Method and system for transforming a rocket stage into an orbital space station

Abstract

A spacecraft (100) for functioning as an upper rocket stage (second stage or third stage) of a rocket during launch and as an orbital space station in orbit is disclosed The spacecraft (100) includes a payload section (Z3) have a plurality of modules adapted to facilitate orbital operation of the spacecraft (100). A central zone includes a compartmentalized tank module operationally coupled to the payload section (Z3). The central compartmentalized tank module having a plurality of compartments (7) adapted to store propellants during launch, transition into pressurized habitable compartments suitable for habitation and storage after venting and purging of residual propellants. A propulsion zone (Z1) is adapted to provide thrust during ascent and is adapted to detach from the central compartmentalized tank module upon achieving orbit.

Description

[0001] TITLE OF THE INVENTION: “METHOD AND SYSTEM FOR TRANSFORMING A ROCKET STAGE INTO AN ORBITAL SPACE STATION” The following specification describes the invention and the manner in which it is to be performed.

[0002] FIELD OF THE INVENTION

[0001] The present invention relates to a field of rocket technology for launchingpayloads into space, and more particularly, relates to a spacecraft for functioning as an upper stage (second or third stage) of a rocket during launch and as an orbital space station in orbit and a method of transitioning thereof. BACKGROUND OF THE INVENTION

[0002] The following description provides the information that may be useful inunderstanding the present invention. It is not an admission that any of theinformation provided herein is prior art or relevant to the presently claimedinvention, or that any publication specifically or implicitly referenced is prior art.

[0003] Traditional methods of constructing orbital space stations typically involvelaunching prefabricated modules separately and assembling them in orbit. Thisprocess requires multiple launches, with each mission carrying a portion of thespace station, which is then pieced together in space. While effective, thisapproach is resource-intensive, as it necessitates discarding spent rocket stagesafter each launch, leading to significant material wastage. Some prior technologies have attempted to address this inefficiency by repurposing spent rocket stages asstorage compartments or living quarters. However, these solutions rely onretrofitting rocket components post-launch rather than designing them from the outset for dual purposes, propulsion and habitation. As a result, these adaptations often face limitations in structural efficiency and overall functionality.

[0004] One of the primary challenges with repurposing spent rocket stages is thatthey are engineered specifically for propulsion, not for habitation or storage. Their structural design and material composition are optimized for fuel containment and thrust generation rather than human occupancy or extended use in space. This leads to inefficiencies when attempting to modify them post-launch. Additionally, retrofitting requires extensive modifications, often necessitating the transportation of extra materials, tools, and equipment, which increases both mission complexity and cost. Human spacewalks or robotic interventions to convert these tanks into habitable spaces further add to the expense and time constraints of space missions. Moreover, the internal structure of rocket tanks, such as their bulkheads and fuel compartments, may not be easily adaptable for habitation or other critical space station functions, further limiting their practicality in space station construction.

[0005] Therefore, there is a need for a modular spacecraft pre-designed to serve asboth an upper stage of the rocket and an orbital station that will address thelimitations as mentioned above. SUMMARY OF THE INVENTION

[0006] In accordance with an embodiment, a spacecraft for functioning as anupper stage (second stage or third stage) of a rocket during launch and as anorbital space station in orbit is disclosed. The spacecraft includes a payloadsection having a plurality of modules adapted to facilitate orbital operation of thespacecraft. Further, the spacecraft includes a central zone comprising acompartmentalized tank module operationally coupled to the payload section. Thecentral compartmentalized tank module having a plurality of compartmentsadapted to store propellants during launch. Further, the central compartmentalizedtank module is adapted to transition into pressurized habitable compartmentssuitable for habitation and storage after venting and purging of residualpropellants. Further, the spacecraft includes a propulsion zone, positioned at a rearend of the spacecraft, the propulsion zone is adapted to provide thrust duringascent and is adapted to detach from the central compartmentalized tank module upon achieving orbit.

[0007] In an embodiment, the propulsion zone houses at least one combustionchamber coupled to the central compartmentalized tank module for receivingpropellants from each of the plurality of compartments. Further, the propulsion zone houses at least one nozzle coupled to the at least one combustion chamber, for ejecting exhaust gases from the at least one combustion chamber. Further, the propulsion zone includes a pair of gimbal-mounted rocket engines configured for thrust vector control during ascent, further adapted to function as station-keeping thrusters for orbital stability and attitude adjustments.

[0008] In an embodiment, the propulsion zone is secured to the centralcompartmentalized tank module via an ejection mechanism for controlleddetachment of the propulsion zone in orbit, facilitating the transition from a rocket stage to a space station.

[0009] In an embodiment, the payload section includes a payload fairing adaptedto be carried to the orbit, wherein an interior of the payload fairing is laid out with solar cells. The payload fairing includes at least two cut sections adapted to open like flower petals. Further, each of the at least two cut sections rotate on an axis to align the solar cells to face sunlight for power generation.

[0010] In an embodiment, the plurality of compartments in central zone aremodular compartments lined with thermal insulation and radiation shielding to maintain cryogenic conditions for liquid propellants - liquid propane and liquid oxygen or liquid methane-liquid oxygen or liquid hydrogen-liquid oxygen and to shield from harmful radiations in space.

[0011] In an embodiment, the plurality of compartments includes interconnectedpathways equipped with electro mechanically operable seals to facilitate a secure transition from propellant storage to pressurized habitats in orbit.

[0012] In an embodiment, the payload section includes navigation and guidancemodules configured to assist in aligning docking ports with the spacecraft.

[0013] In an embodiment, the plurality of modules of the payload section includedeployable solar panels, energy management units, communication modules,docking mechanisms, and life support units to maintain the orbital operations. The energy management unit is configured to store and distribute energy generated by the deployable solar panels.

[0014] In an embodiment, the spacecraft is integrated with additional modules andextensions to form a scalable and modular orbital space station.

[0015] In accordance with another embodiment, a method for transitioning aspacecraft from a rocket stage configuration to an orbital space station isdisclosed. The method includes detaching, by an ejection mechanism, apropulsion zone including at least one combustion chamber and at least onenozzle, from the spacecraft upon reaching an orbit. Further, the method includesventing, by symmetrical venting ports, residual propellants from a plurality ofcompartments of a central compartmentalized tank module into space. Further, the method includes purging, by inert nitrogen gas or carbon dioxide or combination of both, each of the plurality of compartments of the central compartmentalizedtank to eliminate contaminants. Further, the method includes activating orbitaloperational units by deploying a plurality of modules from a payload section. The payload section includes a payload fairing having at least two cut sections with solar cells laid out inside. Further, the method includes pressurizing each of the plurality of compartments of the central compartmentalized tank with a breathableatmosphere and configuring each of the plurality of compartments intointerconnected habitats and storage spaces.

[0016] In an embodiment, detaching, by the ejection mechanism, the propulsionzone includes activating a plurality of explosive bolts to release the at least one combustion chamber and the at least one nozzle from the spacecraft.

[0017] In an embodiment, purging each of the plurality of compartments includesintroducing the inert nitrogen gas or carbon dioxide or combination of boththrough automated flow controllers and expelling contaminants via vacuum-assisted exhaust valves.

[0018] In an embodiment, activating orbital operational units by deploying theplurality of modules from the payload section includes opening all sections of the payload fairing like flower petals and rotate on the axis to align solar cells to sunlight for power generation.

[0019] In this respect, before explaining at least one object of the invention indetail, it is to be understood that the invention is not limited in its application to the details of the set of rules and to the arrangements of the various models set forth in the following description or illustrated in the drawings. The invention is capable of other objects and of being practiced and carried out in various ways,according to the needs of that industry. Also, it is to be understood that thephraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

[0020] These together with other objects of the invention, along with the variousfeatures of novelty which characterize the invention, are pointed out withparticularity in the disclosure. For a better understanding of the invention, itsoperating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The invention will be better understood and objects other than those setforth above will become apparent when consideration is given to the followingdetailed description thereof. Such description makes reference to the annexeddrawings wherein:

[0022] Figure 1 illustrates a schematic of a typical rocket with three stages alongwith payload fairing and payload at top of the rocket, wherein third stage is thedual functional spacecraft in accordance with an example embodiment of thepresent disclosure;

[0023] Figure 2 illustrates a schematic layout of the spacecraft depicting dualfunction rocket stage / orbital station, in accordance with an example embodiment of the present disclosure;

[0024] Figure 3 illustrates another schematic layout of the spacecraft depictingopened up payload fairing and exposing payload bay, in accordance with anexample embodiment of the present disclosure;

[0025] Figure 4 illustrates a top view of the spacecraft in a transitioning state witha docking port and solar cells embedded on an outer surface of the payloadfairing, in accordance with an example embodiment of the present disclosure;

[0026] Figure 5 illustrates a top view of the spacecraft transitioning with thepayload fairing extending from a central compartmentalized module, inaccordance with an example embodiment of the present disclosure;

[0027] Figure 6 illustrates a schematic view of the spacecraft transitioned into acomplete orbital space station, in accordance with an example embodiment of the present disclosure; and

[0028] Figure 7 illustrates a flowchart depicting a method for transitioning aspacecraft from a rocket stage configuration to an orbital space station, inaccordance with an example embodiment of the present disclosure. DETAILED DESCRIPTION OF THE DRAWINGS

[0029] Reference will now be made in detail to specific embodiments or features,examples of which are illustrated in the accompanying drawings. Whereverpossible, corresponding, or similar reference numbers will be used throughout thedrawings to refer to the same or corresponding parts. Moreover, references tovarious elements described herein, are made collectively or individually whenthere may be more than one element of the same type. However, such references are merely exemplary in nature. It may be noted that any reference to elements in the singular may also be construed to relate to the plural and vice-versa without limiting the scope of the disclosure to the exact number or type of such elements unless set forth explicitly in the appended claims.

[0030] Some embodiments of this disclosure, illustrating all its features, will nowbe discussed in detail. The words “comprising,” “having,” “containing,” and“including,” and other forms thereof, are intended to be equivalent in meaning and be open-ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items.

[0031] It must also be noted that as used herein and in the appended claims, thesingular forms “a,” “an,” and “the” include plural references unless the context dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the preferred systems, and methods are now described.

[0032] Embodiments of the present disclosure will be described more fullyhereinafter with reference to the accompanying drawings in which like numeralsrepresent like elements throughout the several figures, and in which exampleembodiments are shown. Embodiments of the present disclosure may, however, be embodied in alternative forms and should not be construed as being limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.

[0033] Embodiments of the present disclosure disclose an orbital space stationdesigned to function as an upper stage (second or third stage) of a launch vehicleor referred to as a spacecraft, serving both as a propulsion stage and a fullyoperational space station once deployed in orbit. Throughout the presentdisclosure, rocket stage or the upper stage and orbital space station refer to the same integrated structure and may be used interchangeably.

[0034] Embodiments of the present disclosure disclose a spacecraft forfunctioning as an upper stage of a rocket during launch and as the orbital space station in orbit and a method of transitioning the same.

[0035] Embodiments of the present disclosure will be described below in detailwith reference to the accompanying drawings.

[0036] Figure 1 illustrates a schematic of a spacecraft 100 depicting at least threestages of a typical rocket 100, in accordance with an example embodiment of the present disclosure. The spacecraft 100 may include a first stage 1, a second stage 2, a third stage 3 and a payload fairing 4 with payload.

[0037] In the illustrated embodiment, upper stage, in this case the third stage 3may be adapted to serve as dual functionality stage or rocket serving as both a propulsion stage during ascent and a fully operational orbital space station once inorbit. The third stage 3 may be adapted to integrate features of a completespacecraft designed for habitation and extended use in space. During the launchphase, the third stage 3 may operate as a conventional rocket stage, housingpropellant tanks and an engine system to provide thrust for a final insertion into orbit.

[0038] Further, upon reaching orbit, the engine system and related propulsioncomponents within the upper stage - third stage 3 may be detached. The third stage 3 may transition into a secondary role as an orbital space station. The third stage 3 may be equipped with compartmentalized tanks adapted to be repurposed as living spaces with interconnected pathways, and operational systems such as solar panels, life support mechanisms, and communication modules.

[0039] Figure 2 illustrates a schematic layout of the spacecraft 100 depicting theat least three stages (Z1, Z2, Z3) of the spacecraft 100, in accordance with an example embodiment of the present disclosure.

[0040] The spacecraft 100 may be adapted to operate as a fully functioned orbitalspace station. The third stage 3 of the spacecraft 100 may remain in retracted formduring ascent and transitions into the orbital space station once in orbit. Thespacecraft 100 may include at three primary sections, i.e., the at least three stages Z1, Z2, and Z3. The first stage Z1 (or indicated by 1 in Figure 1) may be referred to as an engine bay or propulsion zone.

[0041] The first stage Z1 may be adapted to house a propulsion system. Thepropulsion system may include a rocket engine and associated support structures.The propulsion system may be adapted to provide thrust during ascent of thespacecraft 100. The first stage Z1 may be adapted to incorporate fuel feed lines,control valves, and thrust vectoring mechanisms to ensure precisemanoeuvrability during flight, i.e., during the ascent. In an embodiment, therocket engine and the associated support structures may be detachable from the second stage Z2. In another embodiment, the propulsion system may be adapted to be secured using the plurality of explosive bolts, electromechanical latches. The explosive bolts and electromechanical latches may enable controlled detachment after the spacecraft 100 may enter into the orbit.

[0042] The first stage Z1 may include a propellant storage 21 for orbit keeping,orbit keeping engines / gimbal engines 22, the plurality of explosive bolts 23, an engine attachment support 24, a main engine nozzle 25, and a main combustion chamber 26. The main combustion chamber 26, also referred to as at least one combustion chamber 26, may be coupled to the central compartmentalized tank module for receiving propellants from each of the plurality of compartments 7.

[0043] Further, the main engine nozzle 25, also referred to as at least one nozzle,may be coupled to the main combustion chamber 26, for ejecting exhaust gases from the main combustion chamber 26.

[0044] The propulsion system or a propulsion zone may be positioned at a rearend of the spacecraft 100. The propulsion zone may be adapted to provide thrust during ascent and may be adapted to detach from a central compartmentalized tank module upon achieving orbit.

[0045] The propulsion zone may be secured to the central compartmentalized tankmodule via an ejection mechanism for controlled detachment of the propulsion zone in orbit, facilitating the transition of the spacecraft 100 from the rocket stage to the orbital space station.

[0046] The second stage Z2 may be referred to as a central compartmentalizedpropellant tank section. The second stage Z2 may include a central zone having a compartmentalized tank module operationally coupled to the payload section. The compartmentalized tank module may be arranged longitudinally over the secondstage Z2. The central compartmentalized tank module having a plurality ofcompartments 7 adapted to store propellants during launch, and transition intopressurized habitable compartments suitable for habitation and storage afterventing and purging of residual propellants.

[0047] The central compartmentalized tank module may include a plurality ofseparators 30, 31, 32, 33, 34 for the plurality of compartments 7. In anembodiment, the plurality of separators 30, 31, 32, 33, 34 may be referred to as inter-compartment airlocks. The plurality of separators 30, 31, 32, 33, 34 may beadapted to create interconnecting pathways to establish a continuous internalspace, facilitating crew activities, storage, and operational efficiency in spacestation mode, while they serve as propellant flow control valves in rocket stage mode. Further, the second stage Z2 may include reaction control system (RCS) thrusters 36 adapted to provide attitude control and translation using thrusters. In an embodiment, the plurality of the compartment 7 may be adapted to store the propellants, i.e., liquid oxygen (oxidizer) and liquid propane (fuel) during launch.

[0048] The third stage Z3 may be referred to as payload section. The third stageZ3 may include solar panels 5 housed within the third stage Z3 in retracted form. Further the third stage Z3 may include a station atmosphere management system or a life support system 8, a station cooling system 9, a life support system 10,battery storage system 11, battery management system 12, docking ports orexpansion ports 13, 14, 15, 17, and a payload fairing 16.

[0049] Further, the third stage Z3 may include a main entry door to station afterdocking chamber 40 and a docking port to station entry compartment 42. Further,the third stage Z3 may include a hinge mechanism or referred to as payloadfairing hinge mechanism 37, 38.

[0050] The third stage Z3 may function as payload bay during the launch phaseand transitions into a primary operational hub of the orbital space station upon reaching orbit. In an embodiment, the solar panels 5 may be compactly stowed during launch and deployed in orbit to generate electrical power. The life support systems 8 may be adapted to regulate air quality, temperature, and humidity to maintain a habitable environment. The third stage Z3 may include communicationmodules adapted to establish data transmission links for station operation andground control coordination.

[0051] Further, the power management and storage 11, 12 may be adapted toincorporate batteries and power distribution electronics for efficient energyregulation. The docking ports or expansion ports 13, 14, 15, 17 may facilitating crew transfer, resupply missions, and modular station expansion through external spacecraft connections.

[0052] Figure 3 illustrates another of the spacecraft 100 depicting opened uppayload fairing 16 and exposing payload bay, in accordance with an exampleembodiment of the present disclosure.

[0053] The third stage Z3 or referred to as the payload bay may be adapted toextend the payload fairing 16. The opened-up payload fairing exposing payload bay is illustrated by 52.

[0054] Figure 4 illustrates a top view of the spacecraft 100 in a transitioning statewith docking ports 64, 65, 66 and solar cells 62 embedded on an outer surface 67of the payload fairing 16, in accordance with an example embodiment of thepresent disclosure. In an illustrated embodiment, at least four cut sections (67)may be adapted to form an entire payload fairing 16. In another embodiment, at least two cut sections may form the entire payload faring 16. The spacecraft 100 may include a docking port system 60, a payload fairing hinge mechanism 61, the solar cells 62 embedded on the outer surface 67 of the payload fairing 16.

[0055] Figure 5 illustrates a top view of the spacecraft 100 transitioning with thepayload fairing 16 extending from a central compartmentalized module, inaccordance with an example embodiment of the present disclosure. Figure 6illustrates a schematic view of the spacecraft 100 transitioned into a completeorbital space station, in accordance with an example embodiment of the present disclosure. In an embodiment, the at least two cut sections of the payload fairing 16 may open like flower petals and may be adapted to also rotate on an axis to align the solar cells to face sunlight for power generation.

[0056] In the illustrated embodiment, the solar cells 71 to 74 may be in extendedform to produce solar electricity. The solar panels may be adapted on rotate on theaxis to face sunlight. Further, the solar panels / cells 75-78 may be in completeextended or deployed manner.

[0057] The spacecraft 100, as described in conjunction with Figures 1-6, isdescribed further in the following embodiments.

[0058] The spacecraft 100 may include the payload section with the plurality ofmodules adapted to facilitate orbital operation of the spacecraft 100. Further, thespacecraft 100 may include the central zone with the compartmentalized tankmodule operationally coupled to the payload section. The centralcompartmentalized tank module may include the plurality of compartments 7adapted to store propellants during launch, as described earlier.

[0059] Further, the central compartmentalized tank module may be adapted totransition into pressurized habitable compartments suitable for habitation andstorage after venting and purging of residual propellants. Further, the spacecraft 100 may include the propulsion zone, positioned at a rear end of the spacecraft 100. The propulsion zone may be adapted to provide thrust during ascent and maybe adapted to detach from the central compartmentalized tank module uponachieving orbit.

[0060] In an embodiment, the propulsion zone houses the at least one combustionchamber 26 operationally coupled to the central compartmentalized tank module for receiving propellants from each of the plurality of compartments 7. Further,the propulsion zone houses at least one nozzle 24 coupled to the at least onecombustion chamber 26, for ejecting exhaust gases from the at least onecombustion chamber 26. Further, the propulsion zone includes a pair of gimbal-mounted rocket engines 22 configured for thrust vector control during ascent,further adapted to function as station-keeping thrusters for orbital stability andattitude adjustments.

[0061] In an embodiment, the propulsion zone may be secured to the centralcompartmentalized tank module via the ejection mechanism for controlleddetachment of the propulsion zone in orbit, facilitating the transition from a rocket stage to a space station.

[0062] In an embodiment, the payload section may include the payload fairing 16adapted to be carried to the orbit. In an embodiment, an interior of the payload fairing 16 may be laid out with solar cells 5. The payload fairing 16 includes at least two cut sections 52, adapted to open like flower petals with the solar cells 62, 71-78 and to rotate on the axis to face sunlight for power generation.

[0063] In an embodiment, the plurality of compartments 7 in central zone may bemodular compartments lined with thermal insulation and radiation shielding 29 to maintain cryogenic conditions for liquid propellants - liquid propane and liquid oxygen or liquid methane-liquid oxygen, liquid hydrogen-liquid oxygen (while functioning as rocket stage) and to shield from harmful radiations in space, while functioning as orbital space station.

[0064] In an embodiment, the plurality of compartments 7 may includeinterconnected pathways 30 to 35, as mentioned above, equipped with electromechanically operable seals to facilitate a secure transition from propellantstorage to pressurized habitats in orbit.

[0065] In an embodiment, the payload section includes navigation and guidancemodules configured to assist in aligning docking ports with the spacecraft.

[0066] In an embodiment, the plurality of modules of the payload section includedeployable solar panels 5, energy management units, communication modules,docking mechanisms, and life support units to maintain the orbital operations. The energy management unit is configured to store and distribute energy generated by the deployable solar panels.

