Composite Rocket Nozzle Flange Attachment
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Solution Overview
Problem
The existing nozzle designs that connect a metallic combustion chamber to a composite material divergent using a radial flange significantly increase manufacturing costs due to the need for extra thickness and additional machining, which is not cost-effective for lightweight nozzles.
Innovation Solution
A nozzle design featuring a metallic annular flange with a first part secured to the combustion chamber and a second part extending beyond the combustion chamber, where the composite material divergent is fixed using clamping members with screws passing through the cone-shaped wall, eliminating the need for extra thickness and machining, and incorporating a cooling circuit to maintain reasonable temperatures for refractory metal usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a radial flange is added to the composite nozzle to connect it to the combustion chamber, then the connection strength is improved, but the manufacturing cost and complexity significantly increase due to extra thickness and additional machining
Solution Approach 1:
Instead of adding a flange to the composite nozzle (as done in prior art), the invention inverts the approach by providing the flange as an integral part of the metal combustion chamber. This reversal eliminates the need for expensive composite flange machining while maintaining strong mechanical connection through conventional metal flange attachment methods.
Solution Approach 2:
The flange is merged with the combustion chamber as an integral component rather than a separate attachment. This combining of the flange and combustion chamber into a single metal structure simplifies manufacturing by eliminating the need for separate composite flange fabrication and reduces overall assembly complexity.
2Adaptability or versatility
If a radial flange with extra thickness is created in the composite nozzle, then the attachment capability is improved, but the overall mass of the nozzle increases
Solution Approach 1:
The invention inverts the traditional approach by placing the flange on the metal combustion chamber rather than the composite nozzle. This eliminates the need for heavy composite flange structures while maintaining full attachment capability through the metal flange, thereby reducing overall nozzle mass.
Solution Approach 2:
The flange structure is applied locally to the combustion chamber in the specific region where attachment is needed, rather than adding global thickness to the composite nozzle. This localized approach provides attachment capability only where required, minimizing unnecessary mass addition.
3Manufacturing precision
If complex machining operations are performed on the composite divergent to form a flange, then the connection precision is improved, but the manufacturing time and cost increase
Solution Approach 1:
Instead of machining the flange into the composite divergent (which is time-consuming and costly), the invention inverts the approach by providing the flange as a pre-formed integral part of the metal combustion chamber. This eliminates complex composite machining operations while maintaining precise connection alignment.
Solution Approach 2:
The flange is preliminarily formed as an integral part of the combustion chamber during its manufacturing process, rather than being created through subsequent machining operations on the composite divergent. This preliminary formation of the flange structure streamlines the overall manufacturing sequence and improves productivity.
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
This design reduces the overall mass of the nozzle, simplifies manufacturing, and lowers costs by eliminating the need for extra thickness and machining, while maintaining the connection between the combustion chamber and divergent at relatively low temperatures, allowing for the use of refractory metals and simplifying the manufacturing process.
Implementation Method 1
The cooling circuit comprises at least one first annular channel for circulating a cooling fluid extending along the downstream end of the combustion chamber and near the clamping elements. The area of the combustion chamber where the axial attachment to the divergent part is achieved is thus cooled, thereby maintaining the metallic parts in this area at reasonable temperatures.
Implementation Method 2
The cooling circuit comprises at least one first annular channel for circulating a cooling fluid extending along the downstream end of the combustion chamber and near the clamping elements.
Data Source
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AI summary
A jet nozzle having a longitudinal axis (ZZ') comprises: a combustion chamber which is made of a metal material (14) and has a downstream end (141); and a divergent nozzle section (16) made of a composite material and formed of a cone-shaped wall (160) extending between an upstream end (161) and a downstream end (162). The upstream end (161) of the composite divergent nozzle section is connected to the downstream end (141) of the combustion chamber. The jet nozzle further comprises an annular flange (18) made of a metal material and comprising a first portion (181) secured to the combustion chamber (14) and a second portion (182) extending beyond the downstream end (141) of the combustion chamber (14) in the direction of the longitudinal axis of the jet nozzle (10). The upstream end (161) of the composite divergent nozzle section is fixed to the second portion (182) of the annular flange (18) by a plurality of clamping members (20) each comprising a fixing screw (21), each fixing screw passing through the cone-shaped wall (160) of the composite divergent nozzle section (16) in the region of the upstream end (161) of said wall.