Patent Publication Number: US-2023160359-A1

Title: Reaction control vortex thruster system

Description:
TECHNICAL FIELD 
     The subject matter described herein relates to a vortex thruster system that can generate various thrust levels. 
     BACKGROUND 
     Design requirements for a rocket combustion engine can include competing or conflicting requirements. For example, an efficient rocket combustion chamber can thoroughly mix fuel and oxidizer to generate complete combustion. However, complete combustion can cause intense thermal stress of the rocket engine hardware. A cooling mechanism may be required to prevent overheating, but conventional cooling mechanisms can add weight to a system that is mass-sensitive. 
     Some rocket engines can achieve high mixing rates and combustion efficiencies through the use of complex propellant injectors that can be heavy and expensive to manufacture. Furthermore, some rocket engines include intricate regenerative coolant channels to remove heat from the rocket hardware. Such rocket engine configurations may be difficult and expensive to manufacture, as well as require an increase in overall size and weight of the rocket engine. 
     SUMMARY 
     Aspects of the current subject matter include various embodiments of a vortex thruster system that can generate various thrust levels. In one aspect, the vortex thruster system can include a catalyst bed configured to decompose a monopropellant delivered to the catalyst bed. Additionally, the vortex thruster system can include a first valve for controlling delivery of the monopropellant at a first flow rate into the catalyst bed to transform the monopropellant into a decomposed monopropellant. Furthermore, the vortex thruster system can include a vortex combustion chamber in fluid communication with the catalyst bed. The vortex combustion chamber can be configured to receive the decomposed monopropellant from the catalyst bed and the decomposed monopropellant can assist with creating a first thrust level. 
     In some variations one or more of the following features can optionally be included in any feasible combination. In some embodiments, the vortex thruster system can include a second valve for controlling a second flow rate of the monopropellant into the catalyst bed. The second flow rate can be greater than the first flow rate. The delivery of the monopropellant at the second flow rate can generate a second thrust level that is greater than the first thrust level. 
     In some embodiments, the vortex thruster system can include a secondary propellant valve configured to deliver a secondary propellant into the vortex combustion chamber including the decomposed monopropellant to create a third thrust level that is greater than the second thrust level. 
     In some embodiments, the monopropellant can include hydrogen peroxide or hydrazine. The decomposed monopropellant can include water vapor and oxygen. The decomposed monopropellant can include nitrogen, hydrogen, and ammonia. The secondary propellant can include a kerosene or a mixed oxide of nitrogen. 
     In some embodiments, the vortex combustion chamber can include at least one side injection port positioned proximate to a sidewall of the vortex combustion chamber and configured to deliver a first amount of the decomposed monopropellant into the vortex combustion chamber in a direction that is approximately tangent to the sidewall. In some embodiments, the vortex combustion chamber can include a proximal injection port positioned proximate to a proximal end of the vortex combustion chamber and configured to deliver a second amount of the decomposed monopropellant into a center area of the vortex combustion chamber. 
     In another interrelated aspect of the current subject matter, a method includes activating a first monopropellant valve to deliver a monopropellant at a first flow rate to a catalyst bed of the vortex thruster system to form a decomposed monopropellant. The method can further include decomposing the monopropellant in the catalyst bed. Additionally, the method can include delivering the decomposed monopropellant into a vortex combustion chamber of the vortex thruster system to assist with generating a first thrust level. 
     In some embodiments, the delivering of the decomposed monopropellant into the vortex combustion chamber can include delivering a first amount of the decomposed monopropellant through a first injection port positioned proximate a sidewall of the vortex combustion chamber and configured to deliver the first amount of the decomposed monopropellant in a direction tangent to the sidewall. In some embodiments, the delivering of the decomposed monopropellant into the vortex combustion chamber can include delivering a second amount of the decomposed monopropellant through a second injection port positioned proximate to a proximal end of the vortex combustion chamber and configured to deliver the second amount of the decomposed monopropellant into a center area of the vortex combustion chamber. 
     In some embodiments, the method can further include activating a second monopropellant valve to deliver the monopropellant at a second flow rate to the catalyst bed. The second flow rate can be greater than the first flow rate. The delivery of the monopropellant at the second flow rate can create a second thrust level that is greater than the first thrust level. 