[0067] In an embodiment, the spacecraft 100 may be integrated with additionalmodules and extensions to form a scalable and modular orbital space station.

[0068] Figure 7 illustrates a flowchart depicting a method 700 for transitioning aspacecraft 100 from the rocket stage configuration to the orbital space station, in accordance with an example embodiment of the present disclosure.

[0069] At operation 702, the method 700 may include detaching, by the ejectionmechanism, the propulsion zone including at least one combustion chamber 26 and at least one nozzle 25, from the spacecraft 100 upon reaching the orbit. In thisembodiment, the method 700 may include activating the plurality of explosivebolts 23 to release the at least one combustion chamber 26 and the at least one nozzle 25 from the spacecraft 100.

[0070] At operation 704, the method 700 may include venting, by symmetricalventing ports, residual propellants from the plurality of compartments 7 of the central compartmentalized tank module into space.

[0071] At operation 706, the method 700 may include purging, by inert nitrogengas, each of the plurality of compartments 7 of the central compartmentalized tankto eliminate contaminants. In this embodiment, the method 700 may includeintroducing the inert nitrogen gas or carbon dioxide or combination of boththrough automated flow controllers and expelling contaminants via exhaustvalves.

[0072] At operation 708, the method 700 may include activating orbitaloperational units by deploying the plurality of modules from the payload section.The payload section includes the payload fairing 16 having at least two cutsections with solar cells 5, 62, 71-78, laid out inside. In this embodiment, themethod 700 may include opening all sections of the payload fairing 16 like flower petals and rotate on the axis to align the solar cells to face sunlight for power generation.

[0073] At operation 710, the method 700 may include pressurizing each of theplurality of compartments 7 of the central compartmentalized tank with thebreathable atmosphere and configuring each of the plurality of compartments 7 into interconnected habitats and storage spaces.

[0074] The present disclosure offers a dual-functionality design, integrating theupper stage of rocket and the orbital space station into a single structure. This eliminates the need for retrofitting or deploying separate systems, streamlining the transition from launch vehicle to space station. The compartmentalized propellanttank system initially functions as a fuel storage unit during launch and laterconverts into habitable space or storage once in orbit.

[0075] The present disclosure offers enhanced efficiency by incorporating sharedresources for dual functions, where insulation, structural reinforcements, andthermal management systems serve both propulsion and habitation needs. Pre-designed expandability allows for station scalability by incorporating mechanismsfor module extension or docking with additional components. The life-supportsystems are seamlessly integrated into the compartmentalized structure, ensuring a safe and efficient transition from propellant storage to a habitable environment.Additionally, the design prioritizes safety and contamination control, withrigorous processes for venting hazardous materials and purging tanks before human occupancy. These features collectively contribute to a highly reliable and efficient rocket launch.

[0076] These novel points collectively represent a significant advancement in thedesign and functionality of spacecraft, offering a more efficient and versatileapproach to space exploration.

[0077] The benefits and advantages which may be provided by the presentinvention have been described above with regard to specific embodiments. These benefits and advantages, and any elements or limitations that may cause them to occur or to become more pronounced are not to be construed as critical, required, or essential features of any or all of the embodiments.

[0078] While the present invention has been described with reference to particularembodiments, it should be understood that the embodiments are illustrative andthat the scope of the invention is not limited to these embodiments. Manyvariations, modifications, additions, and improvements to the embodimentsdescribed above are possible. It is contemplated that these variations,modifications, additions, and improvements fall within the scope of the invention.

Claims

We Claim:

1. A spacecraft (100) for functioning as an upper rocket stage (second stageor third stage) of a rocket during launch and as an orbital space station in orbit, the spacecraft (100) comprising: a payload section (Z3) having: a plurality of modules adapted to facilitate orbital operation of the spacecraft (100); acentral zone comprising a compartmentalized tank moduleoperationally coupled to the payload section (Z3), the centralcompartmentalized tank module having a plurality of compartments (7) adapted to: store propellants during launch; and transition into pressurized habitable compartments suitable for habitation and storage after venting and purging of residualpropellants; and a propulsion zone (Z1), positioned at a rear end of the spacecraft (100), the propulsion zone (Z1) is adapted to provide thrust during ascent and is adapted to detach from the central compartmentalized tank module upon achieving orbit.

