A medium-sized liquid rocket ablation-type flow deflector and a manufacturing method of a heat shield cap thereof

Abstract

The present application relates to a kind of medium liquid rocket ablation type flow guide and the manufacturing method of its heat shield cap.The ablation type flow guide includes: two-way flow guide matrix, heat shield cap, pressing part;The two-way flow guide matrix includes: the flow guide plate of human-shaped structure laying;Supporting structure for supporting the flow guide plate is arranged below the flow guide plate;The flow guide plate is arranged on the supporting structure, and located on the two sides of the flow guide direction of the flow guide plate Bancheng flow plate;The heat shield cap is laid on the flow guide plate, and the heat shield cap is multilayer structure;The pressing part is arranged on the flow guide plate, for fixing the heat shield cap;The horizontal cross section length size of the two-way flow guide matrix is 8-10 meters.The technical scheme provided by the present application can effectively improve the convenience of medium liquid rocket launch, reduce the time period of medium rocket launch, and reduce launch cost.

Description

Technical Field

[0001] This application relates to the field of rocket flame deflector technology, and in particular to an ablation-type deflector for a medium-sized liquid rocket; this application also relates to a method for manufacturing a heat shield cap for an ablation-type deflector. Background Technology

[0002] During rocket launch, a deflector (or deflector channel) is needed to smoothly guide the jet of exhaust gas generated by the rocket engine, keeping the exhaust gas away from the launch area. Deflectors can be divided into two types: cooled and uncooled. Preventing the deflector from burning up is a major challenge. Cooled deflectors are generally made of metal and use water as a coolant to keep the surface temperature of the deflector below the melting point of the material. Different structural designs are used depending on the layout of the pumping system.

[0003] Uncooled diffusers are currently used for launching small rockets, but their size is insufficient for launching medium-sized liquid-propellant rockets. Current uncooled diffusers, due to their limited use in small liquid-propellant rockets, are small in size and typically manufactured using molding; production costs and quality are relatively controllable. However, using the same process for small rocket diffusers to manufacture uncooled diffusers for medium-sized liquid-propellant rockets would require creating much larger molds, and the lack of molding equipment of equivalent size makes this production approach difficult to implement.

[0004] Therefore, how to provide an ablation-type guide for medium-sized liquid rockets that can effectively improve the convenience of launching medium-sized liquid rockets, reduce the launch time cycle, and lower launch costs is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] To address the shortcomings of the existing technology, the present invention aims to effectively improve the convenience of launching medium-sized liquid rockets, reduce the launch time cycle, and lower launch costs. The present invention provides an ablation-type flow guide for medium-sized liquid rockets, comprising: a bidirectional flow guide substrate, a heat shield, and a clamping component; the bidirectional flow guide substrate includes: a flow guide plate laid in a human-shaped structure; a load-bearing structure disposed below the flow guide plate for supporting the flow guide plate; baffle plates disposed on the load-bearing structure on both sides of the flow guide plate in the flow direction; the heat shield is laid on the flow guide plate, and the heat shield has a multi-layer structure; the clamping component is disposed on the flow guide plate for fixing the heat shield; the horizontal cross-sectional length of the bidirectional flow guide substrate is 8-10 meters.

[0006] According to a first embodiment of the present invention, an ablation-type deflector for medium-sized liquid rockets is provided:

[0007] A medium-sized liquid rocket ablation-type deflector includes: a bidirectional flow-guiding substrate, a heat shield, and a clamping component; the bidirectional flow-guiding substrate includes: a flow-guiding plate laid in a human-shaped structure; a load-bearing structure disposed below the flow-guiding plate for supporting the flow-guiding plate; baffles disposed on the load-bearing structure on both sides of the flow-guiding direction of the flow-guiding plate; the heat shield is laid on the flow-guiding plate, and the heat shield has a multi-layer structure; the clamping component is disposed on the flow-guiding plate for fixing the heat shield; the horizontal cross-sectional length of the bidirectional flow-guiding substrate is 8-10 meters.

[0008] Furthermore, as a more preferred embodiment of the present invention, the heat protection cap includes: an ablation layer laid on the guide plate; wherein, the heat protection cap further includes: a heat insulation layer laid between the ablation layer and the guide plate; and / or a heat-resistant coating laid on the side of the ablation layer away from the guide plate.

[0009] Furthermore, in a more preferred embodiment of the present invention, the ablation layer is made of carbon fiber as a reinforcing material and phenolic resin as a matrix material; the heat insulation layer is made of high silica fiber as a reinforcing material and phenolic resin as a matrix material; and the heat-resistant coating is made of one of the following: silicone resin, epoxy resin, phenolic resin, and ceramic-based coating.

[0010] Furthermore, as a more preferred embodiment of the present invention, the thickness of the heat insulation layer is H1mm, H1∈[5,10]; the thickness of the ablation layer is H2mm, H2∈[10,40]; and the thickness of the heat-resistant coating is H3mm, H3∈[0.2,1].

[0011] According to a second embodiment of the present invention, a method for manufacturing an ablation-type heat shield cap for a flow deflector is provided:

[0012] A method for manufacturing a heat shield cap for an ablation-type deflector, the method being used to fabricate the heat shield cap for the aforementioned ablation-type deflector of a medium-sized liquid rocket; the method includes: preparing phenolic resin; manually laying the heat insulation layer: firstly, brushing phenolic resin onto the surfaces of the deflector and the baffle, then laying high-silica cloth and removing air bubbles; manually laying the ablation layer: further brushing phenolic resin onto the heat insulation layer, then laying carbon fiber cloth and removing air bubbles; manually spraying the heat-resistant coating: manually spraying the heat-resistant coating onto the ablation layer.

