Modular Wing Leading Edge Assembly for Extreme Heat
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Solution Overview
Problem
Current thermal protection systems for spacecraft, such as those used in reentry, are costly and difficult to replace due to the extreme high temperatures encountered, with existing materials like ceramic tiles being complex and metallic leading edges unable to withstand such conditions.
Innovation Solution
A modular, metallic wing leading edge assembly with a super alloy skin and expandable joints, allowing thermal and aerodynamic growth without permanent deformation, and featuring a T-seal system for easy installation and removal, utilizing materials like INCONEL for high heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic tiles are used for thermal protection, then heat resistance is improved, but device complexity and ease of replacement worsen
Solution Approach 1:
The thermal protection system is divided into modular panels that can be independently replaced. Each panel is a self-contained unit with standardized connections, allowing individual panel replacement without replacing the entire thermal protection system. This segmentation reduces overall system complexity while maintaining high heat resistance through materials like INCONEL superalloy.
2Ease of manufacture
If metallic leading edges are used, then ease of manufacture is improved, but temperature resistance worsens
Solution Approach 1:
The leading edge panels utilize composite construction combining INCONEL superalloy for structural integrity and heat resistance, with integrated thermal protection coatings or linings. This composite approach maintains the manufacturing advantages of metallic materials while achieving the high temperature resistance (up to 6000°F) previously only available from ceramic systems.
3Temperature
If thermal protection systems are designed for high temperature resistance, then temperature resistance is improved, but ease of repair worsens
Solution Approach 1:
The panel connection system incorporates dynamic, movable joints that allow panels to expand and contract thermally while maintaining secure attachment. The T-seal system provides flexible sealing that accommodates thermal deformation, enabling easy panel removal and reinstallation after thermal events without compromising the high-temperature performance of the system.
4Ease of repair
If modular panels are used, then ease of replacement is improved, but structural strength worsens
Solution Approach 1:
The modular panel design integrates multiple functions into unified components: structural load-bearing elements, thermal protection layers, aerodynamic surfaces, and sealing systems are merged into single integrated panels. The connection hardware combines mechanical attachment with thermal sealing functions, maintaining structural integrity while enabling straightforward panel replacement through standardized interfaces.
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 solution provides a durable, cost-effective thermal protection system capable of withstanding extreme temperatures up to 6000°F, allowing for easier maintenance and replacement, while preventing structural deformation and gas infiltration.
Implementation Method 1
The solution provides a durable, cost-effective thermal protection system capable of withstanding extreme temperatures up to 6000°F
Implementation Method 2
the side ends of each section are slideably mounted to a T-seal so as to allow unimpeded expansion of each leading edge section into a gap defined between the adjacent leading edge sections
Data Source
AI summary
A leading edge of a wing for an aircraft that is subject to a wide temperature range. The leading edge includes a plurality of leading edge sections arranged along the wing so as to define its leading edge. Two opposing ends of each section are removably mounted to a spar of the wing and wherein side ends of each section are slidably mounted to a T-seal so as to allow unimpeded expansion of each leading edge section into a gap defined between adjacent leading edge sections.