Corrugated Ring Baffles for Propellant Tank Slosh Control

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Solution Overview

Problem

Rocket-propelled launch vehicles face issues with propellant tanks experiencing loss of function due to slosh loads, tank pressure loads, thermal loads, fatigue, or fracture, and pooling of liquid propellant during flight conditions.

Innovation Solution

The implementation of ring baffles with corrugated surfaces aligned with the longitudinal axis of the propellant tank, featuring corrugated surfaces that extend laterally and are supported by spine and strut sections, which are removably attached to the interior circumference, to manage slosh loads and prevent pooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If propellant tank is used during flight conditions, then propellant storage and delivery is enabled, but slosh loads cause loss of function and pooling occurs

Engineering Contradiction:

Improvepropellant tank functionalityVSAvoidslosh loads

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The propellant tank is segmented by installing multiple ring baffles at different locations along the longitudinal axis. Each ring baffle divides the tank into separate zones, preventing uncontrolled propellant movement. The segmentation creates multiple smaller control volumes that reduce the overall slosh effect while maintaining effective propellant storage and delivery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Ring baffles serve as intermediary structures between the propellant and the tank walls. These baffles absorb and redirect the kinetic energy of sloshing propellant, preventing direct impact loads on the tank structure. The baffles act as mediators that convert harmful slosh loads into manageable local effects that can be accommodated by the tank design.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If ring baffles are installed to mitigate slosh loads, then slosh and pooling are reduced, but device complexity increases

Engineering Contradiction:

Improveslosh loadsVSAvoidpropellant tank structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The ring baffles are constructed using thin-walled cylindrical structures that provide sufficient structural integrity while minimizing weight and complexity. The thin-walled design allows the baffles to flex slightly under load, absorbing energy without requiring complex reinforcement structures. This approach reduces device complexity while maintaining effective slosh mitigation.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

Instead of trying to prevent sloshing through complex active control systems or elaborate passive structures, the invention uses simple ring-shaped baffles that work by inverting the conventional approach - rather than containing the propellant completely, the baffles allow controlled movement while redirecting loads away from critical tank areas.

Inventive Principle:

Principle #13The other way round (Inversion)

3Object-affected harmful factors

If multiple ring baffles are installed throughout the propellant tank, then slosh loads are better mitigated, but manufacturing and installation complexity increases

Engineering Contradiction:

Improveslosh loadsVSAvoidpropellant tank assembly

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The ring baffles are designed as universal components that can be installed at multiple locations along the propellant tank using the same manufacturing process and attachment methodology. Each baffle serves multiple functions: reducing slosh loads, preventing pooling, and providing structural reinforcement. This multi-functionality simplifies manufacturing by using standardized components rather than custom-designed elements for each location.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The ring baffles are designed as simple, easily manufacturable components that can be produced cost-effectively using standard fabrication processes. Their simple ring geometry allows for efficient manufacturing and easy replacement if needed, reducing the overall cost and complexity of propellant tank assembly while maintaining effective slosh mitigation across multiple installation locations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS20250388341A1Launch vehicle with ring baffles

Publication Date: 2025.12.25 BLUE ORIGIN MANUFACTURING LLC

AI summary

A propellant tank can be used with a launch vehicle and can include at least one ring baffle having corrugated surfaces which are aligned circumferentially with respect to a longitudinal axis of the propellant tank. Folds of the corrugated surfaces may rise and fall in a first direction which is along the longitudinal axis. The ring baffle may be on an interior circumference of the propellant tank and the corrugated surfaces can extend in a second direction which is along a lateral axis of the propellant tank. Further, the ring baffle is of a predetermined width from the interior circumference of the propellant tank and can address slosh in a propellant used therein.