[0013] Furthermore, as a more preferred embodiment of the present invention, in the step of "manually laying the insulation layer", the high-silica cloth needs to be impregnated in phenolic resin before laying; after laying one layer of the high-silica cloth, it is heated and cured; after completing the curing and laying of one layer of the high-silica cloth, the thickness of a single curing is h1mm, h1∈[2,5]; repeat the above steps until the thickness of the entire insulation layer reaches H1.

[0014] Furthermore, as a more preferred embodiment of the present invention, the "manual laying of the insulation layer" further includes: heating and curing the entire insulation layer: continuously heating the insulation layer with a heating device at a temperature of 60°C to 200°C; and curing time of at least 48 hours.

[0015] Furthermore, as a more preferred embodiment of the present invention, in the step of "manually laying the ablation layer", the carbon fiber cloth needs to be impregnated in phenolic resin before laying; after laying one layer of the carbon fiber cloth, it is heated and cured; after completing the curing and laying of one layer of the carbon fiber cloth, the thickness of a single curing is h2mm, h1∈[2,5]; repeat the above steps until the thickness of the entire ablation layer reaches H2.

[0016] Furthermore, as a more preferred embodiment of the present invention, the "manual application of the ablation layer" further includes: heating and curing the entire ablation layer: continuously heating the ablation layer using a heating device at a temperature of 60°C to 200°C; and curing for at least 48 hours.

[0017] Furthermore, as a more preferred embodiment of the present invention, the method further includes: before the step of "manually spraying the heat-resistant coating", using an ultrasonic scanner to detect the delamination, porosity, debonding rate and layup thickness of the heat insulation layer and the ablation layer.

[0018] Compared with existing technologies, the technical solution provided in this application can be used for launching medium-sized liquid rockets, even when the launch location lacks a pre-designed flow channel. Furthermore, the bidirectional flow-guiding substrate 1, through the flow-guiding plate 11, can direct the rocket's ejected flames to opposite sides parallel to the ground for exhaust. Simultaneously, the heat-resistant cap 2 laid on the flow-guiding plate improves the heat resistance of the entire flow-guiding device. Furthermore, the heat-resistant cap in this technical solution has a multi-layered structure, providing better heat resistance and ablation resistance compared to existing technologies. Furthermore, the clamping component 3 can better secure the heat-resistant cap to the flow-guiding plate 11. In summary, the technical solution provided in this application can effectively improve the convenience of launching medium-sized liquid rockets, reduce the launch time cycle, and lower launch costs.

[0019] Compared with the prior art, the technical solution provided in this application has the following technical effects:

[0020] 1. The external dimensions of the deflector can reach 8m in length, 3.5m in width, and 3m in height, and can be used to guide the takeoff exhaust flow of medium-sized liquid-propellant launch vehicles.

[0021] 2. The heat shield of the flow guide consists of a heat insulation layer, an ablation layer, and a heat-resistant coating, which are laid sequentially on the metal substrate of the flow guide, reducing material costs and providing good heat insulation, ablation resistance, and impact resistance.

[0022] 3. The production process of heat protection caps does not require the creation of large-size molds, the use of large presses, or large hot vacuum tanks, making single-piece or small-batch production highly economical.

[0023] 4. An ablation-type deflector that does not require water as a coolant, thus avoiding the need for a large water reserve at the launch site, high maintenance costs, and potential groundwater pollution problems.

[0024] 5. The guide vane base is made of metal and can be transported by road to other launch sites, making it mobile.

[0025] The innovations of this application are as follows: First, it provides a large-size ablation-type deflector that can be used to guide the takeoff exhaust flow of medium-sized liquid rockets. Second, the deflector's heat shield is composed of a heat insulation layer, an ablation layer, and a heat-resistant coating, possessing excellent heat insulation performance, ablation resistance, and impact resistance. Third, it provides a manufacturing process for the heat shield. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the ablation-type guide vane for a medium-sized liquid rocket in an embodiment of the present application.

[0027] Figure 2 This is a front view of the flow guide substrate in an embodiment of the present application.

[0028] Figure 3 This is a side view of the flow guide substrate in an embodiment of the present application.

[0029] Figure 4 This is a top view of the flow guide substrate in an embodiment of the present application.

[0030] Figure 5 This is a schematic diagram of the heat-resistant cap in an embodiment of the present application.

[0031] Figure 6 This is a cross-sectional view of the heat shield cap in an embodiment of the present application.

[0032] Figure 7This is a schematic diagram of the structure of the clamping element clamping the heat shield cap in an embodiment of the present application;

[0033] Figure 8 This is a flowchart illustrating the manufacturing method of the ablation-type flow guide heat shield cap in an embodiment of this application.

[0034] Figure label:

[0035] 1. Flow guide base; 11. Flow guide plate; 12. Baffle plate; 13. Load-bearing structure; 14. Connecting hole; 2. Heat protection cap; 21. Heat insulation layer; 22. Ablation layer; 23. Heat protection coating; 3. Clamping component. Detailed Implementation

[0036] To enable those skilled in the art to better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0037] It should be noted that when a component is referred to as "fixed to" or "set on" another component, it can be directly on or indirectly set on the other component; when a component is referred to as "connected to" another component, it can be directly connected to or indirectly connected to the other component.

