Onboard Structural Material Conversion to Propellant

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Solution Overview

Problem

Current propellant systems require external service vehicles for refueling, which is impractical and costly, especially in interplanetary missions, due to the need for additional propellant and time-consuming rendezvous procedures, limiting the mission duration of spacecraft.

Innovation Solution

A propellant system that repurposes excess onboard mass into propellant through processes like de-alloying, heating, or converting structural materials into gas or liquid form, allowing autonomous propellant production without external assistance, using materials like Indium, tin, or alloy materials with lower temperature thresholds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If external service vehicles are used for refueling, then propellant can be replenished, but mission cost and complexity increase significantly

Engineering Contradiction:

Improvepropellant quantityVSAvoidsystem complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The spacecraft converts its own structural materials into propellant using onboard processing equipment. The system includes a propellant conversion device that transforms structural components into usable propellant forms, allowing the vehicle to refuel itself without external assistance, thereby reducing mission complexity and cost while maintaining propellant quantity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system recovers and repurposes structural materials that would otherwise be discarded or depleted. By converting structural components into propellant, the system transforms waste or expendable mass into a valuable resource, extending mission duration without requiring additional launch mass or external service vehicles

Inventive Principle:

Principle #34Discarding and recovering

2Quantity of substance

If external service vehicles are used for refueling, then propellant can be replenished, but mission time increases due to rendezvous procedures

Engineering Contradiction:

Improvepropellant quantityVSAvoidmission time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

The spacecraft performs autonomous propellant production by converting its own structural materials. This self-service capability eliminates the need for time-consuming rendezvous with external service vehicles, allowing immediate propellant replenishment and extending mission duration without time loss

Inventive Principle:

Principle #25Self-service

3Duration of action of moving object

If additional propellant is carried for extended missions, then mission duration increases, but launch mass increases

Engineering Contradiction:

Improvemission durationVSAvoidlaunch mass

Core Design Contradiction:

Duration of action of moving objectVSWeight of moving object

Solution Approach 1:

The structural materials serve dual functions: providing structural support during launch and serving as propellant source during mission operations. This multi-functionality allows the same mass to fulfill both structural and propulsion roles, extending mission duration without increasing launch mass

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system changes the functional state of structural materials from static structural components to dynamic propellant sources. By altering the physical or chemical state of these materials through onboard conversion processes, the system transforms them into usable propellant, effectively increasing mission duration without adding launch mass

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

This approach extends mission duration, reduces launch mass, and achieves cost savings by utilizing existing structural materials as propellant, enabling additional delta-v gains and efficient propulsion without the need for external refueling vehicles.

Implementation Method 1

heating, or converting structural materials into gas or liquid form

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

converting structural materials into gas or liquid form

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS11542926B2Onboard structure convertible into a propellant for electric propulsion

Publication Date: 2023.01.03 AEROSPACE CORP

AI summary

A vehicle comprising a structure, a plurality of heating sources, and a transport mechanism. The structure is comprised of multiple materials, a composite such that some of the material constituents can be extracted leaving behind others via application of energy (such as de-alloying). The extracted material or materials are configured to be re-purposed into a propellant. The plurality of heating elements surrounds or is embedded within the structure configured to convert the material into the propellant. The transport mechanism is configured to transport the propellant from the structure to a reservoir or to the propulsion system.