     In some embodiments, the method can further include activating a secondary propellant valve to deliver a secondary propellant into the vortex combustion chamber including the decomposed monopropellant to create a third thrust level that is greater than the second thrust level. The monopropellant can include hydrogen peroxide or hydrazine. The secondary propellant can include kerosene or a mixed oxide of nitrogen. 
     The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims. 
    
    
     
       DESCRIPTION OF DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawings, 
         FIG.  1    illustrates a first section view of an embodiment of a vortex thruster system consistent with implementations of the current subject matter; 
         FIG.  2    illustrates a second section view of the vortex thruster system of  FIG.  1    showing a first propellant valve and a second propellant valve in fluid communication with a catalyst bed; and 
         FIG.  3    illustrates a partial section view of the vortex thruster system of  FIG.  1    showing a fluid pathway between a secondary propellant injector and a vortex combustion chamber, as well as fluid pathways between the catalyst bed and the vortex combustion chamber. 
     
    
    
     When practical, similar reference numbers denote similar structures, features, or elements. 
     DETAILED DESCRIPTION 
     Various embodiments of a vortex thruster system are described herein that can be included in various propulsion systems and can provide an efficient and effective way to generate various thrust levels. For example, the vortex thruster system can be configured to efficiently generate at least three discrete thrust levels, such as a high thrust level, a medium thrust level, and a low thrust level. Additionally, the vortex thruster system can be configured to generate a swirling or vortex flow field in a combustion chamber to limit thermal loading of the hardware of the vortex thruster system. Various vortex thruster system embodiments are described in greater detail below. 
     In some embodiments, the vortex thruster system can include a catalyst bed and at least one oxidizer or monopropellant injector configured to deliver a monopropellant into the catalyst bed. The catalyst bed can be configured to decompose the monopropellant, such as decompose hydrogen peroxide into high-temperature water vapor and gaseous oxygen. The catalyst bed can be in communication with a vortex combustion chamber such that the decomposed monopropellant formed in the catalyst bed can be delivered into the vortex combustion chamber. Delivery of the decomposed monopropellant into the vortex combustion chamber can generate thrust by exhausting the products of decomposition through a nozzle extending from the vortex combustion chamber. 
     In some embodiments, the vortex thruster system can control a flow rate at which the monopropellant is delivered to the catalyst bed, which can affect the amount of thrust generated at the nozzle. For example, the vortex thruster system can include a first monopropellant valve and a second monopropellant valve that are each configured to deliver the monopropellant at a different flow rate (e.g., a greater flow rate of the monopropellant into the catalyst bed can result in a greater generated thrust). In some embodiments, the vortex thruster system can include a secondary propellant valve that directly injects a secondary propellant (e.g., a kerosene) into the vortex combustion chamber to ignite with the decomposed monopropellant in a bi-propellant configuration to generate a highest thrust level that can be achieved by the vortex thruster system. 
     Furthermore, in some embodiments the vortex combustion chamber can include at least one tangential injection port, such as at least an array of tangential injection ports, that are configured to deliver the decomposed monopropellant in a direction tangential to a circumference of an inner cylindrical surface of the vortex combustion chamber. This tangential injection can cause a flow of the decomposed monopropellant to swirl in the vortex combustion chamber. The swirl flow may translate upwards towards the proximal end of the vortex combustion chamber where the flow can turn inward and move spirally away from a closed proximal end of the vortex combustion chamber, down the center of the vortex combustion chamber, and out the nozzle. 
     In some embodiments, the vortex thruster system may include at least one axial proximal injection port for delivering a portion of the decomposed monopropellant into a center area of the vortex combustion chamber. This may assist with efficiently and effectively optimizing the vortex combustion chamber for achieving a desired thrust level while simultaneously limiting the thermal load on the thruster hardware. As described herein, a thrust level can include an approximate range of thrust loads, such as a low thrust level including a first thrust load range (e.g., approximately 20 lbf to 30 lbf), a medium thrust level including a second thrust load range (e.g., approximately 50 lbf to 60 lbf), and a high thrust level including a third thrust load range (e.g., approximately 100 lbf to 120 lbf). Other thrust levels and thrust load ranges are within the scope of this disclosure. 
       FIGS.  1 - 3    illustrate an embodiment of a vortex thruster system  100  configured to efficiently and effectively generate at least three discrete thrust levels. As shown in  FIG.  1   , the vortex thruster system  100  can include a vortex combustion chamber  102  having a proximal end  104 , a distal end  106 , and a sidewall  108  extending between the proximal end  104  and distal end  106 . The vortex combustion chamber  102  may be cylindrical in shape, as shown in  FIG.  1   , however, other shapes are within the scope of this disclosure. For example, the proximal end  104  of the vortex combustion chamber may include a hollow dome-shape and the distal end  106  may include a converging-diverging nozzle  110  that provides a passageway through the distal end  106  of the vortex combustion chamber  102 , as shown in  FIG.  1   . 
     As shown in  FIG.  1   , the vortex thruster system  100  may include a catalyst bed  120  and at least one monopropellant valve, such as a first monopropellant valve  130  and a second monopropellant valve  140 , in communication with the catalyst bed  120 . In some embodiments, the first monopropellant valve  130  is configured to provide a different flow rate of monopropellant  105  into the catalyst bed  120  compared to the second monopropellant valve  140 . For example, the first monopropellant valve  130  can provide a lower flow rate of monopropellant to allow the vortex thruster system  100  to generate a first, lower thrust level. Additionally, the second monopropellant valve  130  can provide a higher flow rate of monopropellant to allow the vortex thruster system  100  to generate a higher, second thrust level that is greater than the first, lower thrust load. 
     The catalyst bed  120  can be configured to decompose the monopropellant  105  as it flows axially through the catalyst bed  120 . The decomposed monopropellant  107  can then be delivered into the vortex combustion chamber  102  to assist with generating thrust, as will be described in greater detail below. In some embodiments, the monopropellant  105  can include a liquid hydrogen peroxide (e.g., 90% hydrogen peroxide) and the decomposed monopropellant  107  can include water vapor and gaseous oxygen. Other monopropellants (e.g. hydrazine) are within the scope of this disclosure. In some embodiments, the catalyst bed  120  can include a stack of reactive and inert metallic screens. Other catalyst beds that can decompose monopropellants (e.g. iridium-coated alumina pellet beds) are within the scope of this disclosure. 
     As shown in  FIGS.  1  and  3   , some embodiments of the vortex thruster system  100  can include an annular chamber  125  positioned around at least a part of the vortex combustion chamber  102  and in fluid communication with an outlet of the catalyst bed  120 . The annular chamber  125  can allow the decomposed monopropellant  107  to enter the vortex combustion chamber by passing through at least one array of tangential injection ports  127  positioned along the sidewall  108  of the vortex combustion chamber  102 , as shown in  FIG.  3   . The vortex thruster system  100  can include a proximal chamber  126  for allowing the decomposed monopropellant  107  to be injected into a proximal end of the vortex combustion chamber  102  through at least one proximal injection port  129 , as also shown in  FIG.  3   . Any number of chambers and injectors can be included in the vortex thruster system  100  for directing and controlling the delivery of the decomposed monopropellant  107  into the vortex combustion chamber  102 . 
     As shown in  FIGS.  1  and  3   , at least one array of tangential injection ports  127  may be positioned along the sidewall  108  of the vortex combustion chamber and configured to direct the decomposed monopropellant  107  at a direction that is tangential to the circumference of the inner cylindrical surface of the sidewall  108  of the vortex combustion chamber  102 . This creates a swirling or vortex flow field of the decomposed monopropellant  116  along an outer circumference of the vortex combustion chamber  102 . Such swirling can improve combustion efficiency and control hardware temperatures by shielding the vortex combustion chamber walls from high-temperature products of combustion. 
     As shown in  FIGS.  1  and  3   , at least one proximal injection port  129  may be axially positioned along the proximal end  104  of the vortex combustion chamber  102 . For example, the proximal injection port  129  may be positioned approximately parallel to or along a longitudinal axis of the vortex combustion chamber  102 . The proximal injection port  129  may be configured to deliver a portion of the decomposed monopropellant  107  into a combustion zone at or near the centerline of the vortex combustion chamber  102  (e.g., along a longitudinal axis of the vortex combustion chamber). The proximal injection port  129  may provide a trim function that can balance mixing and cooling functions of the vortex flow field. 