[0038] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0039] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" or "several" means two or more, unless otherwise explicitly specified.

[0040] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which this application can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size should still fall within the scope of the technical content disclosed in this application, provided that they do not affect the effects and purposes that this application can produce.

[0041] According to a first embodiment of the present invention, an ablation-type deflector for medium-sized liquid rockets is provided:

[0042] A medium-sized liquid rocket ablation-type deflector includes: a bidirectional flow-guiding substrate 1, a heat shield 2, and a clamping component 3; the bidirectional flow-guiding substrate 1 includes: a flow-guiding plate 11 laid out in a human-shaped structure; a load-bearing structure 13 disposed below the flow-guiding plate 11 for supporting the flow-guiding plate 11; and baffle plates 12 disposed on the load-bearing structure 13 on both sides of the flow-guiding direction of the flow-guiding plate 11; the heat shield 2 is laid on the flow-guiding plate 11 and has a multi-layer structure; the clamping component 3 is disposed on the flow-guiding plate 11 for fixing the heat shield 2; the horizontal cross-sectional length of the bidirectional flow-guiding substrate 1 is 8-10 meters.

[0043] This application provides a technical solution for an ablation-type deflector for medium-sized liquid rockets. This solution can be used for launching medium-sized liquid rockets in situations where the launch location lacks a pre-designed deflector channel. Furthermore, the bidirectional deflector base 1, via a deflector plate 11, directs the rocket's ejected flames to opposite sides parallel to the ground for exhaust. Simultaneously, a heat shield 2 laid on the deflector plate enhances the heat resistance of the entire deflector device. Furthermore, the heat shield in this solution has a multi-layered structure, providing better heat resistance and ablation resistance compared to existing technologies. Finally, a clamping element 3 secures the heat shield to the deflector plate 11. In summary, the technical solution provided by this application effectively improves the convenience of launching medium-sized liquid rockets, reduces launch time, and lowers launch costs.

[0044] It should be noted that in existing technologies, medium-sized liquid rockets are generally launched from launch sites with pre-dug guide channels. However, existing technologies using uncooled guides are only suitable for small rocket launches, and the manufacturing cost of uncooled guides is high due to their compression molding process. Using compression molding to manufacture uncooled guides for medium-sized liquid rocket launches would significantly increase the requirements for the manufacturing process and further increase costs. Therefore, to solve the above technical problems, this technical solution creatively proposes a medium-sized liquid rocket ablation-type guide. This solution meets the size requirements of guides for medium-sized liquid rocket launches while improving the ablation resistance of the entire guide through a multi-layered heat shield, thereby achieving the goal of meeting the guide requirements for medium-sized liquid rocket launches.

[0045] It should be noted that the load-bearing structure 13 is provided with a connection hole 14, which is used to install the bidirectional flow guide substrate at a designated position.

[0046] It should be further noted that the horizontal cross-sectional width of the bidirectional flow guide substrate is 3.5-5.5 meters; the height of the bidirectional flow guide substrate is 3-4 meters; it can be used to guide the takeoff exhaust flow of medium-sized liquid-propellant launch vehicles.

[0047] Specifically, in this embodiment of the invention, the heat protection cap 2 includes: an ablation layer 22 laid on the guide plate 11; wherein, the heat protection cap 2 further includes: a heat insulation layer 21 laid between the ablation layer 22 and the guide plate 11; and / or a heat protection coating 23 laid on the side of the ablation layer 22 away from the guide plate 11.

[0048] It should be noted that the heat-resistant cap of this application has three embodiments:

[0049] In the first embodiment of the heat shield, the heat shield is composed of a heat insulation layer 21 and an ablation layer 22; in the second embodiment, the heat shield is composed of an ablation layer 22 and a heat-resistant coating 23; in the third embodiment, the heat shield is composed of a heat insulation layer 21, an ablation layer 22, and a heat-resistant coating 23 in sequence. In the prior art, there is typically only one ablation layer; however, in this application, the combination of multiple hierarchical structures of different energy types improves the ablation resistance of the heat shield itself, while also reducing the high-temperature impact of rocket jet flames on the bidirectional guide matrix.

[0050] Furthermore, the heat insulation layer can effectively reduce the impact of the high temperature of the ablation layer on the load-bearing structure. The load-bearing structure is welded from steel plates and has a certain degree of heat resistance. However, repeated rocket launches, if not properly insulated, will affect the heat resistance, structural strength, and stiffness of the load-bearing structure, thereby affecting its support for the heat shield and reducing the overall durability of the deflector. Therefore, the heat insulation layer can improve the durability of the load-bearing structure.

[0051] Furthermore, the ablation layer can effectively isolate and reduce the impact of prolonged high temperatures from medium-sized liquid rockets on the guide vane, thereby improving the durability of the device.

[0052] Furthermore, the heat-resistant coating can effectively protect the ablation layer and improve its durability.

[0053] Specifically, in this embodiment of the invention, the ablation layer 22 is made of carbon fiber as the reinforcing material and phenolic resin as the matrix material; the heat insulation layer 21 is made of high silica fiber as the reinforcing material and phenolic resin as the matrix material; and the heat-resistant coating 23 is made of one of the following: silicone resin, epoxy resin, phenolic resin, and ceramic-based coating.

