Patent ID: 12214911

DETAILED DESCRIPTION OF THE DISCLOSURE

The foregoing summary, as well as the following detailed description of certain embodiments will be better understood when read in conjunction with the appended drawings. As used herein, an element or step recited in the singular and preceded by the word “a” or “an” should be understood as not necessarily excluding the plural of the elements or steps. Further, references to “one embodiment” are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising” or “having” an element or a plurality of elements having a particular condition may include additional elements not having that condition.

Embodiments of the present disclosure provide a baffle assembly that is configured to span areas where it may be difficult to create interfaces that react to acceleration and slosh pressure loads. In at least one embodiment, the baffle assembly includes features that accommodate deflections caused by thermal, inertial and pressure loads. By coupling the ability to span large areas of tank area while accommodating tank deflections through specific joint designs, embodiments of the present disclosure are able to take advantage of manufacturing techniques that do not accommodate direct baffle interfaces in certain areas but are nevertheless used to minimize or otherwise reduce the mass of a vehicle.

Certain embodiments of the present disclosure provide a baffle assembly for a propellant tank for a space launch system. The baffle assembly includes one or more baffle tiers secured to a plurality of beams. A fore end coupling joint is located at a fore end of a bracket. The fore end coupling joint includes a spherical bearing. An aft end coupling joint is located at an aft end of the bracket. The aft end coupling joint includes a slot. The fore end coupling joint enables rotational movement at the fore end of the bracket, and the aft end coupling joint enables translational movement at the aft end of the bracket to provide freedom of movement for decoupling loads.

FIG.1illustrates a front view of a vehicle100, according to an embodiment of the present disclosure. The vehicle100is a launch and/or space vehicle, such as a rocket. The vehicle100includes an integrally stiffened barrel102(a portion shown transparent for clarity), which may surround a portion of a vehicle stage104. Optionally, embodiments of the present disclosure may be used with various other types of vehicles, such as airplanes, land-based vehicles, watercraft, and/or the like.

FIG.2illustrates a front view of the vehicle stage104, according to an embodiment of the present disclosure. The vehicle stage104includes a main body106, a truss assembly108secured to stiffening ring124attached to the integrally stiffened barrel122, a liquid propellant tank112(such as tank that retains liquid hydrogen) secured to the stiffening ring124, and an engine assembly116secured to a beam assembly118. One or more components, such as tanks120(for example, Helium tanks) are secured to the truss assembly108.

FIG.3illustrates a perspective view of the liquid propellant tank112, according to an embodiment of the present disclosure. The liquid propellant tank112is configured to retain a liquid propellant, such as liquid hydrogen. The liquid propellant tank112includes a forward end130(such as a forward hemisphere) coupled to a central Y-ring132. In particular, the forward end130is secured to a forward edge134of the Y-ring132. The liquid propellant tank also includes an aft end136(such as an aft hemisphere) coupled to the Y-ring132. In particular, the aft end136is secured to an aft edge137of the Y-ring132.

The forward end130includes a plurality of panels138(such as gore panels) that are meridianally connected together between the Y-ring132and a forward cap140. The panels138can be formed of aluminum, for example. In at least one embodiment, ten or more panels138are meridianally connected together to form an annular structure between the Y-ring132and the cap140.

FIG.4illustrates a perspective internal view of the liquid propellant tank112ofFIG.3. For the sake of clarity, the forward end130, the Y-ring132, and the aft end136are transparent inFIG.4.

In order to control motion of the liquid propellant within the liquid propellant tank112, a baffle assembly150is secured within the forward end130. The baffle assembly150secures between the Y-ring132and the cap140. As described herein, the baffle assembly150includes a plurality of fore end coupling joints that connect to the cap140, and a plurality of aft end coupling joints that connect to the Y-ring132. In at least one embodiment, neither the fore end coupling joints, nor the aft end coupling joints directly connect to the panels138. As such, the baffle assembly150is secured within the forward end130and spans the panels138without directly interfacing therewith.

