Reusable Upper Stage Rocket With Integrated Aerospike Heat Shield
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Solution Overview
Problem
Existing technologies have not adequately addressed the problem of high costs and inefficiencies in single-use rockets, particularly for the upper stages of multi-stage space launch systems, and the challenge of reusing these stages due to the extreme re-entry heating environment.
Innovation Solution
A fully reusable upper stage rocket system utilizing an aerospike engine with a heat shield that integrates scarfed nozzles and secondary fluid injectors, allowing for vertical landing and active cooling to withstand re-entry heating, and repurposing turbomachinery components for cost-effective engine development.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional reusable rocket design is used, then the lower stage can be reused, but the upper stage cannot be reused due to re-entry heating
Solution Approach 1:
The patent merges the heat shield and aerospike engine into a single integrated structure. The heat shield forms the base of the aerospike nozzle, combining thermal protection with propulsion functionality. This integration allows the upper stage to survive re-entry heating while maintaining reusable capability, as the same structure serves both protective and propulsive functions across multiple missions.
Solution Approach 2:
The aerospike engine with integrated heat shield serves multiple functions: it provides propulsion during ascent, enables controlled descent during re-entry, and protects against thermal heating. This multi-functionality allows the upper stage to be reused across different mission profiles, transforming a single-use component into a versatile, reusable system that handles both launch and recovery operations.
2Productivity
If an aerospike engine with integrated heat shield is used, then reusability is enabled, but development costs and risks increase
Solution Approach 1:
The patent segments the upper stage into modular components including the aerospike engine, heat shield, and payload accommodation sections. This segmentation allows for independent testing, assembly, and maintenance of each component, reducing overall development risk and cost while enabling reusability. The modular design facilitates easier manufacturing and inspection compared to monolithic structures.
Solution Approach 2:
The aerospike engine design incorporates variable geometric parameters that can be adjusted for different mission requirements. The nozzle geometry and heat shield dimensions can be modified to optimize performance for various payload masses and mission profiles, reducing the need for multiple specialized vehicle designs and lowering development costs through a single versatile platform.
3Power
If scarfed nozzles are used in the heat shield, then engine performance is maintained, but manufacturing complexity increases
Solution Approach 1:
The scarfed nozzles are strategically positioned at specific locations within the heat shield where exhaust flow requires directional control. Rather than applying complex geometries throughout the entire structure, the scarfed nozzles are localized to specific regions where they provide optimal exhaust expansion and directionality. This localized approach maintains engine performance while minimizing overall manufacturing complexity.
Solution Approach 2:
The heat shield incorporates curved and spherical surface geometries that simplify manufacturing compared to flat or angular surfaces. The scarfed nozzles are integrated into these curved surfaces, allowing for smoother material flow and easier fabrication processes. The curved geometry of the heat shield base and nozzle structures reduces the number of sharp corners and complex joints required, lowering manufacturing difficulty while maintaining aerodynamic performance.
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 reduces development costs and risks by reusing existing hardware, enables efficient re-entry and landing, and maintains engine performance across various altitudes, facilitating multiple uses of the upper stage rocket.
Implementation Method 1
a heat shield at the aft end of the rocket body, the heat shield configured to spherically cap the aft end of the rocket body and dissipate heat encountered upon reentry of the upper stage into the atmosphere
Implementation Method 2
The heat shield may be actively cooled. The heat shield may include a cooling circuit configured to dissipate heat encountered during reentry of the upper stage
Implementation Method 3
the plurality of thruster modules configured to eject exhaust along at least the inboard portions of the scarfed nozzles defining portions of the aerospike contour
Implementation Method 4
secondary fluid injectors configured to eject fluid that joins with the exhaust ejected by the plurality of thruster modules
Data Source
AI summary
Systems and methods for a fully reusable upper stage for a multi-stage launch vehicle are provided. The reusable upper stage uses an aerospike engine for main propulsion and for vertical landing. A heat shield can include a plurality of scarfed nozzles embedded radially around a semi-spherical surface of the heat shield, wherein inboard surfaces of the plurality of scarfed nozzles collectively define an aerospike contour. The heat shield can be actively cooled to dissipate heat encountered during reentry of the upper stage.