[0054] It should be noted that in this embodiment, different raw materials are used for the different layers of the heat protection cap; the application of the above-mentioned raw materials is a conventional application in the prior art. The inventiveness of this application embodiment lies in combining different raw materials to form heat protection caps with different layers, thereby improving the heat protection cap's ablation resistance.

[0055] Specifically, in this embodiment of the invention, the thickness of the heat insulation layer 21 is H1 mm, where H1 ∈ [5, 10]; the thickness of the ablation layer 22 is H2 mm, where H2 ∈ [10, 40]; and the thickness of the heat-resistant coating 23 is H3 mm, where H3 ∈ [0.2, 1].

[0056] It should be further explained that the thickness design of the heat insulation layer, ablation layer, and heat-resistant coating includes the following methods: First, based on the simulation results of the rocket engine's gas flow field, the temperature and pressure parameters that the guide vane experiences during rocket takeoff are obtained. Second, ablation test specimens are then fabricated, using the same manufacturing process as the final product. Third, using oxygen-gas and kerosene engines as gas generators, the temperature and pressure parameters experienced during rocket takeoff are simulated to conduct ablation tests on the heat-resistant cap, obtaining a linear ablation rate between 0.5 mm / s and 2 mm / s. Fourth, the values ​​of H1, H2, and H3 are designed based on the linear ablation rate and rocket takeoff time. When the linear ablation rate is low, H1, H2, and H3 are taken as low values, and vice versa.

[0057] According to a second embodiment of the present invention, a method for manufacturing an ablation-type heat shield cap for a flow deflector is provided:

[0058] A method for manufacturing an ablation-type deflector heat shield, the method being used to fabricate the heat shield 2 of the aforementioned medium-sized liquid rocket ablation-type deflector; the method includes:

[0059] S101 is formulated with phenolic resin;

[0060] S102 Manually lay the heat insulation layer 21: First, apply phenolic resin to the surface of the guide plate 11 and the baffle plate 12, and then lay high silica cloth and remove air bubbles.

[0061] S103 Manually lay the ablation layer 22: Further brush phenolic resin onto the heat insulation layer 21, and then lay carbon fiber cloth and remove air bubbles;

[0062] S104 Manually spray the heat-resistant coating 23: Manually spray the heat-resistant coating 23 onto the ablation layer 22.

[0063] Based on the first embodiment of this application, this application also provides a method for manufacturing a heat shield specifically for producing ablation-type deflectors for medium-sized liquid rockets according to the first embodiment. As described above, in the prior art, there is no economical solution specifically for producing deflectors for medium-sized liquid rockets. The solution of this application involves manually laying a multi-layered heat shield layer by layer onto a pre-fabricated bidirectional deflector substrate; this avoids the high cost of developing dedicated molds in the prior art. Furthermore, by laying the heat insulation layer, ablation layer, and heat-resistant coating layer by layer, the ablation resistance and heat insulation capability of the entire heat shield are improved; thereby realizing the production of uncooled deflectors for medium-sized liquid rockets, improving the durability of uncooled deflectors for medium-sized liquid rockets, reducing the launch preparation time of medium-sized liquid rockets, and reducing the launch cost of medium-sized liquid rockets.

[0064] Specifically, in this embodiment of the invention, in the step of "manually laying the insulation layer 21", the high-silica cloth needs to be impregnated in phenolic resin before laying; after laying one layer of the high-silica cloth, it is heated and cured; after completing the curing and laying of one layer of the high-silica cloth, the thickness of a single curing is h1mm, h1∈[2,5]; repeat the above steps until the thickness of the entire insulation layer 21 reaches H1.

[0065] Specifically, in this embodiment of the invention, the "manual laying of the insulation layer 21" further includes: heating and curing the entire insulation layer 21: continuously heating the insulation layer 21 using a heating device, with a heating temperature of 60°C to 200°C; and a curing time of at least 48 hours.

[0066] It should be noted that each layer of high-silica fabric needs to be heated and cured during the laying process to ensure that the entire insulation layer has good thermal insulation performance.

[0067] It should be noted that heating equipment such as hot air blowers and hot air guns continuously heat the heat protection cap by blowing hot air continuously onto its surface.

[0068] Specifically, in the embodiment of the present invention, in the step of "manually laying the ablation layer 22", the carbon fiber cloth needs to be impregnated in phenolic resin before laying; after laying one layer of the carbon fiber cloth, it is heated and cured; after completing the curing and laying of one layer of the carbon fiber cloth, the thickness of a single curing is h2mm, h1∈[2,5]; repeat the above steps until the thickness of the entire ablation layer 22 reaches H2.

[0069] Specifically, in this embodiment of the invention, the "manually laying the ablation layer 22" further includes: heating and curing the entire ablation layer 22: continuously heating the ablation layer 22 using a heating device, with a heating temperature of 60°C to 200°C; and a curing time of at least 48 hours.

[0070] It should be noted that each single layer of carbon fiber cloth needs to be heated and cured during the laying process to ensure that the entire ablation layer has good ablation resistance.

