Because the AAAV operates within a particularly harsh environment, EMI seals must perform to an exceptional degree of efficiency. The access ports of the AAAV must contain the highest level of EMI protection while demonstrating outstanding sealing and anti-corrosive capabilities. Seal durability and chemical/steam resistance is an important consideration for any material selection in this program. The design concepts Unitech will explore and develop in Phase I and II of this program will continually address these important issues. Corrosion testing and EMI shielding, as well as, seal integrity will be central to all design formats. Although cost and attachment will also be important considerations in Phase I, primary emphases will center on designing the most efficient possible. Phase I efforts will also include a spray system of fabrication that has proved successful in ongoing aerospace program production. This allows layering of materials to tailor the seals cross-section for optimal performance. Unitech will select several matrix candidates in three material categories noted for their sealing ability and strength. A silicon (RTV) currently approved and used in the F22 program will be specifically examined due to its unique properties demonstrated in 3 year R&D program. It is available commercially and can be post treated to achieve much higher levels of performance than initially advertised. UniShield fill materials (used in commercially available coatings) are already established as some of the highest performance EMI shielding materials ever tested. Listed in the National Security Agency (NSA) databases and currently used by Department of Defense (DOD) for several ongoing applications. We will also investigate several other fill materials that are highly regarded for shielding effectiveness and compatibility. We are confident an exceptional EMI seal system will result in combining these material formulations. Benefits It is expected the principle immediate usage for this type technology would be within the Department of Defense. Initial effects would concentrate on making it available for DODs internal use, with sales to the private sector of secondary importance. Private sector use is anticipated eventually because of the continuing emphases being placed on protection of financial data and propriety industrial trade secrets. Current EMI gasket materials may not provide all the necessary environmental protection in efforts to contain data and protect equipment. Keywords durability, anti corrosive, EMI shielding, Unishield conductive coatings, RTV silicon
