CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure claims priority to United States Provisional Patent Application No. 61/988,680, filed May 5, 2014.

BACKGROUND

[0002] This disclosure relates to propulsion systems and, more particularly, to a nozzle. Nozzles are used in propulsion systems, such as rocket motors, to provide a flow path for a propellant or propellants. Generally, the propellant expands through the nozzle to provide reaction forces, pressure, or thrust.

SUMMARY

[0003] A fragmenting nozzle system according to an example of the present disclosure includes a first nozzle at least partially disposed within a second nozzle. The first nozzle includes an ablative shell, a syntactic foam support disposed between the ablative shell and the second nozzle, and an ignition system disposed at least partially within the syntactic foam support.

[0004] In a further embodiment of any of the foregoing embodiments, the syntactic foam support includes cyanate ester.

[0005] In a further embodiment of any of the foregoing embodiments, the syntactic foam support includes, by weight, 40% -70% of the cyanate ester.

[0006] In a further embodiment of any of the foregoing embodiments, the syntactic foam support includes, by weight, 10%-40% of microspheres.

[0007] In a further embodiment of any of the foregoing embodiments, the syntactic foam support includes, by weight, 5%-40% of glycidal ether.

[0008] In a further embodiment of any of the foregoing embodiments, the syntactic foam support includes, by weight, up to 15% silica selected from the group consisting of fumed silica, amorphous silica powder, silica glass fibers, and combinations thereof.

[0009] In a further embodiment of any of the foregoing embodiments, the ablative shell includes cyanate ester.

[0010] In a further embodiment of any of the foregoing embodiments, the ablative shell includes, by weight, 30%-65% of the cyanate ester. [0011] In a further embodiment of any of the foregoing embodiments, the ablative shell includes, by weight, up to 35% quartz fiber and by weight, up to 35% of glass selected from the group consisting of chopped glass fiber, milled glass fiber, and combinations thereof.

[0012] In a further embodiment of any of the foregoing embodiments, the ablative shell includes, by weight, up to 65% of silica fabric.

[0013] In a further embodiment of any of the foregoing embodiments, the ablative shell includes, by weight, up to 15% of amorphous silica powder.

[0014] In a further embodiment of any of the foregoing embodiments, the ignition system includes an ignition cord.

[0015] In a further embodiment of any of the foregoing embodiments, the ignition system is operable to generate a controlled-energy deflagration pressure wave that fragments the first nozzle but not the second nozzle.

[0016] A fragmenting nozzle system according to an example of the present disclosure includes inner and outer convergent-divergent nozzles. The inner convergent- divergent nozzle lines an interior of the outer convergent-divergent nozzle and defines an initial nozzle throat geometry. An ignition system is operable to trigger a controlled-energy deflagration pressure wave across the inner and outer convergent-divergent nozzles. The inner convergent-divergent nozzle is formed of a fragmenting material with respect to the deflagration pressure wave and the outer convergent-divergent nozzle is formed of a fragment-resistant material with respect to the deflagration pressure wave such that upon triggering of the deflagration pressure wave, the inner convergent-divergent nozzle fragments and exposes a secondary, different nozzle throat geometry of the outer convergent-divergent nozzle.

[0017] In a further embodiment of any of the foregoing embodiments, the inner convergent-divergent nozzle includes a shell and a foam support. The shell includes a first cyanate ester and the foam support including a second cyanate ester.

[0018] In a further embodiment of any of the foregoing embodiments, the foam support includes, by weight, 40%-70% of the first cyanate ester and the shell includes, by weight, 30%-65% of the second cyanate ester.

[0019] In a further embodiment of any of the foregoing embodiments, the foam support is a syntactic foam and the shell is a non-foam.

[0020] In a further embodiment of any of the foregoing embodiments, the ignition system includes an ignition cord. [0021] In a further embodiment of any of the foregoing embodiments, the inner convergent-divergent nozzle includes at least one groove in which the ignition cord is disposed.

