Abstract: A dual control system for a solid propellant propelled exoatmospheric kill-vehicle is disclosed. The system includes a primary solid propellant propulsion mechanism for controlling the propulsion of the kill-vehicle during a first phase of rocket flight, and a secondary solid propellant propulsion mechanism for maneuvering the kill-vehicle during a second phase of rocket flight. The primary propulsion mechanism controls the propulsion and direction of the kill-vehicle towards its target while the secondary propulsion mechanism may be used to provide lateral acceleration with a lower time-constant.

Abstract: A rocket engine for manned or unmanned space flight and atmospheric flight uses an elongated fuel structure that is external to the combustion chamber and that is fed into the combustion chamber during operation of the rocket. The elongated fuel structure includes propellant elements and may include coolant elements as well. The elongated fuel structure of one embodiment is a ribbon and a wide ribbon may be formed of plural side-by-side ribbon sections. The wide ribbon is cut into separate ribbon sections and is fed between two opposed pinion gears of a fuel injector. The fuel injector has multiple pairs of opposed pinion gears forming multiple stages of the injector, which seal the engine from escaping gases while permitting the elongated fuel structure to be drawn into the engine. The injector has a cutting wheel at the outlet to cut open the coolant and propellant bodies in the ribbon. The propellant ribbon has an outer slow burning layer and an inner fast burning layer.

Abstract: Solid composite propellants are provided that include a matrix comprising an energetic oxidizer and a binder. A multi-layered reactive thin film is provided in the matrix. The reactive thin film includes metal and inorganic oxidizer. Methods of making the solid composite propellants are also provided.

Abstract: A propulsion system and method are described configured to exert a force upon a vehicle. The system includes a concentrated mass which may be discharged from the vehicle by a propellant typically via an ejection tube. The system is optimized so that the discharged concentrated-mass imparts a large impulse upon the vehicle. The system and method may be used to alter the momentum of vehicles for propulsion, attitude correction, vehicle separation and the like.

Abstract: The present invention relates to the field of propellant devices and more particularly to the propellant devices used in weapon systems and munitions. The invention has the two advantages of minimizing the risk associated with accidental attack to which propellant devices may be exposed thanks to the filling of the central channel commonly provided along the core of the cylindrical explosive charge and of greatly increasing the effectiveness of these propellant charges by the use of explosive materials having a very high burn rate.

Abstract: Spacecraft thrusters capable of dual-mode operation, and a method of applying propulsion to a spacecraft using a dual-mode thruster are provided. In one embodiment, the thrusters of the current invention can operate as a chemical motor to provide high thrust and low propellant exhaust velocity to achieve fast maneuverability, or as an electric propulsion thruster to provide low thrust and high exhaust velocity to perform maneuvers with a minimal amount of propellant.

Abstract: A rocket engine for manned or unmanned space flight and atmospheric flight uses an elongated fuel structure that is external to the combustion chamber and that is fed into the combustion chamber during operation of the rocket. The elongated fuel structure includes propellant elements and may include coolant elements and gas generating elements as well. The elongated fuel structure of one embodiment is a ribbon. The ribbon is fed between two opposed wheels of the fuel pump, which seal the engine from escaping gases while permitting the elongated fuel structure to be drawn into the engine. The opposed wheels may serve to activate the gas generating elements, so that gas pressure generated thereby drives the propellant elements into the combustion chamber of the rocket engine. The activation of the gas generating elements also provides coolant to the engine from the coolant elements, in one embodiment.

Abstract: There is disclosed a solid fuel rocket motor which may include a case and a nozzle coupled to the case. A plurality of fuel pellets may be disposed within the case. An igniter may be disposed to ignite at least a portion of the fuel pellets. A pellet retainer may be positioned within the case to retain the plurality of fuel pellets within the case. The pellet retainer may be perforated to allow exhaust gases to flow from the ignited fuel pellets to the nozzle while preventing unburned fuel pellets from being expelled through the nozzle.

