Abstract
A rocket engine pintle injector with optimized spray pattern and with integrated ignitor design for providing construction simplicity, throttleable thrust, stop/start/restart capability, optimized operational combustion, and improved ignition combustion stability. A user can start, throttle, and stop the engine by moving the internal concentric injector sleeve forward and backward to cause the fuel/oxidizer to spray out of the pintle head at different flow rates. The concentric ignitor can be deployed so that the hot gasses or spark produced are radially projected into the spray of fuel/oxidizer surrounding the ignitor. Once the fuel/oxidizer spray has been ignited, the ignitor is stopped and retracted to protect the device from the heat of the combustion chamber and is ready for redeployment and restart of the engine as needed. Thus, a versatile, fully integrated, and scalable device can be used to start, throttle, stop, and restart any size rocket engine during any mission phase from launch to return from space.
Claims
1. An integrated pintle and igniter comprising: an injector body which provides the structure subsuming the pintle shaft and is mounted to the forward end of the rocket engine combustion chamber, and a concentrically mounted and hydraulically or mechanically controlled injector sleeve around the outside of the pintle injector shaft within the aft portion of the injector body, and spray dividing vanes radially mounted along the inner pintle shaft abutting the pintle head and coordinated spray dividing vanes radially mounted along the inside of the fuel channel at the exit, and a coaxially mounted and hydraulically or mechanically deployable ignitor assembly within the pintle injector shaft with multiple ports capable of projecting hot ignition gases into the pintle fuel/oxidizer spray when deployed, and a cap on the end of the ignitor tube that acts as a heat shield and control valve when the ignitor assembly is retracted whereby (a) the hydraulically/electromechanically controlled injector sleeve around the outside of the pintle injector shaft is placed in the open position to allow flow of fuel/oxidizer mix into the combustion chamber, (b) as the fuel/oxidizer mix begins to flow into the combustion chamber, the spark torch ignitor assembly is hydraulically/electromechanically placed in the deployed position and ignited to inject hot gas into the fuel/oxidizer spray, (c) once the fuel/oxidizer spray has been ignited, the spark torch ignitor assembly is placed in the retracted position so that the tip of the ignitor conforms with the tip of the pintle, and (d) the hydraulically controlled injector sleeve is moved back and forth to throttle and shut off the engine.
Description
DRAWINGS
[0021] FIG. 1 is a simplified orthographic view of the cylindrical fuel spray produced by a pintle injector without the oxidizer impingement.
[0022] FIG. 2 is a simplified orthographic view of the radial oxidizer spray produced by a pintle injector without the fuel impingement.
[0023] FIG. 3 is a simplified orthographic view of the conical spray produced by a pintle injector with the fuel spray impinging on the oxidizer spray.
[0024] FIG. 4 is an orthographic projection of the exploded view of the main parts of this device.
[0025] FIG. 5 is a cross section example of the entire pintle injector with internal ignitor.
[0026] FIG. 6 is a partial cross section example of the one side of the pintle injector with the sliding flow control sleeve in the closed position with fuel and oxidizer flow shut off.
[0027] FIG. 7 is a partial cross section example of the one side of the pintle injector with the sliding flow control sleeve in the open position with fuel and oxidizer mixture spraying at an angle from the injector centerline.
[0028] FIG. 8A is an orthographic cutaway view of the pintle head illustrating the pintle shaft and the forward face of the pintle head.
[0029] FIG. 8B is an orthographic cutaway view of the pintle head illustrating the location of optional pintle shaft oxidizer vanes located on the pintle shaft.
[0030] FIG. 8C is an orthographic cutaway view of the pintle head illustrating the surrounding flow control sleeve in the open position creating a channel for the flow of oxidizer.
[0031] FIG. 8D is an orthographic cutaway view of the pintle head illustrating the surrounding flow control sleeve in the closed position creating a contact seal between the flow control sleeve and the forward face of the pintle head.
[0032] FIG. 9A is an orthographic cutaway view the radial vanes on the outside of the flow control sleeve, an orthographic view of the flow control sleeve, pintle shaft, and their vanes inside a cutaway of the inside of the aft section of the pintle housing, with the outer sleeve created by the pintle body and a cross sectional end view of the internal oxidizer channels created within the assembly.