[0022] In a further embodiment of any of the foregoing embodiments, the ignition cord includes one or more annular portions and one or more wave portions.

[0023] A method of operating a fragmenting nozzle system according to an example of the present disclosure includes operating a rocket motor in a first mode by expanding a propellant through an initial nozzle throat geometry of an inner convergent- divergent nozzle. The inner convergent-divergent nozzle lines an interior of an outer convergent-divergent nozzle. The method further includes operating the rocket motor in a second mode by shedding the inner convergent-divergent nozzle to expose a secondary, different nozzle throat geometry of the outer convergent-divergent nozzle. The shedding includes triggering a controlled-energy deflagration pressure wave across the inner and outer convergent-divergent nozzles. The inner convergent-divergent nozzle is formed of a fragmenting material with respect to the deflagration pressure wave and the outer convergent- divergent nozzle is formed of a fragment-resistant material with respect to the deflagration pressure wave. The deflagration pressure wave causes the inner convergent-divergent nozzle to fragment and expose the secondary, different nozzle throat geometry of the outer convergent-divergent nozzle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.

[0025] Figure 1 illustrates an example rocket motor that has a fragmenting nozzle system.

[0026] Figure 2 illustrates a cross-section through a portion of the rocket motor and fragmenting nozzle system of Figure 1.

[0027] Figure 3A illustrates a cross-section through an example first nozzle of a fragmenting nozzle system.

[0028] Figure 3B illustrates an isolated view of an ignition system including an ignition cord.

[0029] Figures 4A, 4B, 4C, and 4D illustrate a serial assembling of the first nozzle of Figure 3A. DETAILED DESCRIPTION

[0030] Figure 1 schematically illustrates a longitudinal cross-section through an example rocket motor 20 that has a fragmentable or fragmenting nozzle system 22. Although not limited, the rocket motor 20 may be a rocket booster that includes a solid fuel gas generator, such as a solid propellant grain 23 contained within the ramjet combustor that produces exhaust gases through the fragmenting nozzle system 22 to provide thrust. The examples herein are not limited to rocket motors and may be implemented in other types of vehicles. As will be described, the fragmenting nozzle system 22 enables dual mode operation using different nozzle throat geometries, as well as the ability to rapidly change from one mode to the other. For example, the modes of operation are different pressure modes for flow through the fragmenting nozzle system 22.

[0031] Figure 2 illustrates an isolated view of a cross-section through a portion of the rocket motor 20 and the fragmenting nozzle system 22. In this example, the fragmenting nozzle system 22 is within a case 24 of the rocket motor 20. The fragmenting nozzle system 22 includes a first (or inner) nozzle 26 and a second (or outer) nozzle 28. Each of the nozzles 26/28 are convergent-divergent nozzles (with regard to left-to-right flow in Figure 2). The first nozzle 26 is located at least partially within the second nozzle 28. In this regard, the first nozzle 26 lines the interior of the second nozzle 28, although the axial lengths of the nozzles 26/28 may differ. The first nozzle 26, the second nozzle 28, or both may be fabricated from two or more arc segments.

[0032] The nozzles 26/28 include, respectively, convergent sections 26a/28a that narrow to respective throat sections 26b/28b that expand to respective divergent sections 26c/28c. As shown, the throat sections 26b/28b have different geometries with regard to at least minimum diametric size. The nozzles 26/28 may alternatively or additionally differ in other flow path geometries, such as the geometries of the throat angles with regard to the slope angles of the convergent sections 26a/28a and divergent sections 26c/28c to a plane that is perpendicular to the central axis A of the nozzles 26/28.

[0033] The first nozzle 26 is a multi-piece structure that includes an ablative shell 30 and a syntactic foam support 32 that is situated between the ablative shell 30 and the second nozzle 28. An ignition system 34 (for controlled, rapid removal or shedding of the first nozzle 26) is situated at least partially within the syntactic foam support 32 in this example. The ablative shell 30 is relatively strong for bearing thermal ablative and structural operational loads during use. The syntactