Rocket Injector Support Column Layout for Simpler Thrust Chamber Assembly
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Solution Overview
Problem
Traditional rocket engine manufacturing techniques are complex and costly, involving intricate assembly procedures for thrust chambers, injectors, and turbopump systems, which complicate design and increase production costs.
Innovation Solution
The use of additive manufacturing techniques, specifically direct metal laser sintering, to produce rocket engine components such as thrust chambers, injectors, and turbopumps, allowing for complex geometries and reduced assembly complexity by creating sintered metal structures with varying surface roughness for enhanced cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing techniques are used for thrust chambers and injectors, then manufacturing precision can be achieved, but device complexity and production costs increase significantly
Solution Approach 1:
The patent combines multiple separate components (thrust chamber, injector, turbopump) into integrated assemblies using additive manufacturing. The injector is built directly within the thrust chamber structure, and the turbopump is integrated with the thrust chamber, eliminating complex assembly procedures and reducing the number of separate parts while maintaining manufacturing precision through direct digital manufacturing
Solution Approach 2:
The additive manufacturing process enables local variation in surface roughness within coolant flow passages, allowing different regions of the thrust chamber to have optimized surface properties for heat transfer. This local quality control improves cooling efficiency without requiring complex post-processing of entire components
2Device complexity
If additive manufacturing is used to create complex geometries, then device complexity is reduced, but manufacturing precision may be compromised
Solution Approach 1:
The additive manufacturing process allows different regions of the thrust chamber to be printed with different surface roughness characteristics. Coolant flow passages can be engineered with specific surface finishes optimized for heat transfer, while other regions maintain structural integrity, achieving both geometric complexity and manufacturing precision through localized material properties
3Loss of energy
If smooth surfaces are used in coolant flow passages, then pressure drop is reduced, but heat transfer efficiency decreases
Solution Approach 1:
The thrust chamber incorporates regions with different surface roughness along the coolant flow path. Entrance regions may have smoother surfaces to minimize pressure drop, while regions requiring enhanced heat transfer have increased surface roughness to promote turbulence and improve cooling efficiency, optimizing both energy loss and temperature control
Solution Approach 2:
The additive manufacturing process enables variation of surface roughness parameters along the coolant flow passages. By changing the surface finish characteristics at different locations, the system optimizes the balance between pressure drop and heat transfer coefficient, allowing turbulent flow enhancement where needed while maintaining acceptable pressure losses
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 approach simplifies the assembly and design of rocket engine components, reduces production costs, and enhances cooling performance by varying surface roughness within coolant flow passages, improving heat transfer and reducing pressure drop.
Implementation Method 1
The sections may be a contiguous sintered metal structure manufactured using direct metal laser sintering
Implementation Method 2
The walls may define a plurality of coolant flow passages that extend from a first end of the thrust chamber to a second end of the thrust chamber
Implementation Method 3
enhances cooling performance by varying surface roughness within coolant flow passages, improving heat transfer
Data Source
AI summary
Disclosed herein are various technologies pertinent to rocket engines, including injector, thrust chamber, and electrical turbopump devices that may be combined to provide a more efficient rocket engine. The thrust chamber may be coupled with an injector having a circular array of support columns supporting a distribution system. Liquid may be flowed from the distribution system, through the support columns, and into a combustion chamber of the thrust chamber.