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Department of News Services
Clemson University
Clemson, South Carolina

CONTACTS:

Christine Jarvis, Clemson
(864) 646-8454, cwjrv{at}clemson.edu

Mike Braley, A&P Technology
(513) 688-3286, mbraley{at}braider.com

WRITERS:

Sandy Dees, Clemson
(864) 656-4103, sandy.dees{at}pubaff.clemson.edu

Molly Dingeldein, A&P Technology
(513) 688-3226, mdingeldein{at}braider.com

DATE: 5-22-03

CLEMSON INFLATABLE FABRIC AIRLOCK BREEZES THROUGH INITIAL TESTS

CLEMSON -- Space just got skinnier: an inflatable fabric airlock
could become standard equipment on future space stations after
breezing through its prototype testing in April.

The inflatable airlock, developed in conjunction with Clemson 
University's Clemson Apparel Research, is a prototype designed to
permit astronauts to exit from vehicles and structures into space.
It's part of NASA Johnson Space Center's Advanced Inflatable Airlock
(AIA) program.

When inflated, the nearly 10-foot tube is 50 percent bigger than the 
hardwall-construction airlock currently in use. Its greatest benefit, 
however, is what isn't there. When deflated, it's only one-quarter
the volume of the current space shuttle airlock.

"New fibers and fabric designs are revolutionizing how architects and 
designers think about structures," said Christine Jarvis, a Clemson 
faculty member and director of Clemson Apparel Research (CAR). CAR, 
which began as a demonstration facility for the U.S. Department of 
Defense, has developed products ranging from chemical-resistant suits 
and supply chain software to gloves that are virtually impervious to 
razor wire typically found in combat zones.

The two-layer fabric airlock is made of about 180 pounds of fabric 
sandwiched on either end by metal hatches that together weigh a
whopping 3,200 pounds. The internal layer is the bladder, which holds
the air. The external restraining layer, manufactured by A&P
Technology, is the largest structural braid ever produced.

"We could not have designed and built this structure even five years 
ago," said Jarvis. "Typically, seams limit the strength of fabric 
structures, so we decided to eliminate them. It seems ironic that the 
state-of-the-art sewing facility was the group that figured out how
to eliminate seams. Our engineers and designers constantly think of
novel ways to solve problems."

Future earth-bound uses for the material could include any large 
engineered products, such as domed covers for stadiums, said Jarvis.

Honeywell is the prime contractor for the AIA program. Subcontractors 
include Clemson, Cincinnati-based A&P Technology, New York-based FTL 
Design Studio and Charlotte-based Celanese Advanced Materials.

The airlock was designed by and CAR and FTL. The braid was designed
by CAR, FTL and A&P CAR designed and manufactured the other fabric
components, such as the bladder.

Engineers from NASA and Honeywell tested the airlock at four
atmospheres of internal pressure, which means it withstood a
terrestrial tensile force of about 675,000 pounds on its equator.

The airlock braid was produced on A&P Technology's 800 carrier 
Megabraider, currently the largest braid machine in the world.

The manufacture and test of the airlock is the culmination of a
two-year development effort that also included coupon and subscale
tests.

Regional textile companies Milliken and Co. in Spartanburg, Southern 
Weaving in Greenville and Precision Fibers in Greensboro, N.C.,
supplied other fabric components and testing and, in many cases, the
talent, since Clemson alumni work in all three companies.

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