COMBUSTION CHAMBER SECTION WITH INTEGRAL BAFFLE AND METHOD OF MAKING A COMBUSTION CHAMBER SECTION

Abstract

A combustion chamber section (110) for a combustion chamber (100) for a rocket engine (10) is described, the combustion chambersection (110) comprising a combustion chamber body (120) enclosing a combustion chamber volume and having coolant channels (130) disposed therein, and at least one baffle (140) integrally formed with the combustion chamber body (120) and projecting from the combustion chamber body (120) into the interior of the combustion chamber. The at least one baffle (140) comprises at least one coolant channel (133-135) fluidly connected to at least one of the coolant channels (130) in the combustion chamber body (120). Furthermore, an additive layer manufacturing method for manufacturing such a combustion chamber section is described.

Claims

1. A combustion chamber section for a combustion chamber for a rocket engine, the combustion chamber section comprising: a combustion chamber body which encloses a combustion chamber volume and in which coolant channels are arranged, at least one baffle formed integrally with the combustion chamber body and projecting from the combustion chamber body into the interior of the combustion chamber, wherein the at least one baffle comprises at least one coolant channel fluidly connected to at least one of the coolant channels in the combustion chamber body.

2. The combustion chamber section according to claim 1, wherein the baffle comprises a coolant inlet and a coolant outlet, and wherein the at least one coolant channel of the baffle extends between the coolant inlet and the coolant outlet.

3. The combustion chamber section according to claim 2, wherein the coolant inlet of the baffle is fluidly connected to the at least one of the coolant channels in the combustion chamber body.

4. The combustion chamber section according to claim 3, wherein each of the coolant channels in the combustion chamber body has a coolant outlet, and wherein in a circumferential direction along a cross-section of the combustion chamber body, next to one of the coolant outlets, another coolant outlet of a coolant channel in the combustion chamber body or the coolant outlet of the baffle is arranged.

5. The combustion chamber section according to claim 4, wherein a coolant channel in the combustion chamber body ends in the longitudinal direction of the combustion chamber body at the level of the coolant inlet of the baffle and opens into the at least one coolant channel of the baffle.

6. The combustion chamber section according to claim 5, wherein a first coolant channel in the baffle is a coolant supply channel fluidically connected to the at least one coolant channel in the combustion chamber body and extending on a first side of the baffle, and wherein a second coolant channel in the baffle is a coolant discharge channel extending on a second side of the baffle.

7. The combustion chamber section according to claim 6, wherein a plurality of baffles protrude into the interior of the combustion chamber, and wherein all of the plurality of baffles are connected at their inner end by an annular baffle.

8. The combustion chamber section according to claim 7, wherein the annular baffle comprises at least one coolant channel fluidly coupled to the at least one coolant channel of the plurality of baffles.

9. The combustion chamber section according to claim 8, wherein the at least one coolant channel of the annular baffle comprises a coolant outlet.

10. A combustion chamber for a rocket engine comprising a combustion chamber section according to claim 1.

11. A rocket engine comprising: a combustion chamber section including a combustion chamber body which encloses a combustion chamber volume and in which coolant channels are arranged, at least one baffle formed integrally with the combustion chamber body and projecting from the combustion chamber body into the interior of the combustion chamber, wherein the at least one baffle comprises at least one coolant channel fluidly connected to at least one of the coolant channels in the combustion chamber body; or a combustion chamber according to claim 10.

12. (canceled)

13. (canceled)

14. A method of manufacturing a combustion chamber section including a combustion chamber body which encloses a combustion chamber volume and in which coolant channels are arranged, a baffle formed integrally with the combustion chamber body and projecting from the combustion chamber body into the interior of the combustion chamber, the baffle includes at least one coolant channel fluidly connected to at least one of the coolant channels in the combustion chamber body, the method comprising: building up the combustion chamber section by an additive layer manufacturing technique; and no material joining together by the additive layer manufacturing method at positions where the coolant channels of the combustion chamber body and the at least one coolant channel of the baffle are located.

