Segmented Rocket Thrust Chamber Joints for Regenerative Cooling

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Solution Overview

Problem

Conventional manufacturing methods for thrust chambers in rocket engines are complex and costly, particularly due to the need for complex machining and forging, and alternative methods like additive manufacturing struggle with large component sizes and accuracy, leading to high costs and inefficiencies.

Innovation Solution

A multi-part rocket engine thrust compartment is formed using additive manufacturing with segments coupled via a coupling system that includes joint inserts, allowing for reduced machining operations and efficient regenerative cooling through annular flow passages, enabling cost-effective production and maintaining cooling effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional machining and forging methods are used to form thrust chambers, then manufacturing precision and structural integrity can be achieved, but production complexity and costs increase significantly

Engineering Contradiction:

Improvethrust chamber manufacturing precisionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The thrust chamber is divided into multiple segments that are manufactured separately using additive manufacturing and then joined together using coupling systems with joint inserts. This segmentation allows each segment to be produced with simpler processes while maintaining overall manufacturing precision through controlled joining interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the manufacturing parameters by transitioning from conventional machining and forging to additive manufacturing processes. This parameter change enables complex internal cooling channels to be formed directly during fabrication, reducing the need for subsequent complex machining operations.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If additive manufacturing is used for large thrust chamber components, then production costs and time can be reduced, but manufacturing precision and component accuracy deteriorate

Engineering Contradiction:

Improvethrust chamber production efficiencyVSAvoidlarge component manufacturing accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Large thrust chambers are segmented into smaller, manageable sections that can be manufactured with higher accuracy using additive manufacturing. The segments are then joined using coupling systems that maintain overall structural integrity and precision while enabling production of large-scale components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Joining features and coupling interfaces are designed and prepared in advance during the additive manufacturing process. This preliminary action ensures that when segments are assembled, the joining operations can be performed with high precision, maintaining overall component accuracy.

Inventive Principle:

Principle #10Preliminary action

3Strength

If thrust chambers are manufactured as single large components, then structural integrity can be maintained, but manufacturing complexity and costs increase

Engineering Contradiction:

Improvethrust chamber structural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The thrust chamber is segmented into multiple sections that are joined using coupling systems with joint inserts. These coupling systems are designed to maintain structural integrity at the joints, ensuring that the assembled chamber can withstand combustion pressures and thermal loads equivalent to monolithic constructions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Coupling systems with joint inserts serve as intermediaries between segments, providing a reliable joining mechanism that maintains structural integrity. The joint inserts facilitate welding and debris management, ensuring strong connections while simplifying the overall manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Temperature

If complex machining operations are performed to create cooling channels, then regenerative cooling effectiveness can be achieved, but production time and costs increase

Engineering Contradiction:

Improvecooling effectivenessVSAvoidmanufacturing time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The manufacturing process parameters are changed by using additive manufacturing to directly form complex internal cooling channels within the thrust chamber segments. This eliminates the need for complex machining operations to create the channels, reducing manufacturing time while maintaining the cooling effectiveness required for regenerative cooling.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11448163B1Multi-part fluid chamber and method of manufacturing

Publication Date: 2022.09.20 LONG WALL CO

AI summary

A coupling system is utilized to form a multi-part rocket engine thrust compartment that maintains inner channels within walls of the thrust compartment for regenerative cooling. The coupling system includes an insert joint arranged between joint faces of a first segment and a second segment. The first segment and the second segment include inner edges that, when jointed together, form an inner wall. The joint insert is installed between the first segment and the second segment after the inner wall is formed and coupled to the first segment and the second segment. The joint faces of the first segment and the second segment include extending feature to form a flow passage along with cavities at least partially defined by the joint insert.