FIG.5illustrates a perspective view of a portion of the forward end130of the liquid propellant tank112with a panel138removed to show internal components, according to an embodiment of the present disclosure. The baffle assembly150includes a plurality of baffle tiers152that circumferentially extend within the forward end130. The baffle tiers152are annular ledges that are configured to control motion of liquid propellant within the forward end130. For example, the baffle tiers152are configured to reduced motion of the liquid propellant in an aft-to-forward direction, and a forward-to-aft direction. In this manner, the baffle tiers152are configured to control liquid sloshing within the forward end130.

The baffle tiers152are coupled to a plurality of arcuate beams154that are between the baffle tiers152and inner surfaces156of the panels138. In at least one embodiment, the beams154do not connect to the inner surfaces156through couplings. The curve of the arcuate beams154may follow and/or conform to the curvature of the inner surfaces156of the panels138.

Instead of having nodes or pads that connect to the inner surfaces156, the baffle assembly150includes a fore end coupling joint160at a fore end162of each beam154, and an aft end coupling joint164at an aft end166of each beam154. The fore end coupling joint160securely connects the fore end162to the cap140, while the aft end coupling joint164securely connects the aft end166to the Y-ring132. In this manner, the baffle assembly150spans the panels138(such as the internal surfaces156of the panels138) without connecting thereto via pads, nodes, or couplings. As such, the panels138are able to deflect, such as due to thermal, inertial and pressure loads, without being constrained by couplings to the baffle assembly150. Moreover, additional baffle tiers152can be used, as they are not directly connected to the panels138. The baffle assembly150can include more or less baffle tiers152than shown.

FIG.6illustrates a perspective top view of the baffle assembly150, according to an embodiment of the present disclosure. As noted, the baffle assembly150includes the baffle tiers152coupled to the beams154. The baffle assembly150can include more or less baffle tiers152and more or less beams154than shown. The fore end coupling joints160are at the fore ends162of the beams154. The aft end coupling joints164are at the aft ends166of the beams154.

FIG.7illustrates a perspective internal view of the fore end coupling joint160connected to the fore end162of the beam154and an internal surface202of the cap140, according to an embodiment of the present disclosure.FIG.8illustrates a transverse cross-sectional view of the fore end coupling joint160through line8-8ofFIG.7. Referring toFIGS.7and8, in at least one embodiment, the fore end coupling joint160does not directly connect or otherwise couple to the panels138(shown inFIGS.3-5, for example). The fore end coupling joint160includes a fitting203(for example, a first or fore fitting), such as a bracket, including a base204(for example, a first or fore base) that abuts against the internal surface202of the cap140. The base204can be secured to the internal surface202through one or more fasteners201, such as bolts. Two lugs206(for example, first or fore lugs, such as mirror image lugs) extend from the base204, such as inwardly away from the internal surface202. The lugs206are separated by a gap208(for example, a first or fore gap). The fore end162of the beam154is disposed between the lugs206within the gap208. The lugs206rotationally couple to the fore end162through a spherical bearing210having a pin211extending therethrough and through the lugs206. The fore end162of the beam154is coupled to the spherical bearing210in the fore end coupling joint160, via the pin211that is received and secured within a center219of the spherical bearing210and secured to the lugs206.

The spherical bearing210enables rotational movement of the fore end162of the beam154relative to the fitting203. The spherical bearing210can be coupled to and/or an integral part of the fitting203. Optionally, the spherical bearing210can be coupled to and/or an integral part of the fore end162of the beam154.

FIG.9illustrates a perspective internal view of the aft end coupling joint164connected to the aft end166of the beam154and an internal surface220of the Y-ring132, according to an embodiment of the present disclosure.FIG.10illustrates a cross-sectional view of the aft end coupling joint164through line10-10ofFIG.9. Referring toFIGS.9and10, in at least one embodiment, the aft end coupling joint164does not directly connect or otherwise couple to the panels138(shown inFIGS.3-5, for example). The aft end coupling joint164includes a fitting223(for example, a second or aft fitting), such as a bracket, including a base224(for example, a second or aft base) that abuts against the internal surface220of the Y-ring132. The base224can be secured to the internal surface220through one or more fasteners221, such as bolts. Two lugs226(for example, second or aft lugs, such as mirror image lugs) extend from the base, such as inwardly away from the internal surface220. The lugs226are separated by a gap228(for example, a second or aft gap). The aft end166of the beam154is disposed between the lugs226within the gap228. A slot230is formed through the aft end166of the beam154between the lugs226. The slot230has a length that may be greater than a length231of the lugs226. A pin233extends between the lugs226and through the slot230. The slot230is greater than a diameter235of the pin233. As such, the pin233is able to translate through the slot230, and therefore the fitting223is able to translate relative to the aft end166of the beam154.

The slot230enables linear movement of the aft end166of the beam154relative to the fitting223to provide freedom of movement to decouple loads associated with the baffle and loads associated with the liquid propellant tank112and the vehicle100. The aft end coupling joint164includes the slot230, such as may be formed in the aft end166of the beam154. Optionally, a slot230can be formed in the fitting223, such as in each of the lugs226.

Referring toFIGS.1-6, a load decoupling attachment system200is configured to secure to a primary tank structure, such as the forward end130of the liquid propellant tank112. The load decoupling attachment system200includes the baffle assembly150including one or more baffle tiers152coupled to one or more beams154. The fore end coupling joint160is secured to the fore end162of the beam154. The aft end coupling joint164is secured to the aft end166of the beam154.

The fore end coupling joint160includes the spherical bearing210(such as may be part of one or both of the fitting203and/or the fore end162of the beam154). The aft end coupling joint164includes the slot230(such as formed in the aft end166of the bracket254or the fitting223). The fore end coupling joint160also couples to the primary structure, such as the cap140of the liquid propellant tank112. The aft end166of the beam154couples via the pin233to the slot230of the aft end coupling joint160, which, in turn, couples to the primary structure, such as the Y-ring132of the liquid propellant tank112.

As described herein, the load-decoupling attachment system200is configured to secure to a primary structure (for example, the liquid propellant tank112). The load-decoupling attachment system200includes one or more baffle tiers152. One or more beams154are coupled to the one or more baffle tiers152. The one or more beams154include a fore end162and an aft end166. A fore end coupling joint160secures the fore end162to a first portion (such as the cap140) of the primary structure. The fore end coupling joint160includes a spherical bearing210that allows the fore end162to rotate in relation to the first portion of the primary structure. An aft end coupling joint164secures the aft end166to a second portion (such as the Y-ring132) of the primary structure. The aft end coupling joint164includes a slot230that allows the aft end166to linearly translate in relation to the second portion of the primary structure.

In at least one embodiment, the fore end coupling joint160secures the baffle assembly150to the cap140, while the aft end coupling joint164secures the baffle assembly to the Y-ring132. The fore end coupling joint160and the aft end coupling joint164do not directly connect or otherwise couples to the panels138. In this manner, the baffle assembly150spans the panels138without connecting thereto.

The fore end coupling joints160and the aft end coupling joints164attach the baffle assembly150to the primary structure (for example, the liquid propellant tank112) such that loads associated with the baffle assembly150are decoupled from loads associated with the primary structure.

In at least one embodiment, the primary structure is a propulsion tank, such as the liquid propulsion tank112, which is part of the space launch vehicle100. The baffle assembly150is configured to inhibit slosh of liquid (such as liquid propellant) within the liquid propulsion tank112.

The load decoupling attachment system200provides the baffle assembly150that spans or bridges (for example, does not directly connect thereto, such as through couplings, pads, or nodes) between the Y-ring132and the cap140. The baffle assembly150includes one or more fore end coupling joints160having a spherical bearing210at the fore ends162of the beams154, and aft end coupling joints164having slots230at the aft ends166of the beams154. The spherical bearings210and slots230cooperate to provide ease of installation, as well as accommodate deflections of portions of the primary structure (such as the panels138) that may be caused by thermal, inertial, and pressure loads as the vehicle100operates.

FIG.11illustrates a flow chart of a load-decoupling attachment method for a primary structure, according to an embodiment of the present disclosure. Referring toFIGS.10-11, the load-decoupling attachment method includes coupling, at300, one or more beams154to one or more baffle tiers152, wherein the one or more beams154include a fore end162and an aft end166; securing, at302, by a fore end coupling joint160, the fore end162to a first portion (such as the cap140) of the primary structure, wherein the fore end coupling joint160includes a spherical bearing210that allows the fore end162to rotate in relation to the first portion of the primary structure; and securing, at304, by an aft end coupling joint164, the aft end166to a second portion (such as the Y-ring132) of the primary structure, wherein the aft end coupling joint164includes a slot230that allows the aft end166to linearly translate in relation to the second portion of the primary structure.

Further, the disclosure comprises embodiments according to the following clauses:

Clause 1: A load-decoupling attachment system configured to secure to a primary structure, the load-decoupling attachment system comprising:one or more baffle tiers;one or more beams coupled to the one or more baffle tiers, wherein the one or more beams include a fore end and an aft end;a fore end coupling joint configured to secure the fore end to a first portion of the primary structure, wherein the fore end coupling joint includes a spherical bearing that allows the fore end to rotate in relation to the first portion of the primary structure; andan aft end coupling joint configured to secure the aft end to a second portion of the primary structure, wherein the aft end coupling joint includes a slot that allows the aft end to linearly translate in relation to the second portion of the primary structure.

Clause 2. The load-decoupling attachment system of Clause 1, wherein the primary structure is a liquid propellant tank of a launch vehicle.

Clause 3. The load-decoupling attachment system of Clause 2, wherein the first portion is a cap of a forward end of the liquid propellant tank, and wherein the second portion is a Y-ring of the liquid propellant tank.

Clause 4. The load-decoupling attachment system of Clause 3, wherein the liquid propellant tank further comprises a plurality of panels between the cap and the Y-ring, wherein the one or more baffle tiers and the one or more beams bridge the plurality of panels between the cap and the Y-ring.

Clause 5. The load-decoupling attachment system of Clause 4, wherein the fore end coupling joint and the aft end coupling joint are not configured to secure to the plurality of panels.

Clause 6. The load-decoupling attachment system of any of Clauses 1-5, wherein the fore end coupling joint comprises a fitting including:a base configured to abut against an internal surface of the primary structure; andlugs extending from the base, wherein the lugs are separated by a gap, wherein the fore end of the beam is disposed within the gap between the lugs, and wherein the spherical bearing rotationally couples the lugs to the fore end.

Clause 7. The load-decoupling attachment system of Clause 6, wherein one or both of the fitting or the fore end comprises the spherical bearing.

Clause 8. The load-decoupling attachment system of any of Clauses 1-7, wherein the aft end coupling joint comprises a fitting including:a base configured to abut against an internal surface of the primary structure; andlugs extending from the base, wherein the lugs are separated by a gap, wherein the aft end of the beam is disposed within the gap between the lugs, wherein the slot is formed through the aft end of the beam between the lugs, and wherein a pin extends between the lugs and through the slot.

Clause 9. The load-decoupling attachment system of any of Clauses 1-8, wherein the slot enables linear movement of the aft end of the beam to provide freedom of movement to decouple loads associated with the load-decoupling attachment system and the primary structure.

Clause 10. A load-decoupling attachment method for a primary structure, the load-decoupling attachment method comprising:coupling one or more beams to one or more baffle tiers, wherein the one or more beams include a fore end and an aft end;securing, by a fore end coupling joint, the fore end to a first portion of the primary structure, wherein the fore end coupling joint includes a spherical bearing that allows the fore end to rotate in relation to the first portion of the primary structure; andsecuring, by an aft end coupling joint, the aft end to a second portion of the primary structure, wherein the aft end coupling joint includes a slot that allows the aft end to linearly translate in relation to the second portion of the primary structure.

Clause 11. The load-decoupling attachment method of Clause 10, wherein the primary structure is a liquid propellant tank of a launch vehicle, wherein the first portion is a cap of a forward end of the liquid propellant tank, and wherein the second portion is a Y-ring of the liquid propellant tank.