15. The combustion chamber section according to claim 2, wherein each of the coolant channels in the combustion chamber body has a coolant outlet, and wherein in a circumferential direction along a cross-section of the combustion chamber body, next to one of the coolant outlets, another coolant outlet of a coolant channel in the combustion chamber body or the coolant outlet of the baffle is arranged.

16. The combustion chamber section according to claim 15, wherein a coolant channel in the combustion chamber body ends in the longitudinal direction of the combustion chamber body at the level of the coolant inlet of the baffle and opens into the at least one coolant channel of the baffle.

17. The combustion chamber section according to claim 9, wherein the coolant outlet is arranged either on a side facing away from the combustion chamber or on a side facing the combustion chamber.

18. The combustion chamber section according to claim 1, wherein a first coolant channel in the baffle is a coolant supply channel fluidically connected to the at least one coolant channel in the combustion chamber body and extending on a first side of the baffle, and wherein a second coolant channel in the baffle is a coolant discharge channel extending on a second side of the baffle.

19. The combustion chamber section according to claim 6, wherein at least one third coolant channel fluidically connects the coolant supply channel to the coolant discharge channel.

20. The combustion chamber section according to claim 18, wherein at least one third coolant channel fluidically connects the coolant supply channel to the coolant discharge channel.

21. The combustion chamber section according to claim 1, wherein a plurality of baffles protrude into the interior of the combustion chamber, and wherein all of the plurality of baffles are connected at their inner end by an annular baffle.

22. The combustion chamber section according to claim 21, wherein the annular baffle comprises at least one coolant channel fluidly coupled to the at least one coolant channel of the plurality of baffles; and wherein the at least one coolant channel of the annular baffle comprises a coolant outlet arranged either on a side facing away from the combustion chamber or on a side facing the combustion chamber.

Description

[0034] Preferred embodiments of the invention will now be explained in more detail with reference to the accompanying schematic drawings, wherein

[0035] FIG. 1 schematically shows a perspective view of a combustion chamber;

[0036] FIG. 2 schematically shows a section of a combustion chamber section; and

[0037] FIG. 3 schematically shows a detail of a combustion chamber section with annular baffle.

[0038] FIG. 1 schematically shows a perspective view of a combustion chamber 100, which can be used, for example, in a rocket engine 10. The nozzle of the rocket engine 10 is indicated in FIG. 1 by dashed lines only. The combustion chamber 100, as simplified in FIG. 1, includes a combustion chamber section 110 in which much of the mixing and combustion of the propellant components takes place. Downstream (in the direction of flow of the combustion gases) of the combustion chamber section 110 is a subsonic nozzle section 112 in which the combustion gases are accelerated, followed by a nozzle supersonic segment 114.

[0039] In the area of the nozzle supersonic segment 114, there is a connection 131 for coolant which opens into a distribution ring 132 (also called a distribution manifold). The distribution ring 132 extends in the circumferential direction and forms a continuous annular volume. Coolant channels 130 open into this volume or, viewed in the direction of coolant flow (indicated by a dashed arrow in FIG. 1), a plurality of coolant channels 130 begin in the distribution ring 132.

[0040] The combustion chamber section 110 comprises a combustion chamber body 120 which encloses a combustion chamber volume and in which the coolant channels 130 are also arranged. The combustion chamber section 110, shown cylindrically in FIG. 1, may assume any cross-sectional shape that serves to efficiently combust the fuel components. The combustion chamber section 110 further comprises at least one baffle 140 integrally formed with the combustion chamber body 120 and projecting from the combustion chamber body 120 into the interior of the combustion chamber.