[0033] FIG. 9B is an orthographic view the radial vanes on the outside of the flow control sleeve, an orthographic view of the flow control sleeve, pintle shaft, and their vanes inside a cutaway of the inside of the aft section of the pintle housing, and a cross sectional end view of the internal oxidizer channels and the fuel channels created within the assembly.
[0034] FIG. 9C is a cross sectional view the radial vanes on the outside of the flow control sleeve, pintle shaft, and their vane enclosed in the aft section of the pintle housing illustrating the end view of the internal oxidizer channels and the fuel channels created within the assembly.
[0035] FIG. 10A is a cross sectional view of the pintle shaft with vanes.
[0036] FIG. 10B is a cross sectional view of the pintle shaft with vanes inside the fuel injector flow control sleeve with vanes.
[0037] FIG. 10C is a cross sectional view of the aft pintle casing with internal vanes.
[0038] FIG. 10D is a cross sectional view of the aft pintle casing with internal vanes surrounding the fuel injector flow control sleeve.
[0039] FIG. 10E is a cross sectional view of the buildup of the alternate assembly of the pintle shaft, the pintle housing without vanes, and the aft section of the pintle housing with vanes providing both fuel and oxidizer channels.
[0040] FIG. 11 is a side cutaway view of the ignitor illustrating a typical ignitor with a single jet of hot gas radiating axially from the tip of the injector tube.
[0041] FIG. 12 is a side cutaway view of the ignitor illustrating the cruciform jets of hot gas radiating from the tip of the injector tube.
[0042] FIG. 13 is a partial cross section example of the one side of the pintle injector showing the central ignitor in the deployed position with the hot gases radiating out from the pintle centerline to intersect and ignite the fuel and oxidizer mixture spraying at an angle from the injector centerline.
[0043] FIG. 14 is an end view of the enhanced ignitor head in the deployed position on the pintle head with a cruciform hot gas ejection.
[0044] FIG. 15 is a cutaway of the upper pintle body with the central ignitor in the retracted position with steady state concentric fuel/oxidizer flow flame front after ignition.
DETAILED DESCRIPTION
[0045] FIG. 4 is an orthographic projection of the exploded view of the main parts of this device. The aft housing of the aft pintle body casing (3), with internal channels for the fuel, holds the sliding injector flow control sleeve (8), seal (13), and spring (10). The forward pintle casing (1) with the protruding pintle head (2) holds the fixed aft outer pintle sleeve (22) and has the internal channels for the hydraulic fluid, and oxidizer. The sliding spark torch ignitor core (4) with seal (13), ignitor tube (16) and spring (12) are inserted into the forward pintle casing. The sliding injector flow control sleeve (8) is free to slide forward and aft on the fixed aft outer pintle sleeve (22) within the aft pintle body casing (3) and is held under spring tension by the aft face of the forward pintle casing (1). The ignitor (4) is free to slide inside the forward pintle casing (1) and is held under spring tension by the forward endcap (5). A set of bolts pass through the endcap, forward injector body, and into aft injector body to secure the assembly into one unit (not shown).
[0046] Each of the five major modules of this device [the aft pintle body casing (3), injector flow control sleeve (8), The forward pintle casing (1), spark torch ignitor (4 and 16), and forward endcap (5)] may be manufactured as single parts using additive manufacturing. This process will require little or no additional machining to include the complex internal channels for hydraulic control fluid, oxidizer, fuel, or cooling.
[0047] FIG. 5 is a lengthwise cross section example of the entire pintle injector with internal ignitor illustrating the legacy features in harmony with the ignitor. The concentric injector flow control sleeve (8), housed in the injector aft pintle casing, is designed to be movable and slide forward and backward on the outer pintle sleeve. When fully forward it contacts both the inner surface of the injector body (10) to stop the flow of fuel and contacts the rear surface of the fixed pintle (9) to stop the flow of oxidizer. When slid backward by the suction of hydraulic fluid, the springs (11) are compressed and the injector sleeve opens both the fuel flow and the oxidizer flow proportional to the desire mix. This provides a useful and consistent way of throttling the injector to maintain nearly constant injection velocities across a wide range of injected propellant mass flow rates.