Clause 12. The load-decoupling attachment method of Clause 11, wherein a plurality of panels are between the cap and the Y-ring, wherein the one or more baffle tiers and the one or more beams bridge the plurality of panels between the cap and the Y-ring, and wherein the fore end coupling joint and the aft end coupling joint are not configured to secure to the plurality of panels.

Clause 13. A launch vehicle comprising:a primary structure; anda load-decoupling attachment system secured to the primary structure, the load-decoupling attachment system comprising:one or more baffle tiers;one or more beams coupled to the one or more baffle tiers, wherein the one or more beams include a fore end and an aft end;a fore end coupling joint securing the fore end to a first portion of the primary structure, wherein the fore end coupling joint includes a spherical bearing that allows the fore end to rotate in relation to the first portion of the primary structure; andan aft end coupling joint securing the aft end to a second portion of the primary structure, wherein the aft end coupling joint includes a slot that allows the aft end to linearly translate in relation to the second portion of the primary structure.

Clause 14. The launch vehicle of Clause 13, wherein the primary structure is a liquid propellant tank.

Clause 15. The launch vehicle of Clause 14, wherein the first portion is a cap of a forward end of the liquid propellant tank, and wherein the second portion is a Y-ring of the liquid propellant tank.

Clause 16. The launch vehicle of Clause 15, wherein the liquid propellant tank further comprises a plurality of panels between the cap and the Y-ring, wherein the one or more baffle tiers and the one or more beams bridge the plurality of panels between the cap and the Y-ring.

Clause 17. The launch vehicle of Clause 16, wherein the fore end coupling joint and the aft end coupling joint do not secure to the plurality of panels.

Clause 18. The launch vehicle of any of Clauses 13-17, wherein the fore end coupling joint comprises a fitting including:a first base abutting against a first portion of an internal surface of the primary structure; andfirst lugs extending from the first base, wherein the first lugs are separated by a first gap, wherein the fore end of the beam is disposed within the first gap between the first lugs, and wherein the spherical bearing rotationally couples the first lugs to the fore end.

Clause 19. The launch vehicle of Clause 18, wherein the aft end coupling joint comprises a fitting including:a second base configured to abut against a second portion of the internal surface of the primary structure; andsecond lugs extending from the second base, wherein the second lugs are separated by a second gap, wherein the aft end of the beam is disposed within the second gap between the second lugs, wherein the slot is formed through the aft end of the beam between the second lugs, and wherein a pin extends between the second lugs and through the slot.

Clause 20. The launch vehicle of any of Clauses 13-19, wherein the slot enables linear movement of the aft end of the beam to provide freedom of movement to decouple loads associated with the load-decoupling attachment system and the primary structure.

As described herein, embodiments of the present disclosure provide attachments systems and methods that decouple load transmission between a component, such as a baffle assembly, and a primary structure, such as a liquid propellant tank. Further, embodiments of the present disclosure provide a baffle assembly that spans areas, such as panels, where interfaces are impractical.

While various spatial and directional terms, such as top, bottom, lower, mid, lateral, horizontal, vertical, front and the like may be used to describe embodiments of the present disclosure, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like.

As used herein, a structure, limitation, or element that is “configured to” perform a task or operation is particularly structurally formed, constructed, or adapted in a manner corresponding to the task or operation. For purposes of clarity and the avoidance of doubt, an object that is merely capable of being modified to perform the task or operation is not “configured to” perform the task or operation as used herein.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the various embodiments of the disclosure without departing from their scope. While the dimensions and types of materials described herein are intended to define the parameters of the various embodiments of the disclosure, the embodiments are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the various embodiments of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.

This written description uses examples to disclose the various embodiments of the disclosure, including the best mode, and also to enable any person skilled in the art to practice the various embodiments of the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the various embodiments of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if the examples have structural elements that do not differ from the literal language of the claims, or if the examples include equivalent structural elements with insubstantial differences from the literal language of the claims.