Patent Application
20170284339
The invention is in the field of thrusters for flight vehicles, such as satellites.
Thrusters are used in a wide variety of flight vehicles, including spacecraft and aircraft of various sizes, from large to small. Thrusters may be used for any of a variety of purposes, from providing the main motive force for the vehicle to use in steering and/or course correction. There is difficulty in employing such thrusters in small flight vehicles, such as small satellites. A difficulty also arises when it would desirable for a thruster to be used multiple times, such as for multiple course correction or steering burns.
According to an aspect of the invention, a thruster includes plural separate propellant segments, which may be consumed one at a time. Alternatively the propellant segments may be partially consumed.
According to another aspect of the invention, a thruster includes a propellant feeder for feeding propellant segments to be consumed (or partially consumed).
By an embodiment according to any one or more paragraphs of this summary, the propellant feeder has a control rod that pushes the propellant segments.
By an embodiment according to any one or more paragraphs of this summary, the propellant feeder includes a resilient device, such as a spring, that pushes the propellant segments.
By an embodiment according to any one or more paragraphs of this summary, the propellant feed moves the propellant feeders toward electrodes that ignite the propellant segment(s) to be consumed (or partially consumed).
According to yet another aspect of the invention, a thruster includes propellant segments that each include a propellant material surrounded by a sealing material.
By an embodiment according to any one or more paragraphs of this summary, the propellant segments include an electrically-operated propellant.
According to an aspect of the invention, a flight vehicle has thrusters additively manufactured in and part of its frame.
According to another aspect of the invention, a thruster includes: an electrically-operated propellant; electrodes operatively coupled to the electrically-operated propellant; and a propellant feeder for moving the propellant relative to the electrodes.
By an embodiment according to any one or more paragraphs of this summary, the propellant feeder includes a push rod that pushes the propellant toward the electrodes.
By an embodiment according to any one or more paragraphs of this summary, the feed mechanism includes a resilient device providing a resilient force to push the propellant toward the electrodes.
By an embodiment according to any one or more paragraphs of this summary, the resilient device is a coil spring.
By an embodiment according to any one or more paragraphs of this summary, the propellant includes multiple propellant segments.
By an embodiment according to any one or more paragraphs of this summary, the segments include segments of different sizes.
By an embodiment according to any one or more paragraphs of this summary, the segments include multiple relatively small segments and multiple relatively large segments that are larger than the relatively small segments.
By an embodiment according to any one or more paragraphs of this summary, the relatively small segments and the relatively large segments are positioned such that at least some of the relatively small segments are consumed (or partially consumed) before any of the relatively large segments are consumed (or partially consumed).
By an embodiment according to any one or more paragraphs of this summary, each of the segments includes a sealing material surrounding a propellant material.
By an embodiment according to any one or more paragraphs of this summary, a thruster further includes a nozzle through which pass pressurized gasses from combustion of the electrically-operated propellant.
By an embodiment according to any one or more paragraphs of this summary, a thruster is part of a flight vehicle.
By an embodiment according to any one or more paragraphs of this summary, a thruster is part of a space vehicle.
According to still another embodiment of the invention, a method of firing a thruster includes the steps of: igniting a first electrically-operated propellant segment of a plurality of electrically-operated propellant segments, wherein the igniting including using electrodes of the thruster to ignite the electrically-operated propellant segment; moving a second electrically-operated propellant segment into engagement with the electrodes; and subsequent to the moving and to the igniting the first electrically-operated propellant segment, using the electrodes to ignite the second electrically-operated propellant segment.
By an embodiment according to any one or more paragraphs of this summary, the first electrically-operated propellant segment is smaller than the second electrically-operated propellant segment, and the igniting the second electrically-operated propellant segment produces more thrust than the igniting the first electrically-operated propellant segment.
By an embodiment according to any one or more paragraphs of this summary, the first electrically-operated propellant segment is larger than the second electrically-operated propellant segment, and the igniting the second electrically-operated propellant segment produces less thrust than the igniting the first electrically-operated propellant segment.
By an embodiment according to any one or more paragraphs of this summary, the first electrically-operated propellant segment is the same size as the second electrically-operated propellant segment, and the igniting the second electrically-operated propellant segment produces the same amount of thrust as the igniting the first electrically-operated propellant segment.
By an embodiment according to any one or more paragraphs of this summary, the moving the second electrically-operated propellant segment into engagement with the electrodes is performed by a propellant feeder of the thruster.