Abstract: The present invention discloses a flow-restricting filter capable of restricting intentionally the flow of the combustion gas from a solid propellant gas generator to an external member (for example, the nozzle) to rise up combustion pressure resulting in increasing a burning rate of the solid propellant and in reducing a burning area of the solid propellant and the overall size of the gas generator. The flow-restricting filter according to the present invention comprises a hollow member having a plurality of through holes formed thereon; and a flow-blocking plate provided at one end of the hollow member to form a space having one closed end and another opened end in the hollow member.

Abstract: A pulsed plasma thruster and method of operation are provided. The pulsed plasma thruster comprises solid propellant material. A main discharge source provides a pulsed discharge across the propellant material for ablating the propellant material to produce propellant plasma and accelerating the ablated propellant plasma, and an auxiliary discharge source accelerates late ablated propellant plasma without substantially further ablating the propellant material.

Abstract: A vehicle includes at least one polyoxymethylene structural support member. The polyoxymethylene structural support member includes a polyoxymethylene component that is a propellant that provides thrust to the vehicle upon pyrolysis or combustion of the polyoxymethylene component of the product of pyrolysis of the polyoxymethylene component. The vehicle can be a satellite or other type of spacecraft.

Abstract: A solid-fuel rocket assembly including an elongate fuel container having a long axis, and an inner surface spaced outwardly from, and generally circumsurrounding, that axis, and a continuous, elastomeric, heat-insulative, intumescence-behavior jacket adhered to the container's inner surface and defining a central chamber for receiving an elongate body of solid fuel. This structure implements a method for minimizing, in a solid-fuel rocket, heat damage to the wall of a solid-fuel container during burning of contained solid fuel including the steps of (a) producing dual-interface, continuous-presence, heat-insulative barriering in the zone existing between the container and burning fuel, with such barriering being characterized by (1) interfacially following any heat-produced deformations in the container wall, and (2) interfacially confronting the burning fuel with a tendency for intumescence-driven barrier-thickening.

Abstract: A propulsion system, such as for use in a missile, includes a multinozzle grid having a pair of plates that are separably mechanically coupled together. When coupled together in a first configuration, the plates provide multiple nozzles in a first nozzle configuration (geometry). Separation of the plates, such as by separating an aft plate from a forward plate that remains with the missile, reconfigures the multinozzle grid to a second configuration that has nozzles in a second nozzle configuration (geometry). The nozzle configurations may be suitable for different types of propulsion mechanisms. The hybrid propulsion system utilizing the multinozzle grid may include a pair of pressurized gas sources, for example a solid rocket fuel and a combustion chamber for a ramjet.

Abstract: An end burning type gas generator includes a hollow cylindrical combustor, a propellant which is densely charged in the combustor concentrically and in a plurality of layers without leaving a large void in an internal cross section and which has the same sectional area in each of the layers, and an interstructure which separates the plurality of layers from each other and which connects only at a turning portion at an axial end. The end burning of the propellant sequentially progresses via the turning portion, beginning with an outermost layer or an innermost layer. The turning portion includes an end outer plate which continuously surrounds the ends of an inner propellant and an outer propellant, and a burning rate increasing member which is provided along the inner surface of the end outer plate to increase the burning rate of the propellant. The end outer plate is shaped such that the burning area at the turning portion remains substantially constant.

Abstract: The thrust of a rocket motor can be varied while maintaining efficiency over a range of pressure ratios using a design that allows for changing the relative position of a plug and a combustion chamber exit. The plug or the chamber exit may be attached to an adaptive control system for position modification. The plug may be positioned in a plug nozzle configuration or in an expansion-deflection (ED) configuration. In either configuration, the elongated downstream portion of the plug allows for efficiency over a wide range of pressure ratios, while ability to change plug position with respect to the chamber exit allows adjustment of rocket thrust.

Abstract: A pourable opaque centerport for solid propellant rocket motors and method for applying the same are disclosed. The pourable centerport inhibitor for solid propellant rocket motors has a curing system that includes a prepolymer and a curing agent. The prepolymer and the curing agent are combined to form a pourable polymeric binder that cures into an amorphous solid. The pourable centerport inhibitor also includes an opaque agent. The pourable centerport inhibitor may also include a plasticizer. The plasticizer, the prepolymer, and the curing agent are preferably the same type that is in the solid propellant with which it will be used in conjunction.

Abstract: The hybrid rocket system of this invention is characterized by use of an oxidizer tank having a cylindrical midsection surrounded by a skirt and bonded thereto by a layer of elastomeric adhesive. The skirt outer surface is in turn adhesively secured to a spacecraft inner surface. An elongated solid-fuel motor case is mechanically rigidly secured to a central rear surface of the tank, and the case terminates in a throat and nozzle. The elastomeric-adhesive bonding of tank to skirt, and rigid adhesion of skirt to spacecraft forms the sole support for the rocket system, and separate support for the motor case is not required.

Abstract: A fixed sized bell rocket nozzle is lined with a layer of combustible material that is ignited during launch ignition and burns to outgas into the rocket exhaust for spatially variably confining the exhaust and perfecting an effective variably sized altitude compensating exhaust nozzle that maximizes lift during the launch of a spacecraft into orbit.

Abstract: A solid rocket motor including a combustion chamber, in which propellant is ignited to produce combustion gas, and a nozzle having a throat with an effective flow area, implements a system and method to inject gas into the nozzle throat to control its effective cross sectional flow area. Controlling the effective cross sectional flow area of the nozzle throat in turn controls combustion chamber pressure, thus the burn rate of the propellant in the combustion chamber, and thus the thrust generated thereby.

Abstract: An insulation material comprising a low-density EPDM polymer, at least one flame-retardant, and an organic filler. The insulation material is used in an insulation layer of a rocket motor. The organic filler is a polymeric, organic filler such as polyvinyl chloride. A rocket motor comprising an insulation material is also disclosed. The insulation material comprises a low-density EPDM polymer, at least one flame-retardant, and a polymeric, organic filler and is applied between an inner surface of a case of the rocket motor and a propellant. A method of insulating a rocket motor is also disclosed.

Abstract: A thruster stack assembly and method for manufacturing the same is provided. The thruster stack assembly includes a plurality of grain elements having a common core region (e.g., a channel or passageway), where each grain element comprises a volume of electrically ignitable propellant. The thruster stack assembly further includes electrodes associated with the plurality of grain elements, the electrodes adapted for selectively igniting the plurality of grain elements. In one example, one or more of the grain elements may be ignited and combusted without igniting or damaging adjacent grain elements of the stack. The core region serves to channel combustion gases and exhaust from the thruster stack. Multiple stacks may be assembled together to form three-dimensional thruster arrays.

Abstract: Disclosed is a jet vane thrust vector control (JV-TVC) system. A general system has many problems in design techniques considering actual operation environments, and does not have reliability in component assembly design. The JV-TVC system improves thrust vector control and high angle of attack maneuvering performance of a missile by allowing rotational angles of jet vanes to maximum ±30°, precisely controls the thrust vector of the missile by preventing damages of components for the designated flight time of the missile, and improves precision and reliability in the assembly process by modularization.

Abstract: A propulsion system including an extinguishable rocket motor and an incorporated maneuver control system. The rocket motor may be of the solid fuel type. One or more proportional axial thrust valves in communication with a pressure vessel or motor case containing a solid fuel propellant may be used to release combustion products for creating axial thrust. A plurality of proportional maneuver control valves in communication with the pressure vessel and having associated maneuver control thrusters may be selectively actuated in different modes of operation to provide control of pitch, yaw and roll. Fully opening all valves in communication with the pressure vessel may be used to cause rapid depressurization to extinguish the propellant. Reignition of the rocket motor may be effected upon repressurization of the pressure vessel through closing at least some of the valves. Ignition grains may be employed to shorten reignition time, and multiple propellant grains may be provided for multiple pulses.

Abstract: A side thruster module, comprises: a cavity-type body skin extending in a longitudinal direction; a first thruster arranged in the body skin and extending in a longitudinal direction; and a conversion nozzle arranged in the body skin and extending in a radial direction perpendicular to the longitudinal direction, for converting a direction of a thrust generated from the first thruster in the longitudinal direction into the radial direction. A large number of thrusters can be mounted at the side thruster module thus to generate a high thrust, and the side thruster module can be slim in the radial direction perpendicular to the longitudinal direction.

Abstract: A solid propellant rocket engine includes: a propellant formed into a predetermined shape having a combustion cavity and capable of deflagrating into hot, high-pressure gas upon ignition; and a nozzle configured and positioned to expand the hot, high-pressure gas into the atmosphere, where the propellant forms the nozzle as a part of the predetermined shape. A multi-stage rocket unit, a multi-engine rocket stage, and a super-staged rocket each has many rocket engines.

Abstract: A pyrotechnic charge structure, in particular for use as propellant in a rocket motor, is disclosed. The charge structure has a predetermined longitudinal extension and cross sectional area adapted to the intended purpose. The pyrotechnic charge structure (1; 2; 3; 4) is in cross sectional view in cellular form aimed at having similar wall thickness for all the cells of the charge structure. The wall (6) of the cells comprises the pyrotechnic charge, i.e. the propellant, and each cavity of the cells occupies air or oxygen-rich gas.

Abstract: A rocket motor insulation including an elastomer-based polymer is improved in its processability by the addition of silica particles treated with a hydrophobic coating. The insulation also preferably includes a metallic coagent cross-linker, which when used in combination with the hydrophobic silica particles increases the tear strength and the elasticity of the insulation, while at the same time not adversely affecting the bonding characteristics of the insulation.

Abstract: The invention provides a system for passively controlling pressure oscillations of hydrodynamic origin in a solid propellant thruster comprising a body containing a charge of solid propellant, the system comprising at least one insert disposed in the thruster body transversely relative to the flow direction of the combustion gases of the solid propellant. The insert has an opening of non-axisymmetric shape so as to generate a three-dimensional effect on the flow and prevent axisymmetric turbulent modes from forming in the thruster. Thus, the control system of the invention serves to break the symmetry of the flow and thus prevents axisymmetric turbulence forming which is the source of instability that the present invention seeks to control. The present system is applicable to existing thrusters.

Abstract: A super-staged rocket includes at least approximately 50 rocket engines, where the engines are distributed according to at least one of: at least five multi-engine stages connected in series, each stage including at least ten engines connected in parallel; and at least five multi-stage units connected in parallel, each unit including at least five engines connected in series.

Abstract: The present invention comprises a device which is inert and “thermally-equivalent” to actual ordnance. The device can travel with live ordnance and track the propellant temperatures in order to get a more precise propellant temperature for the ordnance. The device comprises a thermally equivalent inert grain instrumented with thermocouples, connected to a data recorder, and packaged in scaled-down ordnance hardware. The hardware is scaled down to enable the device to more easily travel with live munitions.

Abstract: A hydrogen fuel system for a vehicle includes a fuel tank having a fuel inlet for receiving a borohydride fuel into a fuel holding portion of an internal cavity, and a waste inlet arranged to receive the waste liquid generated by an on-board hydrogen reaction process. The waste liquid is received into a waste liquid portion of the internal cavity. An expandable divider element is positioned within the tank to keep the fuel holding portion of the internal cavity separate from the waste liquid holding portion. The waste liquid holding portion can be positioned within the internal cavity so as to allow heat from the waste liquid to preheat the fuel stored in the fuel holding portion.

Abstract: A case-burning rocket booster includes a combustible case containing a solid rocket fuel, a combustion chamber adjustably coupled to the case for burning the case and the solid rocket fuel, a nozzle connected to the combustion chamber for expelling the burned case and fuel to generate thrust, and a drive system for pulling the combustion chamber and nozzle up the case as the case and fuel burn. A hybrid version of the case-burning rocket also includes an oxygen supply system for supplying varying amounts of oxygen to the combustion chamber to vary the thrust generated by burning the case and the fuel.

Abstract: Propellant modules for Micro Pulsed Plasma Thrusters, and techniques for bundling propellant modules and for using a two-stage discharge process to increase MicroPPT propellant throughput, and decrease the output voltage required from the power-processing unit are provided.