[0048] As an alternative configuration, the injector flow control sleeve can be redesigned with an additional flange employing the spring on the other side so that hydraulic pressure is used to move the sleeve forward and aft and the injector would instead fail in the open position should a loss of hydraulic pressure occur. Additionally, an electromechanical servo may be used to control the motion of the flow control sleeve as an alternative to hydraulics.
[0049] As an additional feature, to enhance mixing of the oxidizer and fuel spray droplets, the oxidizer is passed through a concentric and symmetric set of spiral vanes (14), which surround and support the inner pintle shaft (21) to impart a rotational angular momentum to the oxidizer spray as it leaves the pintle oxidizer port (9).
[0050] Central and concentric to the inner pintle shaft (21) and injector body core (1 and 3) is the spark torch injector tube (16) and head (4). When the ignitor is extended toward the aft end of the injector (3), the ignitor ports (7) extend past the pintle head (2) and are open to the combustion chamber so that hot gases from the ignitor are projected perpendicularly to the injector axis into the surrounding fuel-oxidizer mix to ignite the mixture. When retracted, the ignitor tip (15) forms a conformal surface with the face pintle head (2) to protect the internal ignitor and pintle parts from the heat of the combustion chamber. The hot gases in the ignitor are produced by the flow of fuel and oxidizer mixing over the surface of a spark plug (6) centered in the end of the ignitor head (4).
[0051] FIG. 6 is a cross section of the upper portion of the legacy pintle module illustrating the concentric injector sleeve (8) in the shutoff position. Fuel flow is stopped when the injector sleeve (8) contacts the injector body (10) and the oxidizer flow is also stopped when the injector sleeve (8) simultaneously also contacts the injector body (9).
[0052] FIG. 7 is a cross section of the upper portion of the legacy pintle module illustrating the concentric injector flow control sleeve (8) is retracted to the fully open position. Fuel flows when the injector flow control sleeve (8) creates a path with the injector body (10) and the oxidizer flows when the injector flow control sleeve (8) simultaneously creates a path with the injector body (9). The curve of the inner pintle shaft (21) and injector flow control sleeve (8) are designed so that the movement of the injector sleeve maintains the required proportional flow of the fuel and the oxidizer. The impinging of the fuel flow and the oxidizer provide a mixed vapor (17) flow of the two components at an angle proportional to the two individual flows. Spiral support vanes (14) are used to add a rotational component to the oxidizer flow having the effect of improving the vapor mixture (17).
[0053] In addition to internal ignitor, the device described in this patent (illustrated in FIGS. 8A-D) will further enhance combustion efficiency while permitting full face shut off. Small vanes (24) in front (23) of the pintle head (2) to separate the exit flow will create separate small jest, or spokes of oxidizer, which will impinge on the exit jets of fuel from similar, harmonized small vanes to the outside side of the flow control sleeve (illustrated in FIGS. 9A-C).
[0054] FIG. 8A illustrates the pintle shaft (21) and the pintle head (2) from conventional pintles of this type. FIG. 8B illustrates the radial vanes (24) added to the pintle shaft arranged in front of the pintle head (2). FIG. 8C illustrates the pintle shaft (21) and vanes (24) inside the flow control sleeve (10), which creates a set of oxidizer ports (25) directing separate jest, or spokes of oxidizer radially out from the pintle centerline. FIG. 8D illustrates the flow control sleeve (10) in the aft or closed position to provide a seal (28) between the forward edge of the control sleeve (10) and the edge of the aft face of the pintle head (2). The vanes are constructed to slide tightly against the inside of the flow control sleeve to provide efficient channels for the flow of oxidizer.