[0071] Specifically, in this embodiment of the invention, the method further includes: before the step of "manually spraying the heat-resistant coating 23", using an ultrasonic scanner to detect the layering, porosity, debonding rate and auxiliary layer thickness of the heat insulation layer 21 and the ablation layer 22.

[0072] It should be noted that ultrasonic scanners enable closed-loop management of production quality, ensuring the production quality of the technical solutions presented in this application.

[0073] It should be noted that the defects identified by the ultrasonic scanner must not exceed 20% to 40% of the area. If defects are found to exceed the technical specifications, the defective areas should be ground down and locally repaired.

[0074] Example 1

[0075] A medium-sized liquid rocket ablation-type deflector includes: a bidirectional flow-guiding substrate 1, a heat shield 2, and a clamping component 3; the bidirectional flow-guiding substrate 1 includes: a flow-guiding plate 11 laid out in a human-shaped structure; a load-bearing structure 13 disposed below the flow-guiding plate 11 for supporting the flow-guiding plate 11; and baffle plates 12 disposed on the load-bearing structure 13 on both sides of the flow-guiding direction of the flow-guiding plate 11; the heat shield 2 is laid on the flow-guiding plate 11 and has a multi-layer structure; the clamping component 3 is disposed on the flow-guiding plate 11 for fixing the heat shield 2; the horizontal cross-sectional length of the bidirectional flow-guiding substrate 1 is 8 meters.

[0076] Example 2-1

[0077] The embodiment 1 is repeated, except that the heat protection cap 2 includes: an ablation layer 22 laid on the guide plate 11; wherein, the heat protection cap 2 further includes: a heat insulation layer 21 laid between the ablation layer 22 and the guide plate 11.

[0078] Example 2-2

[0079] The embodiment 1 is repeated, except that the heat cap 2 includes: an ablation layer 22 laid on the guide plate 11; wherein, the heat cap 2 further includes: a heat-resistant coating 23 laid on the side of the ablation layer 22 away from the guide plate 11.

[0080] Example 2-3

[0081] The embodiment 1 is repeated, except that the heat protection cap 2 includes: an ablation layer 22 laid on the guide plate 11; wherein, the heat protection cap 2 further includes: a heat insulation layer 21 laid between the ablation layer 22 and the guide plate 11; and a heat protection coating 23 laid on the side of the ablation layer 22 away from the guide plate 11.

[0082] Example 3

[0083] Repeat Example 2-1, Example 2-2, or Example 2-3, except that the ablation layer 22 is made of carbon fiber as the reinforcing material and phenolic resin as the matrix material; the heat insulation layer 21 is made of high silica fiber as the reinforcing material and phenolic resin as the matrix material; and the heat-resistant coating 23 is made of one of the following: silicone resin, epoxy resin, phenolic resin, or ceramic-based coating.

[0084] Example 4

[0085] Repeat Example 2-1, Example 2-2, or Example 2-3, except that the thickness of the heat insulation layer 21 is H1 mm, H1 ∈ [5, 10]; the thickness of the ablation layer 22 is H2 mm, H2 ∈ [10, 40]; and the thickness of the heat-resistant coating 23 is H3 mm, H3 ∈ [0.2, 1].

[0086] Example 5

[0087] A method for manufacturing an ablation-type deflector heat shield cap, the method being used to manufacture the heat shield cap 2 of the aforementioned medium-sized liquid rocket ablation-type deflector; the method includes: preparing phenolic resin; manually laying the heat insulation layer 21: firstly, applying phenolic resin to the surfaces of the deflector plate 11 and the baffle plate 12, and then laying high-silica cloth and removing air bubbles; manually laying the ablation layer 22: further applying phenolic resin to the heat insulation layer 21, and then laying carbon fiber cloth and removing air bubbles; manually spraying the heat-resistant coating 23: manually spraying the heat-resistant coating 23 onto the ablation layer 22.

[0088] Example 6

[0089] Repeat Example 5, except that in the step of "manually laying the insulation layer 21", the high-silica cloth needs to be impregnated in phenolic resin before laying; after laying one layer of the high-silica cloth, it is heated and cured; after completing the curing of one layer of the high-silica cloth, the thickness of a single curing is h1mm, h1∈[2,5]; repeat the above steps until the thickness of the entire insulation layer 21 reaches H1.

[0090] Example 7

[0091] Repeat Example 6, except that the "manually laying the insulation layer 21" further includes: heating and curing the entire insulation layer 21: continuously heating the insulation layer 21 with a heating device at a temperature of 60°C to 200°C; the curing time is at least 48 hours.

[0092] Example 8

[0093] Repeat Example 5, except that in the step of "manually laying the ablation layer 22", the carbon fiber cloth needs to be impregnated in phenolic resin before laying; after laying one layer of the carbon fiber cloth, it is heated and cured; after completing the curing of one layer of the carbon fiber cloth, the thickness of a single curing is h2mm, h1∈[2,5]; repeat the above steps until the thickness of the entire ablation layer 22 reaches H2.

[0094] Example 9

[0095] Repeat Example 8, except that the "manually laying the ablation layer 22" further includes: heating and curing the entire ablation layer 22: continuously heating the ablation layer 22 using a heating device, with a heating temperature of 60°C to 200°C; and a curing time of at least 48 hours.

[0096] Example 10

[0097] Example 5 is repeated, except that the method further includes: before the step of "manually spraying the heat-resistant coating 23", the heat insulation layer 21 and the ablation layer 22 are tested for delamination, pores, debonding rate and auxiliary layer thickness by an ultrasonic scanner.

