Fiber Composite Overwrap Structure for Spacecraft Re-Entry Burnup
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Solution Overview
Problem
Conventional fiber composite overwraps for spacecraft containers face challenges in achieving complete burnup upon re-entry into the Earth's atmosphere while maintaining structural integrity and strength, leading to potential space debris risks.
Innovation Solution
The overwrap consists of multiple fiber bundles embedded in a plastic matrix, with adjacent bundles forming abutment regions and overlap regions to enhance detachment under aerodynamic shear forces, reducing stress concentrations and ensuring complete burnup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a continuous fiber strand is used in the overwrap, then the tensile strength and structural integrity are improved, but the burnup behavior deteriorates due to insulating effect preventing complete degradation
Solution Approach 1:
The continuous fiber strand is segmented into multiple individual fiber bundles that are arranged side-by-side within the plastic matrix. This segmentation reduces the insulating effect by creating gaps between fibers that allow heat penetration, enabling complete burnup while maintaining structural integrity through the collective strength of multiple bundles.
2Object-generated harmful factors
If fiber bundles are separated into individual bundles, then the burnup behavior is improved, but the tensile strength is reduced
Solution Approach 1:
The invention creates a composite structure where multiple fiber bundles are embedded in a plastic matrix. The matrix binds the individual bundles together, transferring and distributing tensile loads across all bundles, thereby compensating for the reduced strength of individual separated bundles and achieving both improved burnup behavior and maintained tensile strength.
3Object-generated harmful factors
If abutment regions are formed only by plastic matrix, then the detachment of fiber bundles is enabled, but stress concentrations are introduced
Solution Approach 1:
The invention applies local quality by creating abutment regions where fiber bundles directly abut each other, providing localized support at critical points. The plastic matrix fills the spaces between bundles and provides overall binding, while the direct bundle-to-bundle contact in abutment regions prevents excessive stress concentration that would occur with matrix-only support.
4Strength
If multiple tape layers are used, then the stress distribution is improved, but the device complexity increases
Solution Approach 1:
The invention merges multiple tape layers into a single integrated winding tape structure. Instead of applying separate layers in distinct manufacturing steps, the multi-layer construction is built into one tape that is wound in a single continuous process, reducing manufacturing complexity while maintaining the stress distribution benefits of multiple layers.
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 improves burnup behavior by allowing effective detachment of fiber bundles, ensuring the underlying container shell melts reliably, while maintaining sufficient strength and stiffness.
Implementation Method 1
after pyrolysis of the plastic matrix, the fiber bundles embedded therein can be effectively detached
Implementation Method 2
the fiber bundles embedded therein can be effectively detached by aerodynamic shear forces
Implementation Method 3
they provide an insulating layer for the metallic spacecraft container shell upon re-entry into the Earth's atmosphere
Data Source
AI summary
A fiber composite plastic overwrap for a spacecraft container shell (8), in particular in connection with spacecraft containers, provides burnup as complete as possible on re-entry into the Earth's atmosphere despite good strength properties and simple production with the aid of conventional fiber winding processes. The overwrap comprises at least one winding tape (1) of a plastic matrix (2) in which at least two tape layers (3, 4) arranged one above the other in a transverse tape direction (y) are embedded. Each of the tape layers (3, 4) comprises a plurality of fiber bundles (5) extending unidirectionally in the longitudinal tape direction (x), Fiber bundles (5) of a tape layer (3, 4) adjacent in the longitudinal tape direction (x) directly adjoin one another in abutment regions (6) provided at least once per winding turn, and fiber bundles (5) adjacent in the transverse tape direction (y) are offset relative to one another in the longitudinal tape direction (x), forming an overlap region (7).