Kinetic Metal Ring Seal for Low-Temperature Rocket Motor Joints
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Solution Overview
Problem
Gasket seals in rocket motor assemblies are prone to degradation and failure, especially at low temperatures, leading to potential catastrophic failures, and require careful assembly and excess material to maintain a seal, which is inefficient and risky.
Innovation Solution
A kinetically deposited metal ring seal using a plurality of plasticized metal particles that forms an airtight barrier around a central axis, allowing for low-temperature application and maintaining a seal without degrading over time, reducing the need for high forces and physical space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gasket seals are used in rocket motor assemblies, then sealing function is provided, but the sealant material degrades over time leading to potential catastrophic failure
Solution Approach 1:
The patent replaces the degradable fluoroelastomer sealant with a metal ring seal that does not degrade over time. The metal seal is designed to be replaced if necessary, but provides indefinite service life without the degradation issues of polymer-based sealants, directly resolving the reliability vs. service life contradiction.
Solution Approach 2:
The invention uses a composite structure combining a metal ring with kinetic deposition material (such as nickel or other metals) to create a seal that leverages the non-degradable properties of metal while achieving the conformal sealing capability needed for rocket motor applications. This composite approach eliminates the time-dependent degradation of single-material gasket seals.
2Reliability
If excess sealant material is used to account for degradation and consumption, then seal reliability is improved, but the seal assembly volume increases
Solution Approach 1:
By replacing the excess polymer sealant with a compact metal ring seal, the invention eliminates the need for volume-consuming backup material. The metal seal achieves reliable sealing without requiring excess material to compensate for degradation, directly reducing seal assembly volume while maintaining or improving reliability.
Solution Approach 2:
The invention changes the material parameters from polymer-based sealant to metal-based seal, fundamentally altering the sealing mechanism. This parameter change allows for a compact seal design that does not require excess material volume to ensure reliability under varying temperature and pressure conditions.
3Reliability
If gasket seals are used to enclose hot gases, then sealing function is provided, but the hot gases may burn through the gasket seal
Solution Approach 1:
The patent replaces the polymer gasket seal that can be burned through by hot gases with a metal ring seal that has superior thermal resistance. The metal material (such as nickel) can withstand the high temperatures of rocket motor combustion without degrading, directly resolving the issue of hot gas damage while maintaining seal integrity.
Solution Approach 2:
The composite metal ring structure provides thermal barrier properties that protect the seal from hot gas degradation. The kinetic deposition layer on the metal ring creates a thermally resistant composite structure that maintains seal integrity in high-temperature environments where polymer gaskets would fail.
4Reliability
If careful assembly is performed to account for sealant material limitations, then seal reliability is improved, but the assembly process complexity increases
Solution Approach 1:
The metal ring seal is designed as a simple, replaceable component that eliminates the need for complex assembly procedures required by degradable gasket seals. The simplified design allows for straightforward installation without requiring careful adjustment to account for sealant material limitations, reducing assembly process complexity while maintaining reliability.
5Temperature
If low temperatures are used for assembly, then fuel activation is prevented, but the seal must withstand subsequent elevated temperatures
Solution Approach 1:
The metal ring seal provides temperature-independent performance, allowing cold assembly (preventing fuel activation) while maintaining seal integrity at subsequent elevated operating temperatures. The metal material does not suffer from the temperature-sensitive degradation that plagues polymer gaskets, resolving the contradiction between low-temperature assembly requirements and high-temperature service requirements.
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 metal ring seal provides a durable, low-volume, airtight seal that withstands elevated temperatures and pressures, reducing the risk of failure and eliminating the need for expensive fasteners and solvents, while allowing for increased fuel volume and improved performance.
Implementation Method 1
a kinetically deposited metal layer of a plurality of plasticized metal particles around a central axis of the housing that attaches and forms an airtight barrier
Implementation Method 2
The kinetically deposited metal layer can be applied at low temperatures ensuring the temperature stays below the activation temperature of loaded fuel
Data Source
AI summary
Disclosed herein is a kinetically deposited metal ring seal. In particular, disclosed herein is a joint assembly including a housing, a component, and a seal assembly. The housing defines an opening and a central axis. The component is positioned proximate the opening of the housing. The seal assembly comprises a kinetically deposited metal layer attaching the housing to the component and forming an airtight barrier around the central axis between the housing and the component. The kinetically deposited metal layer comprises a plurality of plasticized metal particles. Accordingly, the kinetically deposited metal layer can be applied at low temperatures, ensuring the temperature stays below the activation temperature of loaded fuel. Further, the kinetically deposited metal layer forms a low volume, airtight seal, which does not degrade over time, and does not require application of high forces to maintain the seal.