Multi-Ply Bellows Conduit With Interstitial Leak Detection
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Solution Overview
Problem
Flexible conduits in cryogenic propulsion systems are susceptible to manufacturing variances and incidental damage, which can lead to potential failure of pressurized-propellant feed lines, posing a risk to the main propulsion system if not timely identified.
Innovation Solution
A conduit design featuring a bellows structure with corrugated plies, weld-through rings, and sensors to detect leaks, providing a compliant and robust fluid transmission system that accommodates displacements and ensures reliable sealing and leak detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible conduit is used to accommodate displacements in cryogenic propulsion systems, then adaptability is improved, but reliability deteriorates due to susceptibility to manufacturing variances and incidental damage
Solution Approach 1:
The conduit is divided into multiple corrugated plies (inboard ply, outboard ply, and second outboard ply) that can independently deform and accommodate displacements. Each ply acts as a separate segment that can absorb stress and strain, maintaining overall conduit integrity while allowing necessary movement in cryogenic propulsion systems.
2Device complexity
If traditional sealing methods are used in flexible conduits, then manufacturing complexity is reduced, but detection precision of leaks deteriorates
Solution Approach 1:
A sensor is introduced as an intermediary element between the fluid being transported and the environment. The sensor detects leaks by monitoring changes in the interstitial space or fluid properties, providing precise leak detection without requiring complex sealing structures. The sensor acts as a mediator that translates physical leak conditions into detectable signals.
3Strength
If multiple corrugated plies are used to enhance conduit strength, then strength is improved, but device complexity increases
Solution Approach 1:
The conduit employs a nested configuration where the inboard corrugated ply, outboard corrugated ply, and second outboard corrugated ply are arranged concentrically. Each ply is nested within or adjacent to the others, creating a layered structure that enhances strength while maintaining a compact geometry. The nested arrangement allows multiple plies to contribute to strength without proportionally increasing overall complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The conduit design enhances the reliability and safety of cryogenic fluid transmission by detecting leaks and maintaining a strong, sealed connection, reducing the risk of damage to the propulsion system.
Implementation Method 1
a first weld hermetically interconnecting the corrugated inboard ply, the first corrugated outboard ply, and the first collar
Implementation Method 2
the sensor enables detection of leaks in the corrugated inboard ply by detecting changes in conditions within the interstitial space
Implementation Method 3
The conduit provides a compliant structure for transmission of fluids, such as cryogenic fuels, that accommodates displacements encountered during operation
Data Source
AI summary
A method of fabricating a conduit comprises simultaneously corrugating three plies to form a bellows. The method also comprises simultaneously trimming a corrugated inboard ply and a first corrugated outboard ply of the bellows. The method further comprises locating a weld-through ring and a second weld-through ring between the corrugated inboard ply and the first corrugated outboard ply. The method additionally comprises forming a port and a second port through the weld-through ring and the second weld-through ring, respectively. The method also comprises communicatively coupling a sensor and a second sensor with an interstitial space, interposed between the corrugated inboard play and the first corrugated outboard ply, via the port and the second port, respectively.