Various embodiments of a vortex thruster system is described herein that is configured to create at least three discrete thrust levels. In some embodiments, the vortex thruster system is configured to decompose a monopropellant and deliver the decomposed monopropellant into a vortex combustion chamber for generating various thrust levels. In some embodiments, the vortex thruster system includes a secondary propellant valve configured to deliver a secondary propellant into the vortex combustion chamber containing decomposed monopropellant to create a high thrust level. Related systems, methods, and articles of manufacture are also described.

A method for manufacturing a solid propellant includes: forming a tool of layers of a first material wherein cuts in the layers form a first interior chamber in the tool; using the tool to mold a second material in the first interior chamber; removing the molded second material from the tool; using the molded second material to mold an interior chamber in a rocket propellant grain; and removing the molded second material from the rocket propellant grain.

A hybrid rocket includes a housing having first and second ends, a solid-grain fuel material in the housing and defining a bore extending from end to end, two electrodes positioned adjacent to the fuel material to ignite the fuel material at the first end, a primary oxidizer port positioned at the first end to inject a primary oxidizer to flow in a downstream direction from the first end to the second end, a nozzle positioned at the second end and having a converging portion and a diverging portion, and a secondary oxidizer port to inject a secondary oxidizer downstream of the converging portion. The bore has a geometry configured to produce a hot-gas, fuel-rich mixture at the nozzle as the fuel material and primary oxidizer burn while flowing downstream. The diverging portion of the nozzle is configured to spontaneously combust the secondary oxidizer and the hot-gas, fuel-rich mixture.

A hybrid rocket includes a housing having first and second ends, a solid-grain fuel material in the housing and defining a bore extending from end to end, two electrodes positioned adjacent to the fuel material to ignite the fuel material at the first end, a primary oxidizer port positioned at the first end to inject a primary oxidizer to flow in a downstream direction from the first end to the second end, a nozzle positioned at the second end and having a converging portion and a diverging portion, and a secondary oxidizer port to inject a secondary oxidizer downstream of the converging portion. The bore has a geometry configured to produce a hot-gas, fuel-rich mixture at the nozzle as the fuel material and primary oxidizer burn while flowing downstream. The diverging portion of the nozzle is configured to spontaneously combust the secondary oxidizer and the hot-gas, fuel-rich mixture.

A hybrid-like liquid fuel motor (the motor) may include a port surrounded by a wall. Surrounding the wall are a plurality of chambers and segmented walls to separate the chambers. In some instances, a single helix chamber may surround the wall, and may operate similar to that of a segmental chamber. During operation of the motor, gas flows from one end of the port to another end of the port. As the walls surrounding the port begin to disintegrate, liquid fuel within chambers begins to begin to mix with the flow of gas. As the segmented walls between the chambers begin to disintegrate, liquid from the other chambers begin to mix with the flow of gas, creating a metering of the liquid fuel.

A hybrid-like liquid fuel motor (the motor) may include a port surrounded by a wall. Surrounding the wall are a plurality of chambers and segmented walls to separate the chambers. In some instances, a single helix chamber may surround the wall, and may operate similar to that of a segmental chamber. During operation of the motor, gas flows from one end of the port to another end of the port. As the walls surrounding the port begin to disintegrate, liquid fuel within chambers begins to begin to mix with the flow of gas. As the segmented walls between the chambers begin to disintegrate, liquid from the other chambers begin to mix with the flow of gas, creating a metering of the liquid fuel.

A hybrid rocket motor includes a solid fuel element, and an oxidizer tank containing an oxidizer. The solid fuel element adjoins and at least partially defines a combustion chamber in which the solid fuel and the oxidizer are burned, to produce thrust from the hybrid rocket motor. The oxidizer tank is at least partially within the combustion chamber, and the entire oxidizer tank may be within the combustion chamber. The oxidizer tank may be protected by an insulating material, which may also serve as a structural material that contains the pressure of the oxidizer. The insulating material and the fuel material may both be polymer-based materials, although they may be different materials having different characteristics, for example including different additives to the same polymer material. The fuel element and the oxidizer tank may be made by additive manufacturing processes, for example by adding different materials in different locations.

A hybrid rocket motor includes a solid fuel element, and an oxidizer tank containing an oxidizer. The solid fuel element adjoins and at least partially defines a combustion chamber in which the solid fuel and the oxidizer are burned, to produce thrust from the hybrid rocket motor. The oxidizer tank is at least partially within the combustion chamber, and the entire oxidizer tank may be within the combustion chamber. The oxidizer tank may be protected by an insulating material, which may also serve as a structural material that contains the pressure of the oxidizer. The insulating material and the fuel material may both be polymer-based materials, although they may be different materials having different characteristics, for example including different additives to the same polymer material. The fuel element and the oxidizer tank may be made by additive manufacturing processes, for example by adding different materials in different locations.

The present invention relates to throttleable propulsion launch escape systems and devices. In one embodiment, the system includes a tower and at least one throttleable motor secured to the tower. The throttleable motor is able to throttle to a reduced power setting during flight. In another embodiment, the system includes at least one throttleable motor and a space vehicle unit that includes a containing structure. In a further embodiment, the throttleable motor may be secured about a boost escape system of a space vehicle unit. In an additional embodiment, the present invention is a three-dimensional nozzle.

The present invention relates to throttleable propulsion launch escape systems and devices. In one embodiment, the system includes a tower and at least one throttleable motor secured to the tower. The throttleable motor is able to throttle to a reduced power setting during flight. In another embodiment, the system includes at least one throttleable motor and a space vehicle unit that includes a containing structure. In a further embodiment, the throttleable motor may be secured about a boost escape system of a space vehicle unit. In an additional embodiment, the present invention is a three-dimensional nozzle.