Layered Secondary-Explosive Bolt for Shrapnel-Free Separation
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Solution Overview
Problem
Existing explosive bolt technologies face challenges in efficiently and safely separating connected components, particularly in aerospace applications, where reliable and shrapnel-free separation is critical.
Innovation Solution
The explosive bolt system incorporates a shank with an internal chamber containing a high-density first secondary explosive material and a low-density second secondary explosive material, arranged in arming communication with an initiator device to ensure controlled detonation and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional explosive bolts are used for separating connected components, then separation function is achieved, but safety risks increase due to use of primary explosive materials and potential shrapnel generation
Solution Approach 1:
The patent removes primary explosive materials from the explosive bolt system, retaining only secondary explosive materials. This extraction eliminates the most hazardous components while preserving the separation function, directly addressing the safety concern without sacrificing operational capability
Solution Approach 2:
The patent designs the explosive bolt to contain fragments within the bolt structure itself, converting potential harmful shrapnel into contained debris that does not pose external threats. The bolt housing acts as a containment structure that redirects fragment energy inward rather than outward, transforming a harmful effect into a controlled internal phenomenon
2Reliability
If high-density explosive material is used to ensure effective detonation, then separation effectiveness improves, but manufacturing complexity increases due to precision requirements
Solution Approach 1:
The patent specifies a density range (1.4-1.6 g/cm³) rather than a single precise value, and provides a minimum density threshold (1.4 g/cm³) for the secondary explosive material. This parameter approach ensures effective detonation while allowing manufacturing flexibility and reducing precision requirements
Solution Approach 2:
The patent applies different density requirements to different regions of the explosive material. The secondary explosive material in the chamber requires a minimum density of 1.4 g/cm³, while the booster explosive material has its own density specifications. This localized quality control ensures effective detonation propagation while simplifying overall manufacturing
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 configuration provides a high safety level by utilizing only secondary explosive materials, ensuring controlled separation without shrapnel, and meeting the stringent safety criteria of MIL-STD-131.
Implementation Method 1
an explosive bolt, comprising a shank having a first longitudinal end, an opposed second longitudinal end and a longitudinal axis, the explosive bolt being configured for securing two elements together between said first longitudinal end and said second longitudinal end; the shank including an internal chamber accommodating a first layer of a high density first secondary explosive material, and further accommodating a second layer of a low density second secondary explosive material in arming communication with the first layer
Data Source
AI summary
An explosive bolt system includes an explosive bolt and an initiator device. The explosive bolt includes a shank having a first longitudinal end, an opposed second longitudinal end, and a longitudinal axis. The explosive bolt is configured for securing two elements together between the first longitudinal end and the second longitudinal end. The shank includes an internal chamber accommodating a first layer of a high density first secondary explosive material, and further accommodating a second layer of a low density second secondary explosive material in arming communication with the first layer. The initiator device is positioned with respect to the explosive bolt such that the initiator device is in arming communication with the explosive bolt.