[0055] FIG. 9A illustrates the radial vanes (29) on the outside of the flow control sleeve (10). FIG. 9B illustrates the flow control sleeve (10), pintle shaft (21), and their vanes (24 and 29) inside a cutaway of the inside of the aft section of the pintle housing (30) creating a cylindrical set of fuel jets parallel to the pintle centerline. These fuel jets will impinge on the radial jets of oxidizer leaving the inner oxidizer ports (25). FIG. 9C illustrates the cross sectional end view of the internal oxidizer channels (25) and the fuel channels (27) created within the assembly. Proper alignment of the vanes ensures the effective impingement of the cylindrical fuel jets on the radial oxidizer jets to provide a highly mixed conical jet of both components. As an optional configuration, the fuel flow vanes could be arranged radially on the interior of the injector aft body channel rather than on the fuel control sleeve depending to have the same effect (as illustrated in FIGS. 10A-E). Similarly, the vanes on the flow control sleeve are constructed to slide tightly against the inside of the aft pintle body to provide efficient channels for the flow of fuel.
[0056] To summarize FIG. 9, The flow control sleeve is free to slide forward and aft between the fixed pintle body and the fixed pintle shaft. This arrangement of vanes creates a dual spray pattern of smaller jets to enhance mixing of fuel/oxidizer droplets in the same manner as the slots used in previous designs while preserving the lip behind the pintle head (2) to which the aft edge of control sleeve (10) can still seal (28) against the pintle head (2) when in the closed position (FIG. 8D) to provide full face shutoff.
[0057] FIGS. 10A-D, illustrate an alternative arrangement of the flow control sleeve (10) and aft pintle body (3), where the flow control sleeve is smooth on both sides and the aft pintle body has the coordinated vanes (26). FIG. 10A illustrates the cross section of the pintle shaft and vanes just forward of the pintle head. FIG. 10B illustrates the oxidizer channels created by the pintle shaft and vanes inside the smooth flow control sleeve (10). FIG. 10C illustrates the cross section of the aft pintle body (3) with vanes (26) on the inside surface. FIG. 10D illustrates the cross section of the fuel channels (27) created by the flow control sleeve (10) inside the aft pintle body. FIG. 12E illustrates the cross section of the oxidizer channels (25) and coordinated fuel channels created when all three parts (the pintle aft body, the flow control sleeve, and the pintle shaft) are assembled. The flow control sleeve is free to slide forward and aft between the fixed pintle body and the fixed pintle shaft.
[0058] In addition to the pintle injector improvement, this patent incorporates a retractable coaxial ignitor. For illustration purposes a spark torch igniter is provided. This concept would be applicable to any type of ignitor capable of projecting a spark or jet of gasified propellants through the center of the pintle and into the combustion chamber with enough intensity to ignite the fuel/oxidizer mixture spray. As an example, the typical torch igniter concept starts with an electrical spark from device similar to an automobile spark plug (1) in FIG. 11. Oxidizer and fuel are passed over the spark causing the gasified propellants to ignite (2) and form a flame. That flame (5) is then directed into the combustion chamber through a tube (3) and out an orifice (4) just as the main propellant flow is passing out of the injector. In this way, the spark torch igniter uses the same gaseous propellants of the rocket engine burning cleanly to ignite the fuel mixture and produce limited to no additional particles into the combustion gases.
[0059] In the case of this patent, as illustrated in FIG. 12, the igniter tube has been modified so that the end is blocked and orifices are provided in the side of the tube (4) to provide jets of hot gas ejected out the sides of the tube (5) into the fuel-oxidizer mixture that will be flowing concentrically outside the injector tube.
[0060] This radial spoke ignitor modification would apply to form of ignitor working with similar hot gas jet or spark principles.
[0061] FIG. 13 is a cutaway of the upper portion of the pintle assembly showing the central, enhanced spark torch ignitor (4) in the extended position used to ignite the concentric fuel/oxidizer vapor (17). The fuel and oxidizer impinge on the spark plug (6) to ignite and cause hot gas to flow down the injector tube (16) and flow out (18) of the radial orifices created by the end plug (15) and contact the fuel/oxygen spray (19).
[0062] FIG. 14 is an end view of the enhanced ignitor head (5) in the deployed position on the pintle head (2) with a cruciform hot gas ejection (18). As an alternative, two or more symmetrically ignitor ports spaced around the end of the ignitor tube may be used as necessary to provide equally distributed hot gas jets to ignite the concentric cone of fuel/oxidizer spray ejected by the pintle.
