name “blackbody sensor” reflects the basic principle of operation. Heat is transferred between the ring and the furnace heater core primarily by blackbody radiation, heat is conducted through the ring to the thermocouples, and the temperature of the ring (and, hence, the temperature of the heater core) is measured by use of the thermocouples.

Posted in: Manufacturing & Prototyping, Briefs

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Improved Assembly for Gas Shielding During Welding or Brazing

Inert gas is distributed evenly over the region surrounding the weld joint. An improved assembly for inert-gas shielding of a metallic joint is designed to be useable during any of a variety of both laser-based and traditional welding and brazing processes. The basic purpose of this assembly or of a typical prior related assembly is to channel the flow of a chemically inert gas to a joint to prevent environmental contamination of the joint during the welding or brazing process and, if required, to accelerate cooling upon completion of the process.

Posted in: Manufacturing & Prototyping, Briefs

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Tool for Crimping Flexible Circuit Leads

A hand tool has been developed for crimping leads in flexible tails that are parts of some electronic circuits — especially some sensor circuits. The tool is used to cut the tails to desired lengths and attach solder tabs to the leads. For tailoring small numbers of circuits for special applications, this hand tool is a less expensive alternative to a commercially available automated crimping tool. The crimping tool consists of an off-the-shelf hand crimping tool plus a specialized crimping insert designed specifically for the intended application.

Posted in: Manufacturing & Prototyping, Briefs, TSP

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Two-Step Plasma Process for Cleaning Indium Bonding Bumps

This process could increase yields in the manufacture of consumer electronic products. A two-step plasma process has been developed as a means of removing surface oxide layers from indium bumps used in flip-chip hybridization (bump bonding) of integrated circuits. This process has considerable commercial potential in that flip-chip hybridization is used in the manufacture of cellular telephones and other compact, portable electronic products.

Posted in: Manufacturing & Prototyping, Briefs

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Further Development of Scaffolds for Regeneration of Nerves

Scale-up toward clinically significant dimensions has been partially completed. Progress has been made in continuing research on scaffolds for the guided growth of nerves to replace damaged ones. The scaffolds contain pores that are approximately cylindrical and parallel, with nearly uniform widths ranging from tens to hundreds of microns. At the earlier stage of development, experimental scaffolds had been made from agarose hydrogel. Such a scaffold was made in a multistep process in which poly(methyl methacrylate) [PMMA] fibers were used as templates for the pores. The process included placement of a bundle of the PMMA fibers in a tube, filling the interstices in the tube with a hot agarose solution, cooling to turn the solution into a gel, and then immersion in acetone to dissolve the PMMA fibers. The scaffolds were typically limited to about 25 pores per scaffold, square cross sections of no more than about 1.5 by 1.5 mm, and lengths of no more than about 2 mm.

Posted in: Bio-Medical, Manufacturing & Prototyping, Medical, Briefs, MDB

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Crashworthy Seats Would Afford Superior Protection

Adjustments enable optimization of support for different body sizes and shapes. Seats to prevent or limit crash injuries to astronauts aboard the crew vehicle of the Orion spacecraft are undergoing development. The design of these seats incorporates and goes beyond crash-protection concepts embodied in prior spacecraft and racing-car seats to afford superior protection against impacts. Although the seats are designed to support astronauts in a recumbent, quasi-fetal posture that would likely not be suitable for non-spacecraft applications, parts of the design could be adapted to military and some civilian aircraft seats and to racing-car seats to increase levels of protection.

Posted in: Bio-Medical, Manufacturing & Prototyping, Medical, Briefs, TSP, MDB

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Droplet-Based Production of Liposomes

A process for making monodisperse liposomes having lipid bilayer membranes involves fewer, simpler process steps than do related prior methods. First, a microfluidic, cross-junction droplet generator is used to produce vesicles comprising aqueous-solution droplets contained in single-layer lipid membranes. The vesicles are collected in a lipid-solvent mix that is at most partially soluble in water and is less dense than is water. A layer of water is dispensed on top of the solvent. By virtue of the difference in densities, the water sinks to the bottom and the solvent floats to the top. The vesicles, which have almost the same density as that of water, become exchanged into the water instead of floating to the top. As there are excess lipids in the solvent solution, in order for the vesicles to remain in the water, the addition of a second lipid layer to each vesicle is energetically favored.

Posted in: Bio-Medical, Manufacturing & Prototyping, Materials, Coatings & Adhesives, Medical, Briefs, MDB

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