Floating Stud Assembly for Thermal Tile Attachment
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Solution Overview
Problem
Current tile-to-structure attaching systems for thermal protection in spacecraft face challenges with misalignment tolerance and the need for convenient removal and reattachment of tiles, as existing adhesive and mechanical methods either lack flexibility or require complex assembly processes.
Innovation Solution
A floating stud assembly system comprising a plate with a pocket and hole, where a stud with a smaller shaft and larger head is inserted through the hole, allowing the stud to move freely in two directions within the plate's constraints, enabling attachment of secondary structures to primary structures while accommodating misalignment and facilitating easy removal and reattachment of tiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive methods are used to attach tiles to structure, then strong and flexible bond is achieved, but removal and reattachment of tiles is not convenient
Solution Approach 1:
The attachment system is divided into separate components: a plate attached to the structure, a stud with shaft and head, and a tile. The stud can be inserted through the plate, allowing the tile to be mechanically attached yet easily removed and reattached by simply detaching the tile from the stud, while the plate remains fixed to the structure.
Solution Approach 2:
The stud is designed with a shaft diameter less than the hole diameter in the plate, allowing the stud to move freely within the plate's constraints. This dynamic capability enables the stud to accommodate misalignment while maintaining a secure mechanical connection that allows for convenient tile removal and reattachment.
2Ease of operation
If mechanical fastening systems are used to allow rapid attachment and removal of tiles, then convenience of removal is improved, but complex assembly processes and additional bonding steps are required
Solution Approach 1:
The invention merges the advantages of adhesive bonding (simple attachment) with mechanical fastening (easy removal) into a unified system. The plate is attached to the structure using simple adhesive bonding, while the stud provides the mechanical fastening element that enables rapid tile attachment and removal without requiring complex assembly procedures.
Solution Approach 2:
The plate-stud assembly serves multiple functions: it provides structural attachment to the vehicle, accommodates thermal expansion and misalignment, enables rapid tile attachment and removal, and eliminates the need for complex hard points or specialized mounting structures. This multi-functionality reduces overall system complexity.
3Ease of operation
If tiles are made with holes and metal fasteners for removable attachment, then convenient removal is achieved, but the assembly becomes more complex requiring adhesive bonding and multiple components
Solution Approach 1:
Instead of placing the fastening mechanism in the tile (as in conventional approaches with holes and fasteners), the invention inverts the approach by placing the plate with the hole in the structure and the stud in the tile. This allows the tile to be simply placed over the stud for attachment and easily removed by lifting off, eliminating the need for adhesive bonding of fasteners and reducing the number of components.
Data Source
AI summary
A floating stud assembly system of particular use in attaching insulating material to aircraft structures is described employing a stud extended through a hole in a plate. The plate comprises a pocket or cavity and an end of the stud is configured to reside in the pocket or cavity such that the stud is retained by the plate while still being allowed movement in a plane.