Reusable upper stage rocket with aerospike engine

Patent metadata

Field	Value
Publication number	US-11933249-B2
Application number	US-202217811408-A
Country	US
Kind code	B2
Filing date	Jul 8, 2022
Priority date	Dec 30, 2021
Publication date	Mar 19, 2024
Grant date	Mar 19, 2024

Abstract

Systems and methods for a fully reusable upper stage for a multi-stage launch vehicle are provided. The reusable upper stage uses an aerospike engine for main propulsion and for vertical landing. A heat shield can include a plurality of scarfed nozzles embedded radially around a semi-spherical surface of the heat shield, wherein inboard surfaces of the plurality of scarfed nozzles collectively define an aerospike contour. The heat shield can be actively cooled to dissipate heat encountered during reentry of the upper stage.

First claim

What is claimed is:

1. A reusable upper stage for a multi-stage launch vehicle, the upper stage comprising:
a rocket body extending from a forward end to an aft end and defining a longitudinal axis;
a heat shield at the aft end of the rocket body, the heat shield configured to spherically cap the aft end of the rocket body and dissipate heat encountered upon reentry of the upper stage into the atmosphere, the heat shield comprising:
a plurality of scarfed nozzles arranged radially around the longitudinal axis of the rocket body, wherein at least an inboard portion of each scarfed nozzle defines at least a portion of an aerospike contour; and

an aerospike engine located at the aft end of the rocket body, the aerospike engine comprising:
at least one powerpack configured to pump propellant at high pressure to a plurality of thruster modules,
wherein at least a portion of each thruster module of the plurality of thruster modules is inset into a respective scarfed nozzle of the plurality of scarfed nozzles of the heat shield, the plurality of thruster modules configured to eject exhaust along at least the inboard portions of the scarfed nozzles defining portions of the aerospike contour.

2. The reusable upper stage of claim 1 , further comprising secondary fluid injectors configured to eject fluid that joins with the exhaust ejected by the plurality of thruster modules.

3. The reusable upper stage of claim 2 , wherein the secondary fluid injectors are arranged radially within the heat shield.

4. The reusable upper stage of claim 3 , wherein the plurality of thruster modules are configured to eject exhaust and the secondary fluid injectors are configured to eject fluid to form an exhaust plume that is similar in geometry to the exhaust plume from a full-length plug nozzle.

5. The reusable upper stage of claim 1 , wherein the heat shield is actively cooled.

6. The reusable upper stage of claim 1 , wherein the heat shield comprises a cooling circuit configured to dissipate heat encountered during reentry of the upper stage.

7. A multi-stage launch vehicle having a reusable upper stage, the launch vehicle comprising:
a lower stage configured to launch the vehicle from ground;
an upper stage configured to separate from the lower stage, the upper stage comprising:
a rocket body extending from a forward end to an aft end and defining a longitudinal axis;
a heat shield at the aft end of the rocket body, the heat shield comprising a semi-spherical surface configured to cap the aft end of the rocket body and dissipate heat encountered upon reentry of the upper stage into the atmosphere, the heat shield comprising:
a plurality of scarfed nozzles embedded radially around the semi- spherical surface of the heat shield, wherein inboard surfaces of the plurality of scarfed nozzles collectively define an aerospike contour; and

an aerospike engine located at the aft end of the rocket body, the aerospike engine comprising:
at least one powerpack configured to pump propellant at high pressure to a plurality of thruster modules,
wherein each thruster module of the plurality of thruster modules is inset into a respective scarfed nozzle of the plurality of scarfed nozzles of the heat shield, the plurality of thruster modules configured to eject exhaust along the aerospike contour collectively defined by inboard surfaces of the plurality of scarfed nozzles.

8. The multi-stage launch vehicle of claim 7 , wherein the upper stage further comprises secondary fluid injectors configured to eject fluid that joins with the exhaust ejected by the plurality of thruster modules.

9. The multi-stage launch vehicle of claim 8 , wherein the secondary fluid injectors are arranged radially within the heat shield.

10. The multi-stage launch vehicle of claim 9 , wherein the plurality of thruster modules are configured to eject exhaust and the secondary fluid injectors are configured to eject fluid to form an exhaust plume that is similar in geometry to the exhaust plume from a full-length plug nozzle.

11. The multi-stage launch vehicle of claim 7 , wherein the heat shield is actively cooled.

12. The multi-stage launch vehicle of claim 7 , wherein the heat shield comprises a cooling circuit configured to dissipate heat encountered during reentry of the upper stage.

13. A method of using an upper stage rocket, the method comprising:
launching a multi-stage space vehicle from earth, the space vehicle comprising:
a lower stage configured to lift the space vehicle off ground; and
a reusable upper stage configured to separate from the lower stage and to land vertically, the upper stage comprising:
a rocket body extending from a forward end to an aft end and defining a longitudinal axis;
a heat shield at the aft end of the rocket body, the heat shield comprising a semi-spherical surface configured to cap the aft end of the rocket body and dissipate heat encountered upon reentry of the upper stage into the atmosphere, the heat shield comprising:
a plurality of scarfed nozzles embedded radially around the semi-spherical surface of the heat shield, wherein inboard surfaces of the plurality of scarfed nozzles collectively define an aerospike contour; and

an aerospike engine located at the aft end of the rocket body, the aerospike engine comprising:
at least one powerpack configured to pump propellant at high pressure to a plurality of thruster modules,
wherein each thruster module of the plurality of thruster modules is inset into a respective scarfed nozzle of the plurality of scarfed nozzles of the heat shield, the plurality of thruster modules configured to eject exhaust along the aerospike contour collectively defined by inboard surfaces of the plurality of scarfed nozzles.

14. The method of claim 13 , further comprising:
descending the upper stage in an aft-end down orientation after separation from the lower stage; and
ejecting the exhaust from the plurality of thruster modules to slow descent of the upper stage.

15. The method of claim 14 , further comprising actively cooling the heat shield during descent of the upper stage.

16. The method of claim 14 , further comprising landing the upper stage vertically.

17. The reusable upper stage of claim 1 , wherein the heat shield comprises a semi-spherical surface, and wherein the plurality of scarfed nozzles are embedded radially around the semi-spherical surface of the heat shield.

18. The reusable upper stage of claim 1 , wherein the heat shield comprises a surface configured to cap the aft end of the rocket body, and wherein the plurality of scarfed nozzles are embedded around the surface of the heat shield.

19. The reusable upper stage of claim 18 , wherein inboard surfaces of the plurality of scarfed nozzles collectively define the aerospike contour, and wherein the plurality of thruster modules are configured to eject exhaust along the aerospike contour.

Assignees

• Blue Origin Llc

Inventors

• French James R
• Ramsey Roger Eugene
• Wuerl Adam

Classifications

• F02K9/94

  Re-ignitable or restartable rocket- engine plants; Intermittently operated rocket-engine plants · CPC title

• F02K9/88

  using auxiliary rocket nozzles · CPC title

• B64G1/641

  Interstage or payload connectors (docking systems B64G1/646) · CPC title

• B64G1/62

  Systems for re-entry into the earth's atmosphere; Retarding or landing devices · CPC title

• B64G1/006

  Reusable launch rockets or boosters · CPC title