[0041] A flange 125 is provided at the upstream end of the combustion chamber section 110 as viewed in the direction of flow of the combustion gases. This flange 125 is used to connect the injection head (not shown). As shown in the detailed view in FIG. 1, a plurality of coolant outlets 138 are located in the region of the flange 125, each coolant channel 130 in the combustion chamber body 120 having one such coolant outlet 138. The coolant outlets 138 are arranged adjacent one another in a circumferential direction along a cross-section of the combustion chamber body 120. The coolant outlets 138 may open into a distribution ring or collector ring, not shown, provided corresponding to the distribution ring 132 at the other end of the combustion chamber 100.

[0042] As can be seen in particular from the detailed view in FIG. 1, at least one of the baffles 140 has a coolant channel 133-135 for cooling the baffle 140. The coolant channel 133-135 is fluidically connected to at least one of the coolant channels 130 in the combustion chamber body 120.

[0043] FIG. 2 schematically shows a detail of a combustion chamber section 110, in which in particular the coolant channels 130 in the combustion chamber body 120 and the coolant channels 133-135 in the baffle 140 can be seen. The baffle 140 is shown as a trapezoidal shape only by way of example, but may take any shape to dampen vibrations within the combustion chamber section 110. The baffle 140 divides the combustion chamber volume into different sections, thereby suppressing or at least damping vibrations. Depending on the type of fuel, the vibrations may have different parameters, such that the baffle 140 must be correspondingly sized in the longitudinal and/or circumferential direction of the combustion chamber section 110 to dampen or suppress the vibrations that would otherwise occur.

[0044] The baffle 140 shown in FIG. 2 as an example has a coolant inlet 136 and a coolant outlet 137. The at least one coolant channel 133-135 of the baffle 140 extends between the coolant inlet 136 and the coolant outlet 137. For example, the coolant inlet 136 of the baffle 140 can be fluidically connected to at least one of the coolant channels 130 in the combustion chamber body 120. In a simple embodiment, as shown in FIG. 2, the baffle has a width in the circumferential direction of the combustion chamber body 120 that is slightly greater than the width of a coolant channel 130 in the combustion chamber body 120. Thus, the coolant channels 133-135 in the baffle 140 may have a width in the circumferential direction of the combustion chamber body 120 that is approximately equal to the width of a coolant channel 130 in the combustion chamber body 120. In particular, the cross-sectional area of the coolant channel 130 in the combustion chamber body 120 may correspond to the cross-sectional area of the coolant channel 133 or the coolant inlet 136 in the baffle 140.

[0045] The coolant inlet 136 of the baffle 140 may be fluidly connected to the at least one of the coolant channels 130 in the combustion chamber body 120. As can be seen in FIG. 2, the coolant channel 130 in the combustion chamber body 120 ends at the level of the coolant inlet 136 of the baffle 140, as viewed in the longitudinal direction of the combustion chamber body 120, so that the coolant channel 130 in the combustion chamber body 120 opens into the coolant channel 133 in the baffle 140. In contrast, when viewed in the longitudinal direction of the combustion chamber body 120, the adjacent coolant channels 130 in the combustion chamber body 120 are longer.

[0046] The coolant outlets 138 of each coolant channel 130 in the combustion chamber body 120 are adjacent to each other in the circumferential direction of the coolant body 120. In the region of the baffle 140, where the coolant channel 130 in the combustion chamber body 120 is shorter, the coolant outlet 137 of the baffle 140 is arranged adjacent to a coolant outlet 138 in the combustion chamber body 120. As a result, all coolant channels 130 in the combustion chamber body 120 and also the coolant channels 133 - 135 in the baffle 140 open into the collecting ring (not shown), as would also be the case with a plurality of coolant channels 130 in the combustion chamber body 120 without baffle 140. Therefore, the collecting ring and the components adjoining it do not have to be modified.

[0047] To achieve sufficient cooling of the baffle 140, the baffle 140 shown in FIG. 2 provides a first coolant channel 133, which is a coolant supply channel. The coolant supply channel 133 is fluidically connected to the (shorter) coolant channel 130 in the combustion chamber body 120. A second coolant channel 134 in the baffle 140 forms a coolant discharge channel and opens into the coolant outlet 137 of the baffle 140. The coolant supply channel 133 and the coolant discharge channel 134 are fluidically connected to each other. For example, they may be connected to each other via at least one third coolant channel 135. The greater the number of the at least one third coolant channel 135, the more uniformly coolant can flow through the baffle 140 and the more uniformly it is cooled.

