Rocket Nozzle Cooling Channel Segmentation for Flow Balance
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Solution Overview
Problem
Existing rocket engine nozzle designs face challenges in efficiently distributing coolant to minimize manifold size and length, while protecting manifolds from high vibration and heat loads, leading to inefficient cooling and reduced engine life due to unbalanced flow and pressure drops.
Innovation Solution
The design incorporates a configuration where at least one second cooling channel is closed to prevent coolant entry from the first portion, with twice the number of cooling channels in the second portion, and a controlled one-way flow to ensure balanced distribution and minimize pressure drops, allowing for optimized cooling efficiency and reduced sensitivity to hot spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a double pass flow arrangement is used to minimize manifold size and duct length, then the manifold size and duct length are reduced, but the flow distribution becomes unbalanced and pressure drops increase
Solution Approach 1:
The cooling channels are divided into first and second portions with different numbers of channels. The first portion has a first number of channels while the second portion has a second number of channels, creating segmented flow paths that allow independent optimization of each section's cooling performance and pressure distribution.
Solution Approach 2:
Different sections of the nozzle wall are assigned different cooling channel configurations based on local thermal loads. The first portion has a first number of channels optimized for its thermal requirements, while the second portion has a second number of channels optimized for its different thermal conditions, achieving localized optimization throughout the component.
2Reliability
If coolant is distributed to all cooling channels in the second portion, then cooling coverage is maximized, but pressure drops and flow imbalance increase
Solution Approach 1:
Some cooling channels in the second portion are selectively deactivated or removed from the active cooling circuit. By taking out certain channels from full operation, the system maintains adequate cooling coverage through the remaining active channels while significantly reducing pressure drops and flow imbalance in the system.
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 configuration achieves improved heat exchange and robust flow balance, reducing the risk of hot spots and extending engine service cycles by ensuring precise coolant distribution and efficient cooling, even with less efficient media like methane.
Implementation Method 1
Heat is transferred from the hot gases to the inner wall, further on to the fuel, from the fuel to the outer wall, and, finally, from the outer wall to any medium surrounding it. Heat is also transported away by the coolant as the coolant temperature increases by the cooling.
Implementation Method 2
at least one second cooling channel in the second portion is closed so that the coolant is at least substantially prevented from entering the closed second cooling channel from a cooling channel in the first portion
Data Source
AI summary
A component configured for being subjected to a high thermal load during operation includes a wall structure with cooling channels adapted for handling a coolant flow. At least one first cooling channel is adapted to convey the coolant from a first portion of the component to a second portion of the component. At least one second cooling channel in the second portion is closed so that the coolant is at least substantially-prevented from entering the closed second cooling channel from a cooling channel in the first portion.