[0098] It should be further noted that in existing technologies, when a medium-sized liquid-fueled launch vehicle is launched, because the launch pad lacks a flow channel and water cooling facilities, a non-cooled flow deflector can only be used to guide the high-temperature, high-speed exhaust gas ejected from the tail engine during the rocket's ignition and takeoff phase. Furthermore, given the rocket's diameter of Φ3.35m, simulation calculations of the exhaust gas flow field during the ignition and takeoff phase indicate that a flow deflector with dimensions of 8m in length, 3.5mm in width, and 3m in height is required, significantly larger than the flow deflectors commonly used in small rockets.

[0099] Furthermore, since uncooled exhaust diffusers must rely on the physical properties of high-temperature resistant materials to withstand the high-temperature erosion from the engine exhaust flame, they are further divided into endothermic and ablative types based on their heat dissipation methods. Endothermic diffusers use materials with high thermal conductivity and high melting points, enabling rapid heat conduction and preventing material melting. Currently, low-carbon steel and copper are suitable materials for this type of diffuser, and heat-resistant stainless steel can also be used. The structural design requires calculating the thickness of the metal material to ensure a balance between heat capacity and thermal conductivity, keeping the surface temperature below the melting point. Ablative diffusers generally consist of an ablative material covering the base material of the diffuser. Under the action of the exhaust flow, the surface material evaporates and melts, carrying away heat and thus controlling the heat transferred to the surface and the base material.

[0100] In existing technologies, if the temperature of the rocket engine exhaust plume acting on the deflector is not high and the heat flow impact time is short, a heat-absorbing deflector made of metal can be used under conditions where deflector ablation is not severe. However, if the temperature of the rocket engine exhaust plume acting on the deflector is high and the heat flow impact is prolonged, an ablation-resistant material is generally coated onto the metal substrate, and an ablation-type deflector is used to improve resistance to flame temperatures and increase the duration of heat flow impact. Therefore, medium and large rockets generally use pre-dug deflector channels on the launch pad to guide the exhaust plume, and rarely use deflectors placed on the launch pad.

[0101] Further explanation: Due to the limitations of the launch pad, a certain medium-sized liquid-propellant launch vehicle can only use an uncooled deflector. The advantage of an endothermic deflector is its low cost, but it is only suitable for missions with short launch times, such as missiles and small rockets. Simulation calculations of the gas flow field during the ignition and takeoff phase of a certain medium-sized liquid-propellant launch vehicle were conducted. In the initial stage of rocket ignition, because the gas jet is close to the deflector, the highest temperature on the deflector's guide surface is between 3000K and 3400K, and the maximum cold wall heat flux on the guide surface is between 20MW / ㎡ and 30MW / ㎡. Several seconds after the rocket leaves the launch pad, the deflector temperature drops below 2000K. Due to the high temperature acting on the deflector and the heat flux duration of only a few seconds, an ablative deflector can be used.

[0102] An ablation-type deflector mainly consists of two parts: a substrate and a heat shield. The substrate is generally welded from metal steel plates, but reinforced concrete structures are also used. Its main function is to withstand the forces generated by the exhaust gas flow during rocket launch. The heat shield is made of ablation-resistant material, and its main function is to resist the ablation and erosion of the high-temperature exhaust gas flow during rocket launch, protecting the substrate.

[0103] In existing technologies, small heat deflectors are generally rarely longer than 3 meters. The ablation-resistant material for the heat shield can be carbon-carbon composite material or other high-temperature resistant composite materials. Compression molding is commonly used, where a certain amount of premixed or prepreg material is added to a metal mold and then cured under heat and pressure. Compression molding requires the fabrication of a metal mold and the corresponding equipment such as a press and autoclave; therefore, production on a single piece is costly.

[0104] In practical applications, the external dimensions of a medium-sized launch vehicle deflector are 8m in length, 3.5m in width, and 3m in height. If the above-mentioned molding process is used, the large-sized molds are expensive, and it is difficult to find the required large-tonnage presses, large-diameter autoclaves, and other equipment. In other words, the production process of small deflectors is difficult to apply to the production and manufacturing of medium-sized deflectors.

[0105] To address the manufacturing challenges of large-sized deflectors for medium-sized liquid-propellant launch vehicles, this invention provides a technical solution for an ablation-type deflector. This deflector comprises a deflector substrate, a heat shield, and a clamping component. It is manufactured using a traditional hand lay-up process, eliminating the need for additional molds or equipment such as presses or autoclaves.

[0106] The first point that needs to be emphasized is that the specific implementation scheme of the ablation-type flow guide provided in this application is as follows:

[0107] like Figure 1The ablation-type flow guide of the present invention includes: a flow guide substrate 1, a heat shield 2, and a clamping member 3. The substrate 1 is fixed on the foundation, the heat shield 2 is bonded to the metal substrate (flow guide substrate 1), and the clamping member 3 is used to press the edge portion of the heat shield 2 onto the substrate 1 to prevent the exhaust gas flow from the rocket engine from peeling the heat shield 2 off the substrate 1 as a whole.

