Thermite Connecting Ring for Clean Stage Separation
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Solution Overview
Problem
Current connection-separation systems in space launchers and missiles generate debris and cause significant structural shocks during the separation of stages or payloads, leading to potential damage and asperities on the launcher surface.
Innovation Solution
A method and device utilizing a pyrogenic material, such as thermite, for rapid and partial heating of the connection point between elements, triggered remotely, to achieve smooth linear separation without debris generation, where the cutting crown is integrated into the connecting element or forms an extension of the launcher's wall, with insulation layers and mechanical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pyrotechnic cutting by local fusion or breaking is used, then separation is achieved, but debris is generated and significant shock is caused to the structure
Solution Approach 1:
The patent replaces mechanical cutting methods (pyrotechnic bolts, riveting, strapping) with a thermal field-based separation method. A pyrogenic material (thermite) is used to generate intense localized heat that melts and vaporizes the connecting element, achieving separation through thermal energy rather than mechanical force. This substitution eliminates the generation of debris and reduces structural shock while maintaining reliable separation.
Solution Approach 2:
The patent changes the physical state and properties of the connecting element through controlled thermal parameters. By delivering a concentrated thermal field that raises the temperature of the connecting element to its melting and vaporization points, the material undergoes phase changes from solid to liquid to gas, enabling clean separation without mechanical stress or debris generation.
2Strength
If multiple bolts or strapping are used for connection, then force transfer is improved, but device complexity and failure risk increase
Solution Approach 1:
The patent merges multiple separate connection devices (bolts, strapping, or other mechanical connectors) into a single integrated connecting element. This monolithic structure maintains the necessary mechanical strength for force transfer during launch while eliminating the complexity and potential failure points associated with multiple discrete components. The thermite-based separation system acts on this single unified element, simplifying both the connection and separation mechanisms.
3Reliability
If pyrotechnic cutting is used for separation, then connection is severed, but asperities are left on the launcher surface
Solution Approach 1:
The patent uses controlled thermal parameters to completely vaporize the connecting element rather than merely cutting it. By delivering sufficient thermal energy to raise the temperature to vaporization levels, the material transitions from solid to gas, eliminating residual fragments and asperities on the launcher surface. This thermal parameter control ensures both reliable separation and surface integrity.
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
Enables clean and shock-minimized separation of stages or payloads, preventing unnecessary heating of the structure and reducing the risk of failure by minimizing structural shocks and debris, while maintaining the integrity of the launcher's surface.
Implementation Method 1
separation in front taking place by rapid and partial heating of the assembly, at or around the connection, this heating being triggered remotely
Implementation Method 2
rapid and partial heating of the assembly, at or around the connection
Implementation Method 3
two annular layers of insulation placed in two parallel planes between the two walls and perpendicular to them
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3C
AI summary
The invention relates to a method and a device allowing the separation of two stages of an aeronautical vehicle, without affecting the structure of said two stages. The device consists mainly of a connecting ring (13) secured to the two stages of the aeronautical vehicle and comprising a cutting ring (20) on the inner surface (13A) thereof, which contains a mixture of thermite and an intermetallic composition. The triggering of the latter allows the heating and melting of part of the ring (13), which separates into two parts. The invention can be applied to an aeronautical launcher.