Micro-satellite Thruster Using Stacked PCB Modules

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Solution Overview

Problem

Conventional thrusters for micro-satellites are large, heavy, and costly due to their complex components, and electric thrusters require excessive power consumption with low propulsive force, making them unsuitable for micro-satellite applications.

Innovation Solution

A thruster design for micro-satellites utilizing stacked printed circuit boards to create multiple thrust modules with injectors, catalyst chambers, and nozzles, allowing for easy manufacturing and modular assembly, leveraging surface mount technology to reduce weight and increase efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If conventional thrusters are used for micro-satellites, then propulsion function is achieved, but weight and size increase

Engineering Contradiction:

Improvethruster weightVSAvoidpropulsion reliability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The thruster is divided into multiple independent thrust modules, each capable of generating thrust independently. This segmentation allows for reduced individual module weight while maintaining overall propulsion capability through parallel operation of multiple modules.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thrust modules are designed with universal structures that can perform multiple functions: propulsion generation, attitude control, and formation flying maneuvers. This multi-functionality eliminates the need for separate specialized devices, reducing total system weight.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Force

If chemical thrusters with additional devices are used, then propulsion force is achieved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvepropulsive forceVSAvoidthruster component complexity

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

Multiple functional components (injector, catalyst chamber, nozzle) are merged into an integrated thrust module structure. This consolidation reduces the number of separate parts and interfaces, simplifying manufacturing while maintaining propulsive force generation capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces complex mechanical ignition systems with a chemical catalyst-based propulsion mechanism. This substitution eliminates the need for igniters, valves, and propellant tanks, significantly reducing device complexity while maintaining effective propulsive force.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Weight of moving object

If electric thrusters are used for micro-satellites, then lightweight design is achieved, but power consumption increases and propulsive force decreases

Engineering Contradiction:

Improvethruster weightVSAvoidelectric power consumption

Core Design Contradiction:

Weight of moving objectVSUse of energy by moving object

Solution Approach 1:

The patent changes the fundamental operating parameters from electric field-based propulsion to chemical reaction-based propulsion. This parameter change enables lightweight design similar to electric thrusters while achieving higher propulsive force with lower power consumption through exothermic chemical reactions.

Inventive Principle:

Principle #35Parameter changes

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 thruster design enables the production of lightweight, efficient, and cost-effective thrusters with varied structures and performance, suitable for micro-satellite propulsion, minimizing thermal loss and facilitating mass production with robust physical properties.

Implementation Method 1

a first catalyst chamber installed in the first substrate assembly and connected to the first injector, a catalyst being positioned in the first catalyst chamber

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

The rocket obtains a propulsive force by discharging gas to the outside to the extent of the momentum of the gas on the basis of the law of action-reaction or conservation of momentum

Methodology Applied

Scientific EffectConservation of momentum: Conservation of Momentum

Data Source

PatentUS20250091733A1Thruster for micro-satellite and manufacturing method thereof

Publication Date: 2025.03.20 POSTECH ACADEMY INDUSTRY FOUNDATION

AI summary

A thruster for a micro-satellite according to an embodiment of the present disclosure includes a first thrust module configured to generate a first thrust in a first direction, a second thrust module configured to generate a second thrust in a second direction intersecting the first direction, and a control substrate on which the first thrust module and the second thrust module are mounted, the control substrate being configured to control the first thrust module and the second thrust module, in which the first thrust module and the second thrust module includes a plurality of printed circuit boards stacked.