[0108] like Figures 2-4 The guide body 1 is generally welded from steel plates and its main function is to withstand the force generated by the exhaust gas flow during rocket launch. The guide body 1 is a structural component welded from steel plates, mainly composed of a guide plate 11, a baffle plate 12, a load-bearing structure 13, and connecting holes 14. The guide plate 11 is used to guide the high-temperature, high-pressure exhaust gas flow along the guide arc surface to both sides. The baffle plate 12 is used to constrain the exhaust gas flow in the non-guided direction and protect equipment in the non-guided direction. The load-bearing structure 13 withstands the pressure generated by the high-temperature, high-pressure exhaust gas flow. The connecting holes 14 are used to install anchor bolts to fix the guide body to the foundation, which can be the ground or a steel plate placed on the ground.

[0109] like Figures 5-6 The main function of the heat shield 2 is to resist the ablation and erosion of the high-temperature exhaust gas flow during rocket launch, protecting the metal substrate 1. The heat shield 2 is attached to the guide surface (guide plate 11) of the substrate 1. The heat shield 2 consists of a three-layer structure: a heat insulation layer 21, an ablation layer 22, and a heat-resistant coating 23. The total thickness H = H1 + H2 + H3. The design values ​​of each thickness can be increased or decreased according to the temperature of the guide surface in thermal simulation and the number of times the heat shield is used. When the operating temperature is high and the number of intended uses is high, the design value increases; conversely, it can be decreased.

[0110] The heat insulation layer 21, with a thickness H1 between 5mm and 10mm, is bonded to the flow guiding surface 11 and the baffle plate 12 of the metal substrate 1. It is made of high-silica fiber as the reinforcing material and phenolic resin as the matrix material, and has good heat insulation performance.

[0111] The ablation layer 22, with a thickness H2 between 10 mm and 40 mm, is bonded to the high-silica layer 21. It uses carbon fiber as the reinforcing material and phenolic resin as the matrix material, exhibiting good ablation resistance.

[0112] A heat-resistant coating 23, with a thickness H3 between 0.2 mm and 1 mm, is sprayed onto the carbon phenolic layer 22. This heat-resistant coating withstands temperatures up to 2000℃ while also enhancing toughness and impact resistance.

[0113] like Figure 7 The clamping element 3 is used to press the edge portion of the heat shield 2 onto the metal body 1, using fasteners (such as bolt fasteners) for connection.

[0114] The second point that needs to be emphasized is that the specific implementation scheme of the manufacturing scheme of the ablation-type flow guide heat shield provided in this application is as follows:

[0115] a) Pre-production preparation: The paste molding work area should be clean, dry, and well-ventilated, with the ambient temperature maintained between 15 and 35°C. Subsequent processing and finishing sections should be equipped with exhaust ventilation and water spraying devices. When preparing the adhesive, prevent air bubbles from entering the adhesive; the amount of adhesive prepared should not be excessive, and each batch should be used before the resin gels. Select the type and specifications of reinforcing materials according to design requirements.

[0116] b) Laying the insulation layer 21: Using a traditional hand lay-up (contact) molding process, a high-silica fiber cloth is laid on the metal substrate 1. A person wearing rubber gloves uses a brush to evenly apply the prepared raw material to the guide surface 11 and baffle plate 12 of the metal substrate 1. Then, the cut high-silica cloth is laid on top and impregnated with resin. Air bubbles are removed by applying pressure with a scraper and iron roller. This lay-up operation is repeated until a single-stage curing thickness h1 is achieved, where h1 is between 2mm and 5mm. After heat curing, another layer of thickness h1 is laid until the designed thickness H1 is reached.

[0117] c) Heat curing insulation layer 21: Phenolic resin cures very slowly naturally. During the curing process, heating equipment (such as a hot air blower) is needed for continuous heating, with the temperature between 60℃ and 200℃. After 48 hours, the degree of curing can reach 70% to 80%.

[0118] d) Laying the ablation layer 22: Using the traditional hand lay-up (contact) molding process, carbon fiber cloth is laid on the insulation layer 21 to achieve a single-stage curing thickness h2, which is between 2mm and 5mm. After heat curing, another layer of thickness h2 is laid until the designed thickness H2 is achieved.

[0119] e) Heat curing ablation layer 22: The method of heat curing ablation layer 22 is the same as that of heat curing insulation layer 21.

[0120] f) Ultrasonic testing: Using an ultrasonic A scanner, the delamination, voids or debonding rate are detected by reflection method, the layup thickness is measured, and the evaluation is carried out according to the Class B standard of "GJB2895-1997 General Specification for Carbon Fiber Composite Laminates and Laminates".

[0121] g) Apply heat-resistant coating 23: Apply heat-resistant coating 23 with a thickness of H3 onto the carbon phenolic layer 22.

[0122] h) Specimen ablation test: Three specimens were manufactured using the same production process as the final product. A free jet of exhaust gas from an oxygen / kerosene engine was used to simulate the heat flow of a real engine, and the ablation resistance of the three specimens was assessed. Test results showed that the average linear ablation rate of the specimens ranged from 0.9 mm / s to 1.5 mm / s. Evaluation indicated that they could be used for guiding the takeoff exhaust gas flow in medium-sized liquid rockets.

[0123] In summary, traditional small deflectors are generally no longer than 3 meters, which does not meet the requirements for use in liquid-fueled medium-lift launch vehicles. They typically employ compression molding, requiring the fabrication of metal molds and the provision of equipment such as presses and autoclaves. If produced piece by piece, the cost is high.

