Space Vehicle Closed-Loop Hydrocarbon Cooling for High-Power Payloads
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Solution Overview
Problem
Current cooling systems for space vehicles, particularly those using ammonia, face limitations in heat dissipation capacity, compatibility issues with materials, and safety concerns due to high pressures, which restrict payload power and design flexibility.
Innovation Solution
A closed-loop cooling system utilizing a single-phase hydrocarbon-based coolant at low pressures, with quick disconnect fittings and additively manufactured heat-exchange components, allowing for higher thermal management capabilities and reduced risk of leakage, enabling payloads with up to 150 Watts of power and 200 Watts/in² power densities, and operating temperatures up to 150 °C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If ammonia-based cooling systems are used, then heat dissipation capability is improved, but safety risks and material compatibility issues worsen due to high pressure and toxicity
Solution Approach 1:
The patent changes the pressure parameter from high (400 psi ammonia) to low (1-10 psi hydrocarbon), fundamentally altering the operating conditions to eliminate safety risks while maintaining heat dissipation capability through the closed-loop design and phase change mechanism
Solution Approach 2:
The patent employs a closed-loop system where the hydrocarbon coolant circulates continuously, eliminating the need for large storage tanks and allowing for compact, integrated cooling components that are safer and more reliable than ammonia systems
2Power
If ammonia is used as coolant, then cooling performance is improved, but material compatibility deteriorates due to corrosion of aluminum components
Solution Approach 1:
The patent changes the chemical composition parameter by substituting ammonia with hydrocarbon coolant, which fundamentally eliminates the corrosive interaction with aluminum and other space vehicle materials while maintaining effective heat transfer performance
Solution Approach 2:
The hydrocarbon coolant acts as a safe intermediary substance that transfers heat without chemically reacting with or corroding the aluminum heat exchanger components, unlike ammonia which directly attacks aluminum materials
3Device complexity
If passive cooling systems are used, then system complexity is reduced, but heat dissipation capacity is limited constraining payload power
Solution Approach 1:
The patent introduces an active pumped fluid circulation system where a pump moves hydrocarbon coolant through the closed-loop heat exchanger network, enabling high-capacity heat removal that scales with payload power requirements while maintaining reasonable system complexity
Solution Approach 2:
The patent utilizes phase change (evaporation and condensation) of the hydrocarbon coolant within the closed-loop system to efficiently transfer and dissipate large amounts of heat, dramatically increasing heat dissipation capacity compared to passive conduction-only systems
4Productivity
If high pressure cooling systems are used, then heat transfer efficiency is improved, but risk of leakage and catastrophic failure increases
Solution Approach 1:
The patent fundamentally changes the pressure operating parameter from high (400 psi) to very low (1-10 psi), eliminating the driving force for leakage while maintaining heat transfer efficiency through the closed-loop phase change mechanism and continuous fluid circulation
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 system effectively dissipates heat at high densities, supports higher power payloads, reduces corrosion risks, and simplifies manufacturing and integration, while maintaining safety through lower operating pressures and non-oxidizing coolant properties.
Implementation Method 1
a first heat exchange component disposed along the coolant passageway transfers heat from heat-producing components (e.g., components of a space vehicle payload) to the coolant
Implementation Method 2
a second heat exchange component disposed along the coolant passageway removes heat from the coolant, thereby rejecting the heat from the space vehicle
Data Source
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AI summary
A space vehicle (100) is described. The space vehicle (100) comprises one or more heat-producing components (102), and a closed loop cooling system (300) configured to remove heat generated by the one or more heat-producing components (102). The closed loop cooling system (300) comprises a coolant passageway (303) defining a closed loop, a coolant located within the coolant passageway (303), the coolant comprising a static pressure of 100 pounds per square inch or lower and the coolant being in a single liquid phase through the coolant passageway (303), and one or more pumps (334) configured to move the coolant through the coolant passageway (303). The closed loop cooling system (300) further comprises a first heat exchange component (306) disposed along the coolant passageway (303), the first heat exchange component (306) configured to transfer heat from the heat-producing components (102) to the coolant, and a second heat exchange component (342) disposed along the coolant passageway (303), the second heat exchange component (342) configured to remove heat from the coolant.