By an embodiment according to any one or more paragraphs of this summary, the moving the second electrically-operated propellant segment into engagement with the electrodes is part of moving all unconsumed electrically-operated propellant segments of the plurality of electrically-operated propellant segments.
By an embodiment according to any one or more paragraphs of this summary, the moving the unconsumed electrically-operated propellant segments includes using a control rod of the propellant feeder to push the unconsumed electrically-operated propellant segments toward the electrodes.
By an embodiment according to any one or more paragraphs of this summary, the moving the unconsumed electrically-operated propellant segments includes using a resilient device of the propellant feeder to push the unconsumed electrically-operated propellant segments toward the electrodes.
By an embodiment according to any one or more paragraphs of this summary, there is only partial burning of one or both of the propellant segments.
By an embodiment according to any one or more paragraphs of this summary, the thruster includes a pressure equalization feature.
By an embodiment according to any one or more paragraphs of this summary, the pressure equalization feature keeps the propellant in position with respect to the electrodes.
By an embodiment according to any one or more paragraphs of this summary, the thruster includes a channel, protrusion, and/or recess extending along and engaging the propellant segments.
To the accomplishment of the foregoing and related ends, the invention comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
The annexed drawings, which are not necessarily to scale, show various aspects of the invention.
A thruster includes multiple segments of electrically-operated propellant, electrodes for igniting one or a few of the electrically-operated propellant segments at a time, and a propellant feeder for moving further propellant segments into engagement with the electrodes. The segments may be configured to provide equal increments of thrust, or different amounts of thrust. The segments may each include an electrically-operated propellant material surrounded by a sealing material, so as to keep the propellant material away from moisture and other contaminants (and/or the vacuum of space) before each individual segment is to be used. The thruster may be included in any of a variety of flight vehicles, for example in a small satellite such as a CubeSat satellite, for instance having a volume of about 1 liter, and a mass of no more than about 1.33 kg.
The nozzle structure 24 may be configured to expel pressurized gases in any of a variety of suitable directions. The nozzle structure 24 may be configured to expel pressurized gases along the longitudinal axis of the thruster 10 (as shown), or may be configured to expel the pressurized gases at a nonzero angle, in any suitable direction, relative to the axis of the thruster 10.
The electrodes 16 cause combustion in a portion of the propellant 14, and the pressurized gases exit a flight vehicle, such as a satellite that the thruster is part of, through the nozzle structure 24. As the propellant 14 is consumed the feeder 12 is used to bring additional amounts of the propellant 14 between the electrodes 16 as desired, to enable consumption of additional amounts of the propellant 14 to produce additional thrust.
The propellant feeder 12 may be any of a variety of mechanical mechanisms for moving the propellant 14 (or parts of the propellant 14) into engagement with the electrodes 16. To give one example, the feeder 12 may include a push rod 30 that pushes the propellant 14 toward the electrodes 16. The push rod 30 may be actively driven, such as by a small actuator, for example a small electrical motor. Alternatively, as shown in the illustrated embodiment, a resilient force, such as that provided by a coil spring 31, may bias movement of the propellant 14 toward the electrodes 16. Many other configurations for the feeder 12 are possible, including use of other sorts of springs, other resilient devices, and/or other sorts of mechanical pusher mechanisms.
The propellant 14 may be made up of multiple propellant segments or packets 32. Each of the segments 32 includes electrically-operated propellant material 34, surrounded by sealing material 36. The sealing material 36 prevents moisture or other contaminants from getting into the propellant segments 32 prior to use, and/or to retain moisture in the segments 32, such as to prevent moisture from escaping into the vacuum of space (or another environment). The sealing material 36 also can serve to keep the correct amount of moisture in when exposed to the vacuum of space. Exposure of the propellant material 34 to moisture, such as from a high-humidity environment, can result in the propellant 34 eventually absorbing enough moisture so as become unusable. Exposure to a desiccating environment, such as the vacuum of space or a low-humidity environment, may also adversely affect the usability of the propellant 34. Therefore the sealing material 36 in essence keeps the propellant material 34 in good condition (with a proper amount of moisture) prior to use.
In operation the propellant material 34 of the segments 32 may be fully or partially consumed, in sequence. For example, the propellant material 34 of the first of the segments 32 may be fully or partially consumed before a second of the segments 32 is put into place, with the propellant material 34 of the second of the segments 32 then fully or partially consumed.