2. The spacecraft (100) as claimed in claim 1, wherein the propulsion zone(Z1) houses: at least one combustion chamber (26) operatively coupled to the central compartmentalized tank module for receiving propellants fromeach of the plurality of compartments (7); at least one nozzle (25) operatively coupled to the at least onecombustion chamber (26), for ejecting exhaust gases from the at least one combustion chamber (26); anda pair of gimbal-mounted rocket engines (22) configured for thrust vector control during ascent, further adapted to function as station-keeping thrusters for orbital stability and attitude adjustments.

3. The spacecraft (100) as claimed in claim 1, wherein the propulsion zone(Z1) is secured to the central compartmentalized tank module via anejection mechanism for controlled detachment of the propulsion zone (Z1) in orbit, facilitating the transition from a rocket stage to a space station.

4. The spacecraft (100) as claimed in claim 1, wherein the payload section(Z3) includes: a payload fairing (16) adapted to be carried to the orbit, wherein an interior of the payload fairing (16) is laid out with solar cells (5, 62, 71, 72, 73, 74, 75, 76, 77, 78), wherein the payload fairing (16) includes at least two cut sections adapted to open like flower petals and to rotate on an axis to align the solar cells (5, 62, 71, 72, 73, 74, 75, 76, 77, 78) to face sunlight for powergeneration.

5. The spacecraft (100) as claimed in claim 1, wherein the plurality ofcompartments (7) in central zone are modular compartments lined with thermal insulation and radiation shielding to maintain cryogenic conditions for liquid propellants - liquid propane and liquid oxygen or liquidmethane-liquid oxygen or liquid hydrogen-liquid oxygen and to shield from harmful radiations in space.

6. The spacecraft (100) as claimed in claim 1, wherein the plurality ofcompartments (7) includes interconnected pathways equipped with electro mechanically operable seals to facilitate a secure transition from propellant storage to pressurized habitats in orbit.

7. The spacecraft (100) as claimed in claim 1, wherein the payload section(Z3) includes navigation and guidance modules configured to assist inaligning docking ports with the spacecraft (100).

8. The spacecraft (100) as claimed in claim 1, wherein the plurality ofmodules of the payload section (Z3) include deployable solar panels,energy management units, communication modules, docking mechanisms, and life support units to maintain the orbital operations, wherein theenergy management unit is configured to store and distribute energygenerated by the deployable solar panels.

9. The spacecraft (100) as claimed in claim 1, wherein the spacecraft (100) isintegrated with additional modules and extensions to form a scalable and modular orbital space station.

10. A method (700) for transitioning a spacecraft (100) from a rocket stageconfiguration to an orbital space station, the method (700) comprising: detaching (702), by an ejection mechanism, a propulsion zone (Z1) including at least one combustion chamber (26) and at least one nozzle (25), from the spacecraft (100) upon reaching an orbit; venting (704), by symmetrical venting ports, residual propellants from a plurality of compartments (7) of a central compartmentalized tank module into space; purging (706), by inert nitrogen gas or carbon dioxide orcombination of both, each of the plurality of compartments (7) of thecentral compartmentalized tank to eliminate contaminants; activating (708) orbital operational units by deploying a plurality of modules from a payload section (Z3), wherein the payload section (Z3) includes a payload fairing (16) having at least two cut sections with solar cells (5, 62, 71, 72, 73, 74, 75, 76, 77, 78) laid out inside; andpressurizing (710) each of the plurality of compartments (7) of the central compartmentalized tank with a breathable atmosphere andconfiguring each of the plurality of compartments (7) into interconnected habitats and storage spaces.

11. The method (700) as claimed in claim 10, wherein detaching, by theejection mechanism, the propulsion zone (Z1) comprises: activating a plurality of explosive bolts to release the at least one combustion chamber (26) and the at least one nozzle (25) from thespacecraft (100).

12. The method (700) as claimed in claim 10, wherein purging each of theplurality of compartments (7) comprises: introducing the inert nitrogen gas or carbon dioxide or combination of both, through automated flow controllers and expelling contaminants via exhaust valves.

13. The method (700) as claimed in claim 10, wherein activating orbitaloperational units by deploying the plurality of modules from the payload section (Z3) includes: opening all sections of the payload fairing (16) like flower petals laid solar cells (5, 62, 71, 72, 73, 74, 75, 76, 77, 78) and rotate on an axis to face towards sunlight for power generation.

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