Multi-ply Composite Duct for Cryogenic Fuel Transport
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current cryogenic ducts for launch and space vehicle systems face challenges such as high mass, complexity, galvanic corrosion, and combustion risks due to metallic materials, and non-metallic materials are brittle and inadequate at cryogenic temperatures, leading to issues with vibration, load transfer, and outgassing, which are not effectively addressed by existing designs.
Innovation Solution
A multi-ply composite duct made of polymer film with inter-ply cryogenic epoxy and structural reinforcement, such as aerospace-grade adhesive and integral structural plastic or metallic wire, providing strength, flexibility, and resistance to occlusion, perforation, and combustion, while minimizing mass and outgassing, and eliminating galvanic corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used for cryogenic ducts, then strength and mechanical performance are improved, but mass and device complexity increase
Solution Approach 1:
The patent employs a composite construction consisting of multiple layers of polymer film with inter-ply cryogenic epoxy or sealing agent and structural reinforcement material. This composite structure provides the necessary strength and mechanical performance at cryogenic temperatures while significantly reducing the mass compared to traditional metallic ducts.
2Reliability
If metallic ducts are used to withstand significant loading environments, then reliability is improved, but mass and device complexity increase
Solution Approach 1:
The multi-layer composite construction with polymer films, cryogenic epoxy, and structural reinforcement provides the necessary reliability to withstand significant loading environments including vibration and acoustic loads during launch, while avoiding the complexity of metallic bellows and mechanical restraints.
Solution Approach 2:
The patent utilizes materials and construction methods specifically optimized for cryogenic parameters, including cryogenic-grade epoxy and polymer films selected for their properties at extremely low temperatures, enabling the duct to reliably withstand loading environments without excessive complexity.
3Weight of moving object
If non-metallic materials are used for cryogenic ducts, then mass is reduced, but strength and reliability deteriorate
Solution Approach 1:
The patent creates a composite material system where polymer films provide flexibility and mass reduction, cryogenic epoxy provides bonding and structural integrity, and structural reinforcement material provides additional strength. This composite approach enables non-metallic ducts to achieve sufficient strength for cryogenic applications.
Solution Approach 2:
Different layers of the composite duct serve different functional requirements: polymer films provide flexibility and corrosion resistance, epoxy layers provide bonding and structural continuity, and reinforcement materials provide localized strength where needed. This distribution of properties throughout the structure achieves overall strength without excessive mass.
4Strength
If metallic materials are used for cryogenic ducts, then mechanical strength is improved, but galvanic corrosion and combustion risks increase
Solution Approach 1:
The patent removes metallic materials from the duct construction entirely, eliminating the sources of galvanic corrosion and combustion risks associated with metals. The design achieves necessary strength through composite construction using non-metallic materials that are inherently resistant to these harmful effects.
Solution Approach 2:
The polymer film and epoxy construction creates an inert, non-reactive environment that is immune to galvanic corrosion and resistant to combustion, even when transporting pressurized oxygen. This eliminates the harmful effects associated with metallic materials in cryogenic oxidizer service.
5Ease of operation
If traditional hose constructions with fabric layers are used, then flexibility is improved, but fire hazard increases
Solution Approach 1:
The patent removes traditional fabric layers from the hose construction, eliminating the fire hazard they present. The design achieves necessary flexibility through multi-ply polymer film construction with cryogenic-grade materials that maintain flexibility at low temperatures without the combustion risks of fabric.
Solution Approach 2:
The polymer film and epoxy construction creates an inert, non-combustible structure that eliminates fire hazards while maintaining flexibility. The materials are selected for their fire resistance and compatibility with cryogenic oxidizers, providing a safe alternative to traditional fabric-reinforced hoses.
Data Source
AI summary
A multi-ply composite duct comprised of polymeric materials, inter-ply cryogenic epoxy or sealing agent, and structural reinforcement material and methods of making the duct are disclosed. Ducts according to the present disclosure demonstrate the ability to satisfy performance requirements for transfer of single and multiphase fluids at cryogenic temperatures, and resist perforation, occlusion, combustion and galvanic coupling.