The thruster 10 may include a pressure equalization feature, to keep the segments in position with respect to the electrodes 16. The pressure equalization feature includes a channel, protrusion, and/or recess extending along and engaging the propellant segments 32. The pressure equalization feature keeps the propellant 14 from being “blown” out of position with respect to the electrodes 12. The feature, such as the channel or other features, may extend from the electrode/burn front of the propellant 14 to the back of where the propellant 14 is being pushed.
The propellant material 34 may be made of materials that produce an electrically-activated (or electrically operated) solid propellant. Examples of such materials may be found in US Patent Publication 2014/0174313 A1, which is incorporated herein by reference in its entirety. As described in that publication, a source material for making an electrically-operated solid propellant may include an oxidizer, a fuel, and a binder. The oxidizer may be a liquid-based perchlorate oxidizer that includes aluminum perchlorate, barium perchlorate, calcium perchlorate, lithium perchlorate, magnesium perchlorate, perchlorate acid, strontium perchlorate, and/or sodium perchlorate, to give a few examples. The fuel may be a metal-based fuel, for example including tungsten, magnesium, copper oxide, copper, titanium, and/or aluminum. The binder may include casein, methyl cellulose, polyethylene oxide, polyvinyl acetate, and/or polyvinyl alcohol. In one example, a material used in an additive manufacturing process may have 150-250% of the solvent (by weight percentage) as that used for a bulk cast or molded material that is produced in a non-additive process.
The electrically operated propellant ignites with the application of electricity and correspondingly extinguishes with the cessation of electricity, even when exposed to high pressures, though below a high pressure threshold. For example, when exposed to ambient or high pressures, such as atmospheric pressure, pressures greater than 200 psi, 500 psi, 1000 psi, 1500 psi and up to 2000 psi, the electrically operated propellant is extinguished with the interruption of electricity (e.g., voltage or current) applied across the electrically operated propellant. In other words, without application of electricity, the combustion of the electrically operated propellant is not self-sustaining at high pressures, such as high pressures of 200 psi or more and less than 2000 psi. Thus, the electrically operated propellant is configured for “on” and “off” operation under the described variety of conditions.
A battery or other power source (not shown) may be electrically coupled to the electrodes 16 to apply a suitable voltage or current across the propellant 34, to ignite and/or maintain combustion in the propellant 34. A controller (not shown), such as an integrated circuit device (or other electrical or electronic controller) with suitable hardware and/or software may used to control the supply of electrical power to the electrodes 16. The controller may be operatively coupled to a communication device, such a radio, to receive instructions from a ground station or space platform, and/or to send data or information.
The oxidizer may be an aqueous solution, with the oxidizer material dissolved in water and/or glycerol. It has been found that controlling the amount of water and/or glycerol in the extruded material is important in additive manufacture of the propellant 34. Too much solvent in the printed mixture can cause problems with curing the extruded material and having the extruded material properly maintain its shape. Too little solvent can result in problems with the material adhering to other material layers.
The raw propellant material that is used to additively manufacture the propellant 34 may have any of a variety of other suitable formulations. Broadly, the raw propellant material may include a fuel, a solvent (e.g., water or glycerin), an oxidizer, and a binder. The fuel and the oxidizer are the chemically-active components that react with one another to produce the pressurized gases. The solvent receives the fuel and other components, to allow mixing together of the components into a flowable material. The binder aids in maintaining the raw material as a unified material that can be cured and/or dried into a solid mass.
The sealing material 36 may combustible, in that it burns off as the propellant material 34 within is fully or partially consumed. The sealing material 36 also may serve to some extent as a barrier, preventing combustion from one propellant segment 32 to another of the propellant segments 32 (preventing ignition of other propellant segments 32) until desired. The sealing material 36 could be made out of any of a variety of suitable materials, for example poly(vinyl alcohol) (PVA), silicone, epoxy, or any other suitable organic or inorganic material.
As shown in
The thruster 10 as shown is generally cylindrical, with the segments 32 having circular cross section shapes and having cylindrical or disc shapes. Alternatively the thruster 10 and the propellant 14 may have a different cross-sectional shape, such as square or other polygonal shape, or a more complicated shape that includes straight segments and curved segments (for instance).
The propellant segments 32 may be manufactured separately and loaded into the cavity 20. Alternatively the segments 32 may be formed in situ, within the cavity, such as by additive manufacturing methods. The segments 32 may be separate pieces. Alternatively some or all of the segments 32 may be parts of unitary structure, with the propellant material 34 and the sealing material 36 of multiple of the segments 32 being parts of a single piece.