[0124] Currently, the external dimensions of a certain launch vehicle's deflector are 8m in length, 3.5m in width, and 3m in height. If a molding process is used, the large-sized metal molds are expensive, and it is difficult to find the necessary large-tonnage presses, large-diameter autoclaves, and other equipment.

[0125] The heat shield production process of the flow guide in this invention does not require the manufacture of large-size molds, the use of large presses, or large hot vacuum tanks, and the production of single pieces or small quantities of products is extremely economical.

[0126] The ablation-type flow deflector of the present invention does not require the use of water as a coolant, thus avoiding the need for a large water reserve at the launch site, and avoiding high maintenance costs and potential groundwater pollution problems.

[0127] The guide body of the present invention is a metal substrate, which can be transported by road to other launch sites and has the feature of being mobile.

[0128] It should be noted that this invention relates to medium-sized liquid rockets. Flow deflectors used in small rockets, especially small solid rockets, are not within the scope of this invention.

[0129] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A medium-sized liquid rocket ablation-type deflector, characterized in that, include: Bidirectional flow-guiding substrate (1), heat shield (2), clamping component (3); The bidirectional flow-guiding matrix (1) includes: The guide vanes (11) are laid out in a human-shaped structure; A load-bearing structure (13) is provided below the guide plate (11) to support the guide plate (11); Baffles (12) are installed on the load-bearing structure (13) and located on both sides of the flow direction of the guide plate (11); The heat shield (2) is laid on the guide plate (11), and the heat shield (2) has a multi-layer structure; The clamping member (3) is disposed on the guide plate (11) for fixing the heat protection cap (2); The horizontal cross-sectional length of the bidirectional flow-guiding substrate (1) is 8-10 meters; The heat protection cap (2) includes: an ablation layer (22) laid on the guide plate (11); A heat insulation layer (21) laid between the ablation layer (22) and the guide plate (11); and A heat-resistant coating (23) is laid on the side of the ablation layer (22) away from the guide plate (11); The ablation layer (22) is made of carbon fiber as the reinforcing material and phenolic resin as the matrix material. The thickness of the ablation layer (22) is H2mm, where H2∈[10,40]. The heat insulation layer (21) is made of high silica fiber as reinforcing material and phenolic resin as matrix material. The thickness of the heat insulation layer (21) is H1mm, where H1∈[5,10]. The heat-resistant coating (23) is made of one of the following materials: silicone resin, epoxy resin, phenolic resin, and ceramic-based coating. The thickness of the heat-resistant coating (23) is H3 mm, where H3 ∈ [0.2, 1]. The thickness parameter of the heat shield (2) is determined based on the simulation of the rocket engine gas flow field and the ablation test, wherein the linear ablation rate of the heat shield (2) is 0.5-2 mm / s.

2. A method for manufacturing an ablation-type flow guide heat shield, characterized in that, This method is used to manufacture the heat shield (2) of the ablation-type guide vane for a medium-sized liquid rocket as described in claim 1; the method includes: Prepare phenolic resin; The insulation layer (21) is laid manually: first, phenolic resin is applied to the surface of the guide plate (11) and the baffle plate (12), and then high silica cloth is laid and air bubbles are removed. Manually lay the ablation layer (22): Further brush phenolic resin onto the heat insulation layer (21), and then lay carbon fiber cloth and remove air bubbles; The heat-resistant coating (23) is applied manually: The heat-resistant coating (23) is applied manually to the ablation layer (22).

3. The method for manufacturing the ablation-type flow guide heat shield cap according to claim 2, characterized in that, In the step of "manually laying the insulation layer (21)", the high silica cloth needs to be impregnated in phenolic resin before laying; after laying one layer of the high silica cloth, it is heated and cured; after laying one layer of the high silica cloth, the curing thickness of a single curing is h1mm, h1∈[2,5]; repeat the above steps until the thickness of the entire insulation layer (21) reaches H1.

4. The method for manufacturing the ablation-type flow guide heat shield cap according to claim 3, characterized in that, The "manually laying the insulation layer (21)" also includes: Heating and curing of the entire insulation layer (21): The insulation layer (21) is continuously heated by a heating device at a temperature of 60°C to 200°C; the curing time is at least 48 hours.

5. The method for manufacturing the ablation-type flow guide heat shield cap according to claim 2, characterized in that, In the step of "manually laying the ablation layer (22)", the carbon fiber cloth needs to be impregnated in phenolic resin before laying; after laying one layer of the carbon fiber cloth, it is heated and cured; after laying one layer of the carbon fiber cloth, the curing thickness of a single curing is h2mm, h1∈[2,5]; repeat the above steps until the thickness of the entire ablation layer (22) reaches H2.

6. The method for manufacturing the ablation-type flow guide heat shield cap according to claim 5, characterized in that, The "manually laying of the ablation layer (22)" also includes: Heating and curing of the entire ablation layer (22): The ablation layer (22) is continuously heated by a heating device at a temperature of 60°C to 200°C; the curing time is at least 48 hours.

7. The method for manufacturing the ablation-type flow guide heat shield cap according to any one of claims 2-6, characterized in that, The method also includes: Before the step of "manually spraying the heat-resistant coating (23)", the heat insulation layer (21) and the ablation layer (22) are tested for delamination, porosity, debonding rate and layup thickness by an ultrasonic scanner.

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