[0048] Since the free tip of the baffle 140, which is spaced farthest from the combustion chamber body 120, extends farthest into the combustion chamber, this tip is also exposed to the highest heat load. In order to continue to be able to achieve uniform cooling, the distance between two third coolant channels 135 can become smaller as the distance from the combustion chamber body 120 increases.

[0049] In order to also cool the outer sides of the baffle 140 (viewed in the direction of flow of the combustion gases), the coolant supply channel 133 can run along a first side of the baffle 140 and the coolant discharge channel 134 can run along a second side of the baffle 140. Of course, the arrangement and the course of the coolant ducts 133-135 can be selected in deviation from the courses shown in such a way that coolant which is as cool as possible is guided past the hottest points of the baffle 140 to be expected.

[0050] FIG. 3 schematically shows a section of a combustion chamber section 110 with an annular guide 150. Both the combustion chamber section 110 and the annular guide 150 are shown in a circular shape. Of course, the annular baffle 150 can also assume another shape, for example a polygonal shape. This annular baffle 150 also divides the combustion chamber volume, thereby damping or avoiding vibrations.

[0051] The annular baffle 150 may also include at least one coolant channel 151, with FIG. 3 showing an example of two coolant channels 151 on opposite sides (as viewed in the direction of flow of the combustion gases) of the annular baffle 150. This at least one coolant channel 151 in the annular baffle 150 may be fluidically coupled to at least one coolant channel 133-135 in at least one of the baffles 140, such that coolant may flow from at least one of the baffles 140 into the annular baffle 150 to cool the annular baffle 150.

[0052] Optionally thereto, at least one of the coolant channels 151 of the annular baffle 150 may comprise a coolant outlet 152, 153. Such a coolant outlet 152, 153 of the annular baffle 150 can be arranged either on a side facing away from the combustion chamber 100 or on a side facing the combustion chamber 100. The coolant outlet 152 facing away from the combustion chamber 100 can be used as a coolant port to direct coolant into the injection head. On the other hand, a coolant outlet 153 arranged on the side of the baffle 150 facing the combustion chamber 100 can be used as an injection element.

[0053] For example, an injection element can be incorporated or integrated into the coolant outlet 153, whereby coolant (in this case, a fuel component) can be directed into the combustion chamber 100 in a region spaced from the injection plate (not shown).

[0054] Also optionally, coolant outlets (not shown) can also be arranged in the baffles 140. In this case, these coolant outlets can also be arranged on a side facing away from the combustion chamber 100 or on a side facing the combustion chamber 100 and fulfill the same functions as the coolant outlets 152, 153.

[0055] From FIGS. 2 and 3, it can be seen that the combustion chamber section 110 (or the entire combustion chamber 100) can be fabricated quite quickly and easily using an additive layer manufacturing method (3D printing or ALM). The material forming the baffle 140 and/or annular baffle 150 can be layered with the combustion chamber body 120, and the entire combustion chamber section 110 can be layered. All of the coolant channels 130, 133, 134, 135, 151 can thereby be fabricated by omitting joining of material and thus creating a cavity. The additive layer manufacturing method allows the different and possibly branched cavities forming the coolant channels 130, 133, 134, 135, 151 and coolant outlets 137, 138, 152, 153 to be produced in a simple manner. As a result, complex structures, especially in the area of the baffles 140, 150, can be realized which would not be possible with other manufacturing processes. Thus, baffles 140, 150 that can be cooled well can be provided in a simple manufacturing process, and in particular good vibration damping can also be achieved, irrespective of a complicated course of the coolant channels 130, 133, 134, 135, 151.