[0063] FIG. 15 is a cutaway of the upper portion of the pintle assembly showing the central ignitor (4) in the retracted position used with steady state concentric fuel/oxidizer flow (7) flame front (20) after ignition. The flange of the spark torch ignitor body rests on the forward endcap (5) attached to forward end of the pintle body and is held there by the springs (12). This version of the design uses the hydraulic suction to pull against the springs to move the ignitor to the deployed position and, should hydraulic pressure be lost, will fail with the ignitor in the fully retracted position.
[0064] As an alternative configuration, the springs (12) could be placed on the forward face of the flange between the forward endcap (5) and the forward face of the flange so that hydraulic pressure is used to move the ignitor forward and aft and the injector would instead fail in the deployed position should a loss of hydraulic pressure occur.
[0065] To further simplify the rocket engine design, instead of employing a separate conventional hydraulic control system with hydraulic oil, high-pressure fuel flow may be used as a control medium for both the injector control sleeve and the ignitor unit.
[0066] Additionally, an electromechanical servo may be used to control the motion of the ignitor as an alternative to hydraulics.
REFERENCE NUMERALS
[0067] 1 forward pintle casing [0068] 2 pintle head [0069] 3 aft pintle casing [0070] 4 spark torch ignitor head [0071] 5 forward pintle endcap [0072] 6 ignitor spark plug [0073] 7 ignitor tube orifice [0074] 8 injector flow control sleeve [0075] 9 oxidizer injection orifice flow control surface [0076] 10 fuel injection orifice flow control point [0077] 11 injector flow control sleeve spring [0078] 12 ignitor spring [0079] 13 ignitor and injector flow control sleeve seals [0080] 14 oxidizer pintle support vane [0081] 15 ignitor tube end cap [0082] 16 ignitor tube [0083] 17 fuel/oxidizer vapor [0084] 18 ignitor hot gas ejection [0085] 19 hot gas fuel/oxidizer ignition intersection [0086] 20 fuel/oxidizer flame front [0087] 21 inner pintle shaft [0088] 22 outer pintle sleeve [0089] 23 forward face of pintle head [0090] 24 pintle shaft oxidizer vanes [0091] 25 oxidizer channel [0092] 26 alternative inner vanes on inside of aft pintle body [0093] 27 fuel channel [0094] 28 contact seal of the aft edge of the flow control sleeve and the forward face of the pintle head [0095] 29 flow control shaft fuel vanes [0096] 30 cutaway of aft pintle body
[0097] Operation
[0098] In operation one uses the pintle injector and spark torch ignitor to start, throttle, and shut down the rocket engine. The user can start and restart the engine by using the hydraulically controlled injector sleeve around the outside of the pintle injector shaft to control the fuel/oxidizer flow in concert with the deployable spark torch ignitor. Throttling and shut down of the rocket engine is performed:
[0099] (1) shut off is achieved when the hydraulically controlled injector sleeve is pushed aft to the closed position where the injector sleeve 8 contacts the injector body 10 and the oxidizer flow is also stopped when the injector sleeve 8 simultaneously contacts the injector body 9,
[0100] (2) fuel/oxidizer flows are proportionally modulated by moving the injector sleeve 8 forward and aft to expand or contract the area between the injector body 10 and when the injector sleeve 8 simultaneously also expands or contracts the flow area around injector body 9.
[0101] Starting the rocket engine with the momentary ignition of the initial fuel/oxidizer flow is performed:
[0102] (1) preparation ignition is achieved by hydraulically deploying the spark torch ignitor assembly toward the aft of the pintle injector so that the ignition injector ports are exposed,
[0103] (2) the spark plug ignites the impinging flow of fuel/oxidizer so that hot gases are injected into the fuel/oxidizer flow coming out of the pintle,
[0104] (3) ignition cycle is completed by shutting down the ignitor fuel/oxidizer flow and the spark torch ignitor assembly is hydraulically retracted.
[0105] Shutoff of the rocket engine is performed by shutting off the pintle fuel/oxidizer flow with the injector sleeve.
[0106] Restart of the engine is performed by reopening the fuel/oxidizer flow using the injector sleeve and repeating the ignition steps above.
