Infused Solid Polymer Fuel for Reliable Hybrid Rocket Ignition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current propulsion technologies for small spacecraft, such as hydrazine and ionic liquid-based systems, pose environmental hazards, require complex handling, and have performance limitations, while conventional hybrid rockets face ignition challenges and low fuel regression rates, making them unsuitable for reliable and efficient use in SmallSats.
Innovation Solution
Development of infused solid polymeric fuels using 3D printing technology, which incorporates a combustion enhancement agent into a porous polymeric body, enabling reliable arc-ignition and multiple restarts without external catalysts or preheating, and utilizing a direct current source for efficient combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hybrid rockets are used, then propulsion capability is provided, but ignition reliability is poor and fuel regression rate is low
Solution Approach 1:
The patent applies local quality by creating a porous structure within the solid fuel grain that concentrates combustion enhancement agents at specific locations (pore surfaces and interfaces) rather than uniformly throughout the fuel. This localized concentration of catalysts and oxidizers at the pore boundaries creates high-reactivity zones that improve ignition reliability while maintaining controlled fuel regression rates through the porous matrix.
Solution Approach 2:
The patent utilizes porous materials by incorporating a porous structure into the solid fuel grain and filling the pores with combustion enhancement agents. The porous morphology provides increased surface area for catalytic reactions, improves oxidizer penetration, and enables more reliable ignition while controlling the fuel regression rate through the pore structure's characteristics.
2Object-affected harmful factors
If ionic liquid-based green propellants are used, then environmental safety is improved, but handling complexity and toxicity remain issues
Solution Approach 1:
The patent employs solid polymeric fuels that can be manufactured, stored, and handled as stable solid materials without the handling complexities of liquid ionic liquids. The solid fuel grains can be pre-fabricated with embedded porous structures and combustion enhancement agents, eliminating the need for complex storage and handling systems required for toxic ionic liquids while maintaining environmental safety benefits.
Solution Approach 2:
The patent creates composite materials by combining solid polymeric fuel with embedded porous structures and combustion enhancement agents. This composite approach provides the environmental benefits of green propellants while achieving reliable combustion characteristics through the integrated porous-fuel-catalyst system, avoiding the handling issues of liquid ionic liquids.
3Productivity
If solid polymeric fuel with porous structure is used, then combustion efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the porous structure within the solid polymeric fuel grain before final assembly. The porous morphology is created in advance through manufacturing processes such as 3D printing with infill patterns, foam insertion, or controlled foaming, allowing combustion enhancement agents to be subsequently infused into the pre-formed pores without adding complex real-time manufacturing steps.
Solution Approach 2:
The patent utilizes parameter changes by controlling the porosity, pore size distribution, and pore connectivity parameters of the solid fuel structure to optimize combustion efficiency. By adjusting these physical parameters during manufacturing (such as infill density in 3D printing or foam cell structure), the fuel achieves improved combustion characteristics without requiring fundamentally complex manufacturing processes.
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 achieves high vacuum specific impulse (Isp) of over 300 seconds, reliable ignition, and multiple restart capability, reducing system complexity and weight, making it suitable for SmallSat applications.
Implementation Method 1
A porous polymeric body can be soaked in a composition comprising a combustion enhancement agent and a solvent to deposit the combustion enhancement agent on interior surfaces of the pores and on the external surface of the polymeric body
Implementation Method 2
The solvent can be evaporated
Implementation Method 3
a decomposition catalyst infused into the polymeric body, wherein the catalyst catalyzes a decomposition of the liquid oxidizer
Implementation Method 4
enabling reliable arc-ignition and multiple restarts without external catalysts or preheating, and utilizing a direct current source for efficient combustion
Data Source
AI summary
An infused solid polymeric fuel for use in a hybrid rocket or as explosive ordnance. An infused solid polymeric fuel can include a porous polymeric body having continuous pores distributed throughout a volume of the polymeric body and connecting to an external surface of the polymeric body. A combustion enhancement agent can be infused into the polymeric body. The combustion enhancement agent can be deposited on interior surfaces of the pores and on the external surface of the polymeric body. The combustion enhancement agent can include a catalyst, an oxidizer, a hypergolic fuel, or a combination.