Modular Rocket Propulsion System for Reusable Launch
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Solution Overview
Problem
Current rocket-powered launch vehicles face challenges in reusability, reliability, scalability, and cost-effectiveness due to their design origins from military expendable missiles, restrictive ground support facilities, and costly, proprietary propulsion systems, which hinder efficient and safe passenger and cargo transportation to orbit.
Innovation Solution
A modular propulsion system with Thrust Chamber Units and fluid pumps that are easily removable and replaceable, integrated into a vehicle design allowing vertical takeoff and landing, combined with a flexible ground operations facility that supports frequent flight operations and safety features like passenger escape capsules and parachute recovery systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete propulsion units with integrated thrust chambers are used, then expendable launch vehicles can be designed with generic engine units, but reusability and operational flexibility are limited
Solution Approach 1:
The propulsion system is divided into discrete Thrust Chamber Units (TCUs) that can be independently removed and replaced. Each TCU is a separate module with standardized interfaces, allowing individual replacement without affecting the entire vehicle. This segmentation enables the vehicle to be reused by simply replacing consumed TCUs rather than the entire propulsion system.
Solution Approach 2:
The propulsion system transitions from static integrated engines to dynamic replaceable modules. The TCUs are designed with quick-release mechanisms and standardized mounting interfaces that allow rapid removal and replacement during ground operations. This dynamic capability enables the system to adapt between flight and maintenance states efficiently.
2Reliability
If flight termination devices and escape means are included, then safety for non-reusable vehicles is ensured, but reusability is compromised
Solution Approach 1:
The flight termination device is extracted from the vehicle structure and placed on the ground support facility. Instead of having the vehicle destroy itself or carry complex escape mechanisms, the ground facility provides a safe landing zone and recovery capability. This extraction eliminates the need for in-vehicle termination mechanisms while maintaining safety.
Solution Approach 2:
The ground support facility acts as an intermediary between the vehicle and the environment. It provides the safety functions that would otherwise need to be built into the vehicle, such as controlled landing zones, exhaust management, and recovery operations. This intermediary approach allows the vehicle to be designed purely for propulsion and reuse.
3Stability of the object's composition
If physical support interfaces restrict vertical movement, then ground support stability is improved, but flight abort capability and wind tolerance are limited
Solution Approach 1:
The ground support interface uses dynamic positioning capabilities rather than fixed restrictive constraints. The vehicle can be precisely positioned and held during launch, then quickly released when flight abort is needed. The interface transitions from a static constraint to a dynamic control mechanism that adapts to different operational requirements.
Solution Approach 2:
The ground support facility can change its support parameters dynamically - adjusting hold-down forces, positioning constraints, and release criteria based on flight conditions. This allows the system to maintain stability during normal launch while enabling quick abort capability when necessary, without permanent structural modifications.
4Reliability
If proprietary propulsion systems are used, then performance requirements can be met, but cost-effectiveness and scalability are reduced
Solution Approach 1:
The Thrust Chamber Units are designed with universal interfaces and standardized mounting systems that can be applied across different vehicle configurations and mission types. The same TCU design can serve multiple functions - different payload capacities, orbit types, and mission profiles - eliminating the need for proprietary custom propulsion systems for each application.
Solution Approach 2:
By segmenting the propulsion system into standardized TCUs, the complexity of proprietary integrated engines is replaced with modular components. Each TCU is a simple, standardized unit that can be mass-produced and replaced, reducing overall system complexity while maintaining performance through configurable numbers and arrangements of modules.
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 enhances the reliability and cost-effectiveness of rocket-powered launch systems, enabling frequent and safe operations by reducing unit costs and increasing mission success rates, bridging the reliability gap between rocket vehicles and commercial aircraft.
Implementation Method 1
rocket-powered launch system
Implementation Method 2
Thrust Chamber Units (TCUs) arranged around a perimeter of a primary propulsion unit
Implementation Method 3
fluid pumps in fluid communication between at least one propellant tank and said TCUs through flow control valves
Implementation Method 4
parachute recovery systems
Data Source
AI summary
A rocket-powered space launch system comprises both a vehicle segment with an integrally designed propulsion subsystem and a supporting ground facility segment. Elements of a propulsion unit as easily accessed for removal and replacement of individual components. Said launch system is highly reusable, operable, and facilitates governmental agency regulatory compliant safety of occupants and public without passenger escape function and/or commanded vehicle destruction.