Abstract: A flame holder is provided at a head end of a combustion chamber of a hybrid rocket motor. The flame holder includes a high-temperature casing defining a cavity, and a solid propellant within cavity around or near the injector. The propellant may be provided in an annulus within the casing, such that the flame plume from the burning propellant is substantially parallel to the flow of the oxidizer, or may be generally cylindrical within a cylindrical casing such that the flame plume of the burning propellant is substantially perpendicular to the oxidizer flow. The solid propellant is preferably ignited substantially simultaneously with the ignition of the hybrid motor. The burning of the solid propellant prevents the flame from combustion of the fluid oxidizer and solid fuel in the hybrid motor from drifting and thereby stabilizes the flame front.

Abstract: A solid combustible composition for use in solid fuel air-augmented rocket engines which very substantially increases the temperature efficiency of afterburner fuel combustion with ram air, thereby greatly increasing engine performance. The improvement comprises dispersing in a matrix comprising the solid, fuel-rich organic compositions conventionally utilized in air-augmented rockets, particles containing solid oxidizable element and fluorine oxidizer compound which reacts with the element to produce gaseous subfluoride compound.

Abstract: An ultraviolet curable bond liner with a high filler content that is curable sufficiently for casting of the propellant by exposure to ultraviolet light at a wavelength between 350 and 400 nm. By irradiating the liner at this wavelength, the initiator can be activated without interference from the filler components or heat cured liner components. After the casting of the propellant, the bond liner is heat cured along with the propellant.

Abstract: A pressure vessel is provided that includes first and second case segments mated with one another. First and second annular rubber layers are disposed inboard of the first and second case segments, respectively. The second annular rubber layer has a slot extending from the radial inner surface across a portion of its thickness to define a main body portion and a flexible portion. The flexible portion has an interfacing surface portion abutting against an interfacing surface portion of the first annular rubber layer to follow movement of the first annular rubber layer during operation of the pressure vessel. The slot receives pressurized gas and establishes a pressure-actuated joint between the interfacing surface portions. At least one of the interfacing surface portions has a plurality of enclosed and sealed recesses formed therein.

Abstract: A method and device for producing a controlled combustion by placing a combustion chamber in communication with a feed chamber that contains a solid propellant/body, introducing at least a portion of the body into the combustion chamber, isolating the combustion chamber from the feed chamber, and igniting the solid propellant in the combustion chamber while the combustion chamber is isolated from the feed chamber.

Abstract: The present invention relates to an actuator system comprising: a matrix (100) of pyrotechnic microthrusters; and control means for controlling the respective firing of said microthrusters (100), and being suitable for generating a specific desired effect.

Abstract: Insulation for a rocket motor is provided, as is a method for insulating a rocket motor. The insulation includes a cured elastomer and vapor-grown carbon fibers dispersed in the cured elastomer. The cured elastomer is preferably formed from a precursor composition comprising an EPDM terpolymer. Generally, the vapor-grown carbon fibers have an internal graphitized tube surrounded by a sheath of vapor-deposited amorphous carbon.

Abstract: An embodiment of the rocket motor of this invention employs an insensitive munitions approach that, when subjected to elevated external temperatures, is activated by thermal expansion of the main propellant and gas generation from a secondary insensitive munitions charge. In a preferred embodiment, the rocket motor also includes a pressure equalizing system that accommodates changing temperature conditions during storage as well as varying gas pressure inherent in gun-launched systems in a manner that allows for thinner case cylinder design and increased propellant volume.

Abstract: A pressure vessel is provided that includes first and second case segments mated with one another. First and second annular rubber layers are disposed inboard of the first and second case segments, respectively. The second annular rubber layer has a slot extending from the radial inner surface across a portion of its thickness to define a main body portion and a flexible portion. The flexible portion has an interfacing surface portion abutting against an interfacing surface portion of the first annular rubber layer to follow movement of the first annular rubber layer during operation of the pressure vessel. The slot receives pressurized gas and establishes a pressure-actuated joint between the interfacing surface portions. At least one of the interfacing surface portions has a plurality of enclosed and sealed recesses formed therein.

Abstract: A rocket motor insulation including an elastomer base polymer is improved in its processability by the addition of silica particles treated with a hydrophobic coating. The insulation also preferably includes a metallic coagent cross-linker, which when used in combination with the hydrophobic silica particles increases the tear strength and the elasticity of the insulation, while at the same time not adversely affecting the bonding characteristics of the insulation.

