Development of a new seal for use on large openings of pressurized spacecraft

The goal of this project was to design, build, and test an example of the seal invented by the author for use on Space Station Freedom and patented in 1991. The seal features a metallic spring core and replaceable elastomeric sealing elements. The metallic spring is designed to retain the sealing force of the elastomeric element against both sides of face seal gland for any specified amount of waviness or separation of the glands. A seal able to tolerate at least 1.3 mm (0.05 in) of flange distortion or separation and a test fixture of this seal which allowed direct comparison testing of O-rings were built. These designs were tested to compare leakage at different amounts of flange deflection. Results of the testing show the development seal exceeded its requirement to seal 1.3 mm of flange separation by 1 mm. This compared with the O-ring leakage, increasing dramatically at 0.5 mm of separation. The development seal also leaked at a lower rate than the O-ring seals in all tests.