Structural Propellant for Ion Rockets
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Solution Overview
Problem
Conventional Hall thruster designs for spacecraft require significant mass for propellant and propellant storage, increasing launch costs and reducing delta-v capability due to excess structure mass that is not utilized effectively in-space.
Innovation Solution
A structural propellant system for ion rockets (SPIR) that utilizes a removal device, such as mechanical cutters or laser cutters, to convert excess spacecraft structure, like magnesium, into a propellant ribbon fed into a Hall thruster system for thrust production, optimizing mass usage and increasing available fuel supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional Hall thruster designs use separate propellant storage bottles, then the propellant can be stored and delivered to the thruster, but the spacecraft mass increases significantly due to the propellant bottle and propellant mass
Solution Approach 1:
The patent merges the propellant storage function with the spacecraft structure by designing the upper stage housing and structural components to be consumed as propellant. The magnesium alloy upper stage structure serves dual purposes: providing structural support during launch and serving as propellant mass for the Hall thruster after orbital insertion, eliminating the need for separate propellant storage bottles.
Solution Approach 2:
The upper stage structure is designed with multi-functionality, serving as both a structural component during launch and as propellant mass for in-space maneuvers. The magnesium alloy material provides both mechanical strength for launch vehicle integration and sufficient mass for Hall thruster propellant requirements, allowing the same structure to fulfill multiple functions across different mission phases.
2Duration of action of moving object
If significant propellant mass is carried in conventional designs, then the Hall thruster can produce thrust for extended maneuvers, but the launch costs increase due to the additional mass
Solution Approach 1:
The patent combines the propellant mass requirement with the upper stage structure mass, eliminating the need to launch separate propellant tanks. The magnesium alloy structure provides both the mechanical integrity needed for launch and the propellant mass for extended Hall thruster operation, reducing launch mass and associated costs while maintaining sufficient thrust duration for orbital maneuvers.
Solution Approach 2:
The patent changes the material parameter by using magnesium alloy for the upper stage structure, which has favorable properties for both structural applications and propellant use in Hall thrusters. This material selection enables the structure to serve dual functions, optimizing the balance between thrust duration capability and launch mass constraints.
3Strength
If excess spacecraft structure mass is present for launch, then the structure can support launch loads, but the delta-v capability is reduced due to the unused structure mass in-space
Solution Approach 1:
The patent merges the excess structure mass that would otherwise be dead weight in-space with the propellant mass requirement for delta-v capability. The magnesium alloy upper stage structure is designed to be consumed by the Hall thruster after launch, converting what would be unused structural mass into useful propellant mass, thereby enhancing delta-v capability while maintaining sufficient structural strength during launch.
Solution Approach 2:
The patent changes the functional state of the structure from a static structural component to a consumable propellant resource. By selecting magnesium alloy with appropriate strength-to-mass ratios and consuming the structure through the Hall thruster, the system transforms excess structural mass into useful propulsion capability, directly improving delta-v while maintaining launch structural requirements.
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 reduces spacecraft mass by repurposing unneeded structure as propellant, enhancing delta-v capability and payload capacity while minimizing launch costs by using existing structure as fuel post-orbit.
Implementation Method 1
at least one laser cutter
Implementation Method 2
Hall thruster system
Implementation Method 3
Hall thruster system
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Systems, methods, and apparatus for a structural propellant for ion rockets (SPIR) are disclosed. A method for in-space propulsion of a spacecraft involves removing, by a removal device, a portion of a structure of the spacecraft. The method further involves feeding, by the removal device, the portion into a Hall thruster system. Further, the method involves utilizing, by the Hall thruster system, the portion as propellant to produce thrust. The structure can be an upper stage of the spacecraft. The upper stage can comprise at least one structural support and/or at least one upper stage housing. The structure can be manufactured from magnesium, bismuth, zinc, and/or indium.