Segmented Heat Shield Reducing Interlayer Thermal Conduction
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Solution Overview
Problem
Aircraft brake systems generate high temperatures during operation, which can cause thermal damage to wheels and tires, and existing heat shields may not adequately mitigate this damage.
Innovation Solution
A heat shield assembly with multiple layers, including an inner and outer layer with tab members and crimped portions for engagement, and an intermediate dimpled layer to enhance thermal protection, is designed to be positioned between the brake stack and the wheel, with a method of manufacturing involving forming surfaces, tab members, crimped portions, and joining the layers to form a segmented heat shield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a heat shield is positioned between the brake stack and the wheel to mitigate thermal damage, then thermal protection is improved, but thermal conduction from the brake stack to the wheel increases
Solution Approach 1:
The heat shield is divided into multiple discrete layers (first layer, intermediate layer, second layer) rather than using a single solid structure. This segmentation creates thermal barriers between layers, reducing overall heat conduction while maintaining structural integrity and protective function.
Solution Approach 2:
An intermediate layer is introduced between the first and second layers of the heat shield. This intermediate layer acts as a thermal mediator with lower thermal conductivity, blocking heat transfer pathways and reducing the amount of thermal energy that reaches the wheel while still allowing the heat shield to perform its protective function.
2Object-affected harmful factors
If multiple layers are used in the heat shield to reduce thermal conduction, then thermal protection is improved, but device complexity increases
Solution Approach 1:
The heat shield layers are arranged in a nested configuration where the intermediate layer is positioned within the structure formed by the first and second layers. The tab members and crimped portions are nested within the layers, creating a compact multi-layer structure that reduces overall complexity compared to distributed fastening systems.
Solution Approach 2:
The tab members and crimped portions serve dual functions: they provide mechanical fastening between layers and simultaneously act as thermal barriers. By combining fastening and thermal protection functions into single structural elements, the overall device complexity is reduced despite the multi-layer construction.
3Strength
If tab members and crimped portions are used to secure the heat shield layers, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The tab members are formed as integral parts of the first layer, and the crimped portions are formed as integral parts of the second layer. These elements self-assemble when the layers are stacked, with the tab members fitting into the crimped portions without requiring additional fasteners or complex assembly operations, thereby improving ease of manufacture while maintaining structural integrity.
Solution Approach 2:
The material properties of the heat shield layers are selected and configured to enable the tab members and crimped portions to form strong mechanical connections. By optimizing parameters such as material ductility, thickness ratios, and geometric dimensions of the tab and crimp features, strong structural integrity is achieved through simple forming and assembly operations.
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 heat shield assembly effectively reduces thermal damage to aircraft wheels by dissipating heat and is securely fastened to the wheel using torque bars and fasteners, providing enhanced protection against high temperatures during brake actuation.
Implementation Method 1
an intermediate layer is disposed between the first layer and the second layer... the intermediate layer comprises a first plurality of dimples oriented toward the first layer... the first plurality of dimples is configured to contact the first layer
Data Source
AI summary
A heat shield assembly is disclosed. In various embodiments, the heat shield assembly defines a first circumferential side and a second circumferential side and an inboard end and an outboard end and includes a first layer defining a first surface of the heat shield assembly and having a first tab member disposed proximate the inboard end at the first circumferential side and a second tab member disposed proximate the outboard end at the first circumferential side; and a second layer defining a second surface of the heat shield assembly and having one or more first crimped portions extending along the first circumferential side and configured to engage the first tab member and the second tab member.