Abstract: A method of making heat engine components, such as rocket nozzle throats, includes forming a body having at least one surface, wherein the body is made of a refractory metal, and compressing a ceramic powder between a die and the at least one surface of the body, with sufficient heat and pressure to densify and thus form a solid ceramic coating on the at least one surface of the body. Nozzle throats made according to the invention have bodies made of refractory metals, such as tantalum, and ceramic coatings on the inner surfaces of the annular bodies, wherein the ceramic coatings are made of ceramic materials such as tantalum carbide.

Abstract: An embodiment of the rocket motor of this invention employs an insensitive munitions approach that, when subjected to elevated external temperatures, is activated by thermal expansion of the main propellant and gas generation from a secondary insensitive munitions charge. In a preferred embodiment, the rocket motor also includes a pressure equalizing system that accommodates changing temperature conditions during storage as well as varying gas pressure inherent in gun-launched systems in a manner that allows for thinner case cylinder design and increased propellant volume.

Abstract: An elastomerized phenolic resin ablative insulation particularly suitable for use in connection with the thermal insulation of selected components of rocket motors. A composition for making the elastomerized ablative insulation is disclosed. Furthermore, an associated method of forming calendered sheets of material formed of the composition is disclosed. The preferred ingredients of the disclosed composition include acrylonitryle butadiene rubber, zinc borate, and phenol formaldehyde resin which can be cured and bonded to structures such as domes of open-ended rocket motors and other rocket motor components. The subject elastomerized ablative insulation is well suited for use independently or in connection with other insulative materials to form a thermal barrier which is highly resistant to the heat and the erosive nature associated with the combustion of propellant fuels, for example.

Abstract: A rocket nozzle assembly is provided for operatively coupling to a rocket motor. The assembly includes a nozzle insert structure having a converging-diverging passageway with a throat region. First and second thrust control cylinders are parallel to each other and rotatable about respective axes transverse to the passageway central axis. The first and second thrust control cylinders intersect the throat region and include respective grooves. A thrust control cylinder-rotating subassembly is operatively associated with the first and second thrust control cylinders to rotate the cylinders about their respective axes and move the grooves relative to the throat region. Movement of the grooves changes the effective cross-sectional throat area of the passageway at the throat region for controlling the thrust when the rocket nozzle assembly is operatively engaged with an operating rocket motor.

Abstract: A gauge for measuring heat flux, especially heat flux encountered in a high temperature environment, is provided. The gauge includes at least one thermocouple and an anisotropic pyrolytic graphite body that covers at least part of, and optionally encases the thermocouple. Heat flux is incident on the anisotropic pyrolytic graphite body by arranging the gauge so that the gauge surface on which convective and radiative fluxes are incident is perpendicular to the basal planes of the pyrolytic graphite. The conductivity of the pyrolytic graphite permits energy, transferred into the pyrolytic graphite body in the form of heat flux on the incident (or facing) surface, to be quickly distributed through the entire pyrolytic graphite body, resulting in small substantially instantaneous temperature gradients. Temperature changes to the body can thereby be measured by the thermocouple, and reduced to quantify the heat flux incident to the body.

Abstract: A towing rocket motor assembly has a tubular solid propellant grain defined by exterior surface area and interior surface area. The exterior surface area is inhibited from ignition within a tubular region of a housing. The housing includes a first end and a second end at either end of the tubular region. The first end defines a plenum having an annular region defined by a diameter larger than that of the tubular region. A plurality of holes formed in the first end communicate with the annular region and are directed substantially in the direction of the second end of the housing. A burn-inhibiting baffle is fitted in the propellant grain wherein an annular spacing is defined between the baffle and the interior surface area of the propellant grain. An ignition assembly, mounted at the second end of the housing, is coupled to the interior surface area of the propellant grain so that the propellant grain burns from the inside out upon ignition.

Abstract: A modular solid-fuel rocket propellent charge has a combustion-chamber wall, a plurality of separate elements including frozen fuel or oxidizer, and respective rigid casings completely surrounding and enclosing the elements. Respective formations on the casing and on the casings directly engage each other for supporting the elements via the respective casings directly an the wall.