While the propellants 114 and 214 are shown with only two sizes of segments, it is possible for there to be three or more sizes of segments. The sizes for the individual propellant segments may be selected based on their need. With additive manufacturing processes it is possible for the segments (their sizes and/or other characteristics) to be tailored to an individual need for the satellite 410, based on an intended use of the satellite. A likely mission might use a large propulsion unit to change orbit in altitude or inclination then use small thrusts to control attitude or de-spin a reaction wheel. Then the mission may finally use a larger thrust to de-orbit the vehicle when it is no longer needed. The additive manufacturing process allows flexibility in configuring the propellant charge (the number and characteristics of segments), while keeping costs low.
The propellants 114 and 214 show only two possible arrangements for relatively large and relatively small segments. Many other arrangements are possible, for example interspersing relatively large segments and relatively small segments, such as by alternating them.
The propellant charges 14, 114, and 214 may include any suitable number of segments, from two segments to ten or more segments. The segments may be of two types or three or more types. Different of the segments 32, 116, and 216 may use the same propellant material, or may use different propellant material, with different burn characteristics and output, if desired.
The satellite has a cubic frame 412 that encloses a payload. The frame 412 may be cubic in shape, having a length, width, and height of about 10 cm, for an overall volume of 1 liter for the satellite 410, as is standard for CubeSat miniaturized satellites. The payload may fit fully within the frame 412, and may have a mass of no more than 1.33 kg. More broadly, the satellite 410 may have a length, width, and height no greater than 15 cm (or no greater than 50 cm), and/or a mass (including the payload 14) of no greater than about 2 kg (or no greater than 20 kg). Other sizes of satellites are possible including satellites that are three times, six times, or nine times the size of this smallest of CubeSat satellites. These larger-sized satellites may also be referred to as CubeSat satellites. Various sizes of CubeSat satellites are referred to as 1U, 3U, 6U, 9U, and 12U satellites, with the notation indicating the size of the satellite in terms of 10 cm-cube units. Example other sizes of satellites include 10×10×30 cm, with or without an added cylindrical or other-shaped volume on an end; 10×20×30 cm; 12×24×36 cm; 20×20×30 cm; and 20×20×30 cm.
The sizes and weights of the previous paragraph may also be applied to a component of a satellite, such as a propulsion unit that may be affixed to larger small satellite, such as a 25 kg satellite (for example). Such a component should itself be considered as fitting under the definition of “satellite,” as the term is used herein.
The payload may be any of a variety of things, able to perform any of a variety of functions. Non-limiting examples include global positioning system (GPS) location devices, communication devices, weather sensors, and cameras or other imaging devices.
The frame 412 may be additively manufactured (3D printed), using any of a variety of know additive manufacturing processes. For example the frame 412 may be made by selectively extruding material in desired locations, selectively building up the frame 412 layer by layer. An alternative manufacturing processes for producing the frame 412 include fused-filament fabrication (FFF), also referred to as fused-deposition modeling (FDM). The frame 412 may be made out of any of a variety of materials suitable for additive manufacturing (and suitable for other characteristics desired from the frame 412). Examples of such materials include acrylonitrile butadiene styrene (ABS), polycarbonate, polyetherimide (PEI), and polyurethane, among others.
As an alternative, at least parts of the frame 412 may be produced other than by additive manufacturing. For example portions of the frame 412 may be produced by conventional manufacturing processes such as casting or rolling, perhaps in conjunction with subtractive processes such as boring or other machining processes to remove material.
A series of the thrusters 10 (or alternatively the thrusters 110 and/or 210) are located within the frame 412. The thrusters 10 may be located along edges of the frame 412, where pairs of sides of the frame 412 come together. The thrusters 10 may be located in cavities 422 within the frame 412 that are formed during the manufacture of the frame 142, such as by omitting material of the frame 412 where the thrusters 10 will be located. The cavities 422 may be elongate cavities have a suitable cross-sectional shape for receiving propellant and/or other components of the thrusters 10. Parts of the frame 412 may be structurally part of the thrusters 10, for example defining combustion cavities of the thrusters 10 in which combustion takes place
The outlets for the thrusters 10 thus may be at corners of the frame 412, where three of the sides of the frame 412 come together. The thrusters 10 may be configured to provide thrust in the same direction, but at different locations. Alternatively one or more of the thrusters 10 may be configured to provide thrust in different directions than other of the thrusters 10.
All or part of the thrusters 10 may be integrally formed as part of the formation of the frame 412, with some or all of the components of the thrusters 10 additively manufactured, perhaps being manufactured at the same time and/or as part of the same additive manufacturing process as the manufacturing of the frame 412.
