3D Lattice Injector Face Plate for Rocket Head Thermal Resistance
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Solution Overview
Problem
Existing injector heads for liquid propellant rocket engines face challenges in withstanding high temperatures without compromising mechanical resistance, are costly to manufacture, and require complex assembly processes.
Innovation Solution
The injector face plate features a three-dimensional structure with interconnected beams, enhancing thermal and mechanical performance while reducing thickness and weight, manufactured through additive processes like Laser Powder Bed Fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the plate thickness is increased to augment injector face plate stiffness, then mechanical resistance is improved, but temperature inside the injector head increases
Solution Approach 1:
The patent transitions from a traditional flat plate structure to a three-dimensional lattice structure. This dimensional change allows the face plate to achieve enhanced mechanical resistance through the spatial arrangement of interconnected beams, while simultaneously improving thermal management by creating channels for heat dissipation and reducing material density, thus lowering the temperature inside the injector head.
Solution Approach 2:
The patent employs a lattice structure with inherent porosity, where the interconnected beams create void spaces throughout the face plate. This porous configuration reduces the overall thermal mass and facilitates heat dissipation, allowing the face plate to maintain mechanical resistance while operating at lower internal temperatures compared to solid plate designs.
2Temperature
If cooling channels are integrated inside the face plate to cool down the injector head, then temperature is reduced, but manufacturing cost and integration time increase
Solution Approach 1:
The patent merges the structural function and cooling function into a single integrated lattice structure. The same interconnected beams that provide mechanical support also define the cooling channels and heat dissipation pathways, eliminating the need for separate cooling channel integration steps and reducing manufacturing complexity.
Solution Approach 2:
The patent changes the fundamental parameter of the face plate structure from a solid or channel-added design to a lattice architecture. This parameter change inherently provides both structural integrity and thermal management capabilities, simplifying the manufacturing process by avoiding additional cooling channel integration steps.
3Temperature
If the number of injector tubes is increased to cool down the injector face plate, then temperature is reduced, but combustion stability is affected
Solution Approach 1:
The patent uses a three-dimensional lattice structure that provides extensive surface area and internal volume for heat dissipation without requiring additional injector tubes. The spatial arrangement of beams creates natural cooling pathways that reduce face plate temperature while maintaining the original injector tube configuration and combustion stability.
4Temperature
If a multi-material design is used for the injector face plate made of high conduction material, then thermal performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs a homogeneous lattice structure made from a single material, eliminating the need for multi-material designs. The interconnected beams are uniformly constructed, simplifying manufacturing processes while the lattice geometry itself provides the thermal management performance through increased surface area and heat dissipation pathways.
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 design improves heat exchange, mechanical resistance, and reduces manufacturing costs by distributing stress evenly, ensuring structural integrity and longevity under demanding conditions.
Implementation Method 1
The three-dimensional structure allows to improve the heat exchange between the injector face plate and the cold propellants contained in the liquid propellant dome. Indeed, the interconnected beams can increase turbulency in the liquid propellant dome and surface area of the injector face plate in contact with the liquid.
Implementation Method 2
the interconnected beams can increase turbulency in the liquid propellant dome and surface area of the injector face plate in contact with the liquid
Implementation Method 3
manufactured through additive processes like Laser Powder Bed Fusion
Data Source
Figure 1~2
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AI summary
The invention relates to an injector face plate (3) of an injector head (2) for a propulsive system, wherein the injector face plate (3) comprises a full plate (31) and a three-dimensional structure extending from the full plate (31), the three-dimensional structure comprising a plurality of beams interconnected with each other. The invention further relates to a corresponding injector head, a thrust chamber for a propulsive system, and the propulsive system itself.