     As shown in  FIG.  1   , some embodiments of the vortex thruster system  100  can include a secondary propellant valve  150  configured to directly inject a secondary propellant (e.g., kerosene, such as RP-1 kerosene) directly into the vortex combustion chamber  102 . Other secondary propellants (e.g., mixed oxides of nitrogen (MON)) are within the scope of this disclosure. As shown in  FIG.  1   , the secondary propellant can be delivered to a proximal end of the vortex combustion chamber. The secondary propellant can mix with high-temperature products of the decomposed monopropellant in the vortex combustion chamber to generate a desired thrust level (e.g., a high thrust mode). 
     As discussed above, the vortex thruster system  100  can be configured to generate at least three different thrust levels that each generate discrete thrust loads or load ranges. For example, the vortex thruster system  100  can generate a low thrust level (e.g., generates approximately 24 lbf), a medium thrust level (e.g., generates approximately 55 lbf), and a high thrust level (e.g., generates approximately 110 lbf). For example, the low thrust level can be achieved by activating the first monopropellant valve  130  thereby delivering the monopropellant at a first, lower flow rate into the catalyst bed  120 . Additionally, the medium thrust level can be achieved by activating the second monopropellant valve  140  thereby delivering the monopropellant at a second, greater flow rate into the catalyst bed  120 . Furthermore, the high thrust level can be achieved by activating the second monopropellant valve  140  as well as the secondary propellant valve  150  to allow the secondary propellant to mix and ignite with the decomposed monopropellant  107  in the vortex combustion chamber  102 . 
     For example, during operation of the vortex thruster system  100  to achieve a low, medium, or high thrust level, liquid hydrogen peroxide can be injected into the catalyst bed  120  where the liquid hydrogen peroxide exothermically decomposes into gaseous oxygen and water vapor as it flows axially through the catalyst bed  120 . Additionally, upon exiting the catalyst bed  120 , the decomposed monopropellant  107  can be approximately 1,400 degrees F. and can flow into the annular chamber  125  and/or proximal chamber  126  surrounding the vortex combustion chamber  102 . The hot oxidizing gas (e.g., the decomposed monopropellant  107 ) can then enter the vortex combustion chamber  102  through the array of tangential injection ports  127  and/or the proximal injection port  129 . The result of the decomposed monopropellant in the vortex combustion chamber can result in the flow of hot gas through the nozzle  110  (e.g., niobium nozzle) and the generation of monopropellant thrust (e.g., low or medium thrust levels). 
     Furthermore, to generate the high thrust level, a secondary propellant (e.g., kerosene) can be added to vortex combustion chamber  102  to allow mixing and burning of the secondary monopropellant and decomposed monopropellant in the vortex combustion chamber  102 . The products of such mixing and burning can result in combustion flow through the nozzle  110  (e.g., niobium nozzle) and generation of bipropellant thrust. In some embodiments, the nozzle  110  may be coated with a silicide coating that can protect against oxidation of the niobium. Other features, functions and benefits of the vortex thruster system  100  are within the scope of this disclosure. 
     In the descriptions above and in the claims, phrases such as “at least one of” or “one or more of” may occur followed by a conjunctive list of elements or features. The term “and/or” may also occur in a list of two or more elements or features. Unless otherwise implicitly or explicitly contradicted by the context in which it is used, such a phrase is intended to mean any of the listed elements or features individually or any of the recited elements or features in combination with any of the other recited elements or features. For example, the phrases “at least one of A and B;” “one or more of A and B;” and “A and/or B” are each intended to mean “A alone, B alone, or A and B together.” A similar interpretation is also intended for lists including three or more items. For example, the phrases “at least one of A, B, and C;” “one or more of A, B, and C;” and “A, B, and/or C” are each intended to mean “A alone, B alone, C alone, A and B together, A and C together, B and C together, or A and B and C together.” Use of the term “based on,” above and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible. 
     The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail herein, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementations described above can be directed to various combinations and sub-combinations of the disclosed features and/or combinations and sub-combinations of one or more features further to those disclosed herein. In addition, the logic flows depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. The scope of the following claims may include other implementations or embodiments.