Non-Parallel Channel Catalyst Bed for Hybrid Rocket Ignition
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Solution Overview
Problem
Existing chemical rocket engines face inefficiencies in catalyzing the decomposition of propellants like nitrous oxide, particularly in hybrid rocket propulsion systems, where the solid fuel and liquid oxidizer interaction is not optimized for reliable and repeatable ignition.
Innovation Solution
A catalyst bed with a structured geometry, manufactured via additive manufacturing, is used to promote the catalytic decomposition of nitrous oxide into gaseous products, enhancing the interaction between the solid and liquid propellants by providing a non-parallel channel orientation and exposing catalysts on the channel surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional catalyst bed structure is used, then the device complexity is low, but the catalytic surface area is insufficient leading to poor decomposition efficiency
Solution Approach 1:
The patent employs a porous monolithic structure with interconnected channels and high surface area-to-volume ratio. This porous architecture provides extensive catalytic surface area while maintaining structural integrity, resolving the contradiction between decomposition efficiency and device complexity by using naturally porous materials rather than complex assembled structures.
Solution Approach 2:
The patent transitions from traditional two-dimensional catalyst surfaces to a three-dimensional monolithic structure with channels extending in multiple directions. This dimensional transformation increases the effective catalytic surface area without proportionally increasing the device footprint, thereby improving decomposition efficiency while controlling structural complexity.
2Productivity
If the catalyst bed size is increased to provide more surface area, then the decomposition efficiency improves, but the reactor volume increases reducing compactness
Solution Approach 1:
The porous monolithic structure achieves high catalytic surface area within a compact volume by utilizing the internal pore network. The three-dimensional channel system provides extensive catalyst exposure without requiring a large external reactor volume, thus improving productivity while maintaining compactness.
Solution Approach 2:
The patent embeds the catalyst-coated monolithic structure within the reactor, creating a nested configuration where the catalyst bed is integrated into the reactor volume rather than occupying separate space. This nesting approach maximizes the use of available reactor volume for catalytic function.
3Productivity
If non-parallel channel orientation is used, then the fluid-catalyst interaction is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent varies the channel orientation parameters within the monolithic structure, creating non-parallel channels at different angles to enhance fluid-catalyst interaction. This parameter variation is achieved through controlled fabrication processes that can accommodate angular variations without significantly increasing manufacturing complexity.
Solution Approach 2:
The monolithic structure serves multiple functions simultaneously: it provides structural support, defines flow channels with optimized orientations, and supports the catalyst coating. This multi-functionality reduces the need for separate components, thereby maintaining ease of manufacture while achieving improved fluid-catalyst interaction through non-parallel channel geometry.
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 structured catalyst bed improves the reliability and repeatability of hybrid rocket ignition, allows for more efficient decomposition, and enables compact reactor designs with higher catalytic surface area, leading to increased thrust and oxidation strength.
Implementation Method 1
a catalyst promotes decomposition of the heated spray of the decomposable fluid into two or more gaseous decomposition products
Data Source
AI summary
A catalyst bed includes a structure defining a plurality of channels configured to receive flow of fluid to be chemically catalyzed. The plurality of channels are oriented at least partially non-parallel to an overall flow direction of the flow from inputs of the plurality of channels to outputs of the plurality of channels. A catalyst is exposed at an exterior of the structure.