Additive Monopropellant Thruster with Integrated Catalyst Bed
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Solution Overview
Problem
Existing catalytic thrusters for satellites and aerospace vehicles often require complex assembly processes and may have geometrical limitations that affect their efficiency and reliability.
Innovation Solution
A monopropellant thruster is designed with a first part integrally formed via additive manufacturing, including a catalyst bed, thrust chamber, and nozzle, which is then attached to a second part, or closeout, using welding or another attachment technique.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used for catalytic thrusters, then assembly processes become complex, but manufacturing precision and geometric flexibility are limited
Solution Approach 1:
The patent merges multiple thruster components (thrust chamber, catalyst bed support, nozzle, feed tube, insulation structures) into a single integrally formed first part using additive manufacturing. This consolidation eliminates the need for separate assembly operations for these components, reducing assembly complexity while achieving complex geometries that would be difficult or impossible to obtain through traditional manufacturing methods.
Solution Approach 2:
The thruster is divided into two main segments: the first part (integrally formed containing chamber, catalyst bed, nozzle) and the second part (closeout). This segmentation allows the complex internal geometries to be manufactured additively in one piece while still enabling modular assembly with the closeout, balancing geometric flexibility with assembly simplicity.
2Adaptability or versatility
If additive manufacturing is used to create complex geometries, then manufacturing flexibility improves, but manufacturing process complexity increases
Solution Approach 1:
Multiple functional components are merged into a single additively manufactured part, allowing complex internal geometries (such as the catalyst bed support structure, feed tube routing, and nozzle configuration) to be created in one manufacturing process. This approach leverages the geometric flexibility of additive manufacturing while consolidating the manufacturing process rather than increasing its complexity.
3Productivity
If components are assembled separately, then manufacturing flexibility improves, but assembly time and potential leakage points increase
Solution Approach 1:
The thrust chamber, catalyst bed support, nozzle, and feed tube are merged into a single integrally formed component, eliminating multiple assembly steps and associated sealing interfaces. This reduces assembly time and eliminates potential leakage points at joints, thereby improving both productivity and reliability. The only assembly step remaining is attaching the closeout, which minimizes the number of seals required.
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
This design allows for the creation of complex geometries and efficient heat transfer, enhancing the thruster's performance and scalability while simplifying the manufacturing process.
Implementation Method 1
The propellant reacts in the presence of the catalyst to generate a gas that is expelled through a nozzle to generate thrust
Implementation Method 2
a thrust chamber that holds a catalyst, and a feed tube for delivering propellant into the thrust chamber. The propellant reacts in the presence of the catalyst to generate a gas that is expelled through a nozzle to generate thrust
Data Source
AI summary
A monopropellant thruster according to an exemplary aspect of the present disclosure includes, among other things, a first part having a catalyst bed, a thrust chamber, and a nozzle. The first part is integrally formed via a single additive manufacturing process. The thruster further includes a second part, which is a closeout. A method is also disclosed.