There may be any number of suitable thrusters 10 included as part of the satellite 410. In one embodiment there may be four thrusters 10, all oriented in the same direction, with longitudinal axes parallel to one another. All four of the thrusters 10 may provide thrust in the same direction. For example to change the velocity of the in order to change its orbit (or deorbit the satellite 410). Alternatively there may be a different number of thrusters, for example more than four thrusters, with some of the thrusters oriented perpendicular relative to other of the thrusters. Some thrusters may be used to change the velocity of the satellite, and other thrusters may be used to spin the satellite, for example.
Some or all of the components of the thrusters 10 may be additively manufactured, perhaps as part of the same additive manufacturing process used to produce the frame 412. The propellant 14, the electrodes 16, and/or the nozzle structure 24 (each individual component or any combination of them) may be additively manufactured, such as by use of different extruder nozzles and/or different raw materials for manufacturing. For example the propellant 14 and the electrodes 16 may be additively manufactured together in a single process, such an extrusion process, along with the additive manufacturing of the frame 412. The nozzle structure 24 may also be additively manufactured as part of this process. Alternatively the propellant 14, the electrodes 16, and/or the nozzle structure 24 may be independently manufactured, using additive methods or other manufacturing methods, and may be inserted into the satellite 410 as a unit (or in pieces), during the build up (additive manufacture) of the frame 412. For example, alternatively the propellant 14 may be cast, and then inserted into the frame 412, either during the additive manufacturing process or after the additive manufacturing process.
The formation of the thrusters 10 integrally with the frame 412 may involve an extrusion process with multiple extrusion heads for extruding separate raw materials to form the frame 412, the propellant 14, and the electrodes 16. A suitable controller may be used to control stepper motors (or other suitable devices) to dispense raw materials (from reservoirs) for the frame 412, the propellant 14, and the electrodes 16, in suitable locations, to build up the satellite 410. Alternatively the electrodes 16 may be formed separately, and inserted in suitable locations during the manufacturing process, with the frame 412 and the propellant 14 formed around the electrodes 16.
The electrodes 16 may be formed by various methods. The electrodes 16 may be formed by an FFF process, using a conductively loaded polymer loaded with graphene, graphite, or metal particles. Another additive manufacturing method is a method of printing solid metal wire integrated with plastic in a FFF machine. As another possibility, the electrodes 16 can formed using a liquid-dispensing system that deposits a fine aerosol or liquid drop with a conductive ink with typically silver or gold loading.
For each of the thrusters 10 the propellant 14 and the electrodes 16 may be configured to produce a desired thrust output. This desired thrust output may involve producing different amounts of thrust at different times, such as providing smaller (relatively small) earlier amounts of thrust, such as for maneuvering or drag make-up burns, and larger (relatively large) later amounts of thrust, such as for de-orbit burns. The thrust output may be used for orbit maintenance and/or orbital adjustments.
Thus a single thruster may be configured to tilt the satellite 410 (moving the satellite in pitch and/or yaw), and/or may be configured to roll the satellite 410 about its longitudinal axis. Firing multiple of the thrusters 410 at the same time may allow for pure acceleration of the satellite 410 so as to cause translation of the satellite 410 without changing the orientation of the satellite 410. In addition, any of a variety of complicated maneuvers may be accomplished or accomplishable, including changes of orientation coupled with accelerations to change the translation velocity of the satellite 410.
The thrusters 10 (or 110 and/or 210) may alternatively be used in a wide variety of other flight vehicles, to provide controlled amounts of thrust. The thrusters described herein could be incorporated in manned or unmanned flight vehicles, and in aircraft or spacecraft. The thrusters may be used in satellites, in airplanes, in unmanned aerial vehicles (UAVs or drones), in manned spacecraft, and/or in missiles, to give a few possibilities.
The thrusters described herein provide numerous advantages over prior thrusters. The use of electrically-operated propellant provides safety, which may provide for a better safety classification than thrusters with more conventional propellants have. This may allow flight vehicles with the thrusters to be stored and/or used in places in which thrusters with conventional propellants are prohibited from. The use of segmented propellant may allow for flexibility in use. The feed mechanism may enable the use of the segmented propellant, and to limiting firing to only one or more of a greater number of segments. The use of sealing material around each of the propellant segments may enable long-term storage of the propellant, and may also enable use of the propellant segment by segment. In addition, the configuration of the thrusters described herein may enable their use in small volumes, and/or may enable integration of the thrusters in a structure such as a frame or fuselage.
Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.
