Integrated Igniter Mixing Head for Rocket Engines

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Solution Overview

Problem

Existing rocket engine thrust chambers require complex configurations and pose risks of leakage and handling hazards due to the need for multiple igniter assemblies and separate gas supplies for hypergolic ignition propellants, limiting machining techniques and simplification.

Innovation Solution

A thrust chamber integrated with an igniter using a mixing head assembly that includes a combustion chamber, manifolds for oxidizer and fuel, an igniter chamber, and a spark plug, formed by additive manufacturing through 3D printing, which simplifies configuration, reduces leakage risks, and facilitates multiple ignitions without separate gas supplies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mixing head assembly with pyrotechnic igniter is used, then ignition function is achieved, but configuration becomes complicated and handling safety deteriorates due to multiple assemblies and gunpowder

Engineering Contradiction:

Improveignition functionVSAvoidconfiguration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The igniter is integrated directly into the mixing head assembly, merging the ignition function with the fuel injection system. This eliminates the need for separate pyrotechnic igniter assemblies and reduces the number of components, directly resolving the configuration complexity issue while maintaining reliable ignition through the integrated design

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If multiple pyrotechnic igniter assemblies are installed for multiple ignitions, then multiple ignition capability is achieved, but device complexity and handling risk increase

Engineering Contradiction:

Improvemultiple ignition capabilityVSAvoidnumber of assemblies

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The igniter uses a reusable electric spark ignition system with a gas supply mechanism that can be activated multiple times. This dynamic design allows the same integrated assembly to perform multiple ignition cycles without requiring multiple separate pyrotechnic devices, reducing complexity while enabling multiple ignitions

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If gas torch is assembled to mixing head for multiple ignitions, then multiple ignition is enabled, but machining limits require separate fabrication and installation

Engineering Contradiction:

Improvemultiple ignition capabilityVSAvoidfabrication simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The gas torch ignition system is merged with the mixing head assembly during the additive manufacturing process. The gas supply channels and ignition components are integrated into a single monolithic structure, eliminating the need for separate fabrication and assembly steps required by traditional machining methods

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If hypergolic ignition propellant ampoule is used, then ignition function is achieved, but configuration becomes complicated and leakage risk increases due to separate containers

Engineering Contradiction:

Improveignition functionVSAvoidleakage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The ignition system uses integrated gas supply channels within the mixing head assembly rather than separate ampoules or containers. This merging of the gas supply system into the main structure eliminates additional connection points and interfaces, thereby reducing leakage risk while maintaining the hypergolic ignition function

Inventive Principle:

Principle #5Merging (Combining)

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 integrated design simplifies the rocket engine configuration, reduces leakage risks, and enables efficient multiple ignitions using cryogenic fuels and liquid oxygen, eliminating the need for separate gas supplies and complex machining techniques.

Implementation Method 1

a spark plug, which is inserted into the interface bore for spark plug to be partially disposed inside the igniter chamber and generates a spark inside the igniter chamber

Methodology Applied

Scientific EffectSpark generation: Electric Spark

Implementation Method 2

a flame injection hole, which is disposed at one side of the igniter chamber to face toward a combustion space disposed inside the combustion chamber

Methodology Applied

Scientific EffectFlame propagation: Combustion

Implementation Method 3

The combustion chamber and the mixing head assembly may be integrally formed by being stacked in a first direction by using an end portion of the combustion chamber nearby an outlet as a stacking base

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS11988174B2Thrust chamber integrated with igniter of rocket engine using cryogenic fuel and liquid oxygen and rocket including the same

Publication Date: 2024.05.21 KOREA AEROSPACE RES INST

AI summary

Provided are an igniter-integrated thrust chamber for a rocket engine using a cryogenic fuel and liquid oxygen and a rocket including the thrust chamber. The thrust chamber includes a combustion chamber and a mixing head assembly, which is disposed at one side of the combustion chamber and is integrated with the combustion chamber.