Sensorized Cryogenic Bellows Conduit for 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 and an interstitial space, hermetically coupled with sensors to detect leaks and accommodate displacements, along with a method of fabrication that includes corrugating and trimming the plies to form a compliant structure for efficient and reliable fluid transport.

Engineering Contradictions & Design Principles

VSEngineering 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

Engineering Contradiction:

Improveaccommodation of displacementsVSAvoidresistance to manufacturing variances and damage

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The conduit is divided into multiple collars (first collar, second collar) connected by a bellows structure. This segmentation allows each component to be optimized independently - the collars provide rigid sealing interfaces while the bellows provides flexible displacement accommodation, resolving the contradiction between adaptability and reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bellows structure employs a composite construction with a corrugated inboard ply and a corrugated outboard ply, hermetically coupled together. This composite structure combines the flexibility needed for displacement accommodation with the structural integrity required for reliability in cryogenic environments.

Inventive Principle:

Principle #40Composite materials

2Reliability

If hermetic coupling of collar portions and bellows plies is implemented, then reliability is improved, but device complexity increases due to multiple welds and assembly steps

Engineering Contradiction:

Improvehermetic sealingVSAvoidnumber of welds and assembly steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The first outer collar portion and first inner collar portion are hermetically coupled through welding to form an integrated first collar assembly. Similarly, the second collar portions are merged. This consolidation reduces the number of separate components and potential leak paths, improving reliability while managing complexity through systematic integration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The collars and bellows plies are hermetically coupled during the fabrication process before final assembly. This preliminary hermetic coupling ensures sealing integrity is established early, preventing contamination and simplifying subsequent assembly steps, thereby managing overall device complexity.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If sensors are integrated into the conduit structure, then reliability is improved through leak detection, but device complexity increases

Engineering Contradiction:

Improveleak detection capabilityVSAvoidsensor integration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A sensor is integrated into the first collar to detect leaks in the corrugated inboard ply. The sensor acts as an intermediary monitoring element that provides leak detection capability without requiring complex structural modifications to the bellows itself, thereby improving reliability while managing device complexity through strategic sensor placement.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 design provides a compliant structure for cryogenic fluids, enabling detection of leaks and accommodating operational displacements, thereby enhancing the reliability and safety of cryogenic propulsion systems by preventing damage to the main propulsion system.

Implementation Method 1

a first weld, hermetically coupling the first outer collar portion and the first inner collar portion

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The conduit provides a compliant structure for transportation of fluids, such as cryogenic fuels, that accommodates displacements encountered during operation

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11512807B2Conduits for transporting fluids and methods of fabricating the same

Publication Date: 2022.11.29 THE BOEING CO

AI summary

A method of fabricating a conduit comprises steps of attaching a first tubular-outboard-ply end of a tubular outboard ply to a first inner collar portion of a first collar with a third weld and attaching a second tubular-outboard-ply end to a second inner collar portion of a second collar with a fifth weld. The method additionally comprises steps of interconnecting the first inner collar portion and a first outer collar portion of the first collar with a first weld and interconnecting the second inner collar portion and a second outer collar portion of the second collar with a sixth weld. The method also comprises attaching a trimmed first corrugated-inboard-ply end to the first outer collar portion with a second weld, attaching a trimmed second corrugated-inboard-ply end to the second outer collar portion with a fourth weld, and communicatively coupling a first sensor with an interstitial space.