Kinematic Countermeasure Flare Housing with Integrated Ribs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current manufacturing processes for countermeasure flares are time-consuming and imprecise due to the challenges of applying adhesive and non-flammable coatings to the interior surfaces of the flare housing, which affects the burn rate and pressure profile of the propellant and the secure placement of the nose weight.
Innovation Solution
The improved housing assembly integrates longitudinal ribs and a retaining bead within the housing structure, formed during the molding process, which secures the nose weight and controls the propellant's burn rate by reducing the exposed surface area, eliminating the need for post-casting coatings and adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is applied to the interior wall at the forward end of the housing to secure the nose weight, then the nose weight is retained in position, but the manufacturing process becomes time-consuming and imprecise
Solution Approach 1:
The nose weight is positioned and secured to the die core before the housing material is formed over it. This preliminary positioning eliminates the need for subsequent adhesive application, as the nose weight is already in its correct position when the housing is molded around it, thereby reducing manufacturing time while ensuring reliable retention.
Solution Approach 2:
The nose weight retention function is merged with the housing formation process itself. By forming the housing material directly over the positioned nose weight in a single molding operation, the patent combines what were previously separate steps (positioning + adhesive application + housing formation) into one integrated process, eliminating time loss while maintaining reliability.
2Manufacturing precision
If non-flammable coating is applied to the exposed surfaces of the propellant after casting, then the burn rate and pressure profile are controlled, but the process is time-consuming and imprecise
Solution Approach 1:
The non-flammable coating is applied to the propellant surfaces before the propellant is cast into the housing. By pre-coating the propellant grain with non-flammable material on its exposed surfaces, the patent eliminates the need for post-casting coating application. The pre-coated propellant is then cast into the housing, achieving precise burn rate control while reducing manufacturing time.
Solution Approach 2:
Instead of applying the non-flammable coating after the propellant is cast (the conventional sequence), the patent inverts the sequence by applying the coating before casting. This reversal allows the coating to be precisely applied to the propellant grain surfaces in a controlled manner before the propellant is formed into its final shape within the housing, achieving both precision and efficiency.
3Manufacturing precision
If manual application of non-flammable coating is used on the propellant grain, then the burn surface area can be controlled, but the placement is not always precise and requires skilled labor
Solution Approach 1:
The manual mechanical application of non-flammable coating is replaced with a molding process. The housing material is formed over the pre-coated propellant grain using mold pressure and heat, which automatically and precisely positions the housing relative to the propellant. This mechanical molding process substitutes for the imprecise manual coating application, eliminating the need for skilled labor while maintaining precise control over the burn surface area.
Data Source
AI summary
The present invention provides an improved kinematic countermeasure flare and method of constructing the same wherein the housing has integrated internal features. The flare nose weight is set at the end of a die core prior to molding for integration with the housing. Longitudinal grooves and other recesses in the die core allow for the formation of internal longitudinal ribs which propellant can bond to and a retaining bead for retaining the nose weight in the housing which are integrated with the housing. Propellant is cast into the formed housing. A propellant shaping mandrel is then inserted into the formed housing thereby forcing the propellant into the internal cavity created by the integrally molded longitudinal ribs, the shaping mandrel and the wall of the flare housing such that the propellant is bonded to the interior housing wall and the longitudinal ribs. This improved housing and method of construction eliminates the need to apply a non-flammable coating to propellant surfaces after its addition to the flare housing which a an imprecise and time consuming process.