Modular Frangible Separation Assemblies for Launch Vehicle Stages

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Solution Overview

Problem

Existing frangible joint separation devices require customized designs for each unique structural component application, leading to increased manufacturing costs and complexity due to the need for long, customized segments, which limits versatility and efficiency in separating components like launch vehicle stages.

Innovation Solution

The development of modular separation device assemblies comprising shorter segment elements with attachment and frangible portions, allowing for flexible assembly and alignment, and the use of an expansion device within a cavity to separate structural components, enabling easier manufacturing and adaptation to various applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If customized long segments are used for each unique structural component application, then the separation device can achieve proper attachment and separation functionality, but manufacturing costs and complexity increase

Engineering Contradiction:

Improveseparation functionalityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The separation device is divided into multiple standardized segment elements that can be assembled in different configurations. Each segment has standardized attachment portions and frangible portions, allowing customization through assembly rather than custom manufacturing of entire long segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Standardized segment elements with universal attachment and frangible portions can be used across multiple different applications and structural components. The same basic segment design serves various purposes by being assembled in different arrangements, eliminating the need for completely customized designs for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If customized long segments are used for each application, then proper attachment to structural components is achieved, but manufacturing costs increase

Engineering Contradiction:

Improveattachment capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By segmenting the device into standardized elements, high-volume production of identical components becomes possible, reducing per-unit manufacturing costs compared to custom manufacturing of entire long segments for each application.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standardized segment elements can be manufactured in advance and stored for reuse across multiple applications. This allows recovery of tooling and setup costs through repeated use of the same standardized components in different configurations.

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If customized long segments are used, then application-specific requirements are met, but versatility across different applications decreases

Engineering Contradiction:

Improveapplication-specific performanceVSAvoidapplication versatility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The standardized segment elements with universal attachment and frangible portions can be assembled in various configurations to meet different application requirements, providing both versatility and application-specific performance through modular assembly rather than custom design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The modular segmented design allows the separation device to be dynamically configured for different applications by assembling segments in appropriate arrangements, rather than being fixed in a single customized design. This enables adaptation to various structural components and separation requirements.

Inventive Principle:

Principle #15Dynamics

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 approach reduces manufacturing costs and complexity by allowing for high-volume production of segmented assemblies that can be easily customized to different lengths and applications, improving the efficiency and versatility of frangible joint separation devices.

Implementation Method 1

an expansion device located within the expansion device cavity, wherein expansion of the expansion device causes the frangible portions of the first segment elements to separate the separation device assembly

Methodology Applied

Scientific EffectExpansion:

Implementation Method 2

each first segment element includes a fracture groove

Methodology Applied

Scientific EffectFracture: Fracture Mechanics

Data Source

PatentUS12145751B2Separation device assemblies

Publication Date: 2024.11.19 ENSIGN BICKFORD AEROSPACE & DEFENSE CO

AI summary

Separation device assemblies are provided. The assemblies include a plurality of first segment elements, each first segment element having an attachment portion and a frangible portion, the attachment portion of the first segment elements is arranged to fixedly connect to a first structural component and at least one second segment element having an attachment portion and a securing portion, wherein the attachment portion of the at least one second segment element is arranged to fixedly connect to a second structural component. At least two of the plurality of first segment elements are attached to the at least one second segment element adjacent to each other and a first segment joint is formed between adjacent first segment elements. An expansion device cavity is formed between the attached first and second segment elements.