Actively Cooled Heat Shield Using Heat-Driven Pump Recirculation
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Solution Overview
Problem
Existing heat management solutions for vehicles traveling at hypersonic speeds, such as reusable rockets, are not robust, controllable, and suitable for long-term reusability due to issues with mass, cost, and operational complexity.
Innovation Solution
An actively-cooled heat shield system incorporating a heat shield, tank, pump, heat exchanger, and turbine that converts heat into energy to drive a liquid coolant pump, using a closed-loop system to maintain thermal protection and power the pump.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heat management solutions (ablative materials, high-temperature materials, transpiration cooling) are used, then thermal protection is provided, but mass, cost, and operational complexity increase
Solution Approach 1:
The patent replaces passive thermal protection systems (ablative materials, high-temperature ceramics, transpiration cooling) with an active cooling system that uses a liquid coolant circulation system. The coolant absorbs heat through heat exchangers integrated into the heat shield, and the heated coolant drives a turbine that generates electricity, converting thermal energy into useful work and reducing the mass of thermal protection structures.
Solution Approach 2:
The system uses the waste heat from the coolant as it passes through the heat exchanger to drive the turbine, which then generates electricity to power the vehicle's systems. This self-service approach converts what would be wasted thermal energy into useful electrical power, reducing the need for additional power generation systems and lowering overall vehicle mass.
2Reliability
If robust thermal protection systems are added to enable reusability, then vehicle durability improves, but payload capacity decreases due to mass addition
Solution Approach 1:
The liquid coolant serves multiple functions: it cools the heat shield during re-entry, drives the turbine to generate electricity, and can be used as propellant or for other vehicle systems. This multi-functionality reduces the need for separate systems, minimizing mass addition while enabling reusability.
Solution Approach 2:
The system changes the state and properties of the coolant as it passes through different components - starting as a cold liquid, absorbing heat to become a hot pressurized fluid, then expanding through the turbine to generate power, and finally being condensed or cooled for reuse. These parameter changes enable the same substance to perform multiple functions throughout the re-entry and operation cycle.
3Temperature
If active cooling systems are implemented, then thermal control precision improves, but system complexity increases
Solution Approach 1:
The system incorporates sensors that monitor temperature, pressure, and flow rate of the coolant, with control systems that adjust pump operation, valve positions, and heat exchanger configurations in real-time to maintain optimal thermal control. This feedback mechanism enables precise thermal management while automating control decisions to reduce operational complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively maintains thermal protection and powers the pump using heat energy, enabling reusable vehicles to withstand high temperatures and reduce structural mass, enhancing reusability and efficiency.
Implementation Method 1
The heat exchanger is configured to receive the pressurized coolant from the pump, transfer heat from the heat shield to the pressurized coolant to generate a heated fluid
Implementation Method 2
The shaft is configured to rotate and thereby power the pump when the heated fluid received from the heat exchanger acts on the turbine blades
Data Source
AI summary
An actively-cooled heat shield system includes a heat shield, a tank, a pump, a heat exchanger, and a turbine. The heat shield defines a windward side of a vehicle. The tank stores a coolant. The pump receives the coolant from the tank and outputs a pressurized coolant. The heat exchanger is integrally connected with the heat shield. The heat exchanger receives the pressurized coolant from the pump, transfers heat from the heat shield to the pressurized coolant to generate a heated fluid, and outputs the heated fluid. The turbine includes an inlet, a shaft, and an outlet. The inlet receives the heated fluid output from the heat exchanger. The shaft is coupled to the pump and includes turbine blades. The shaft rotates and powers the pump when the heated fluid received from the heat exchanger acts on the turbine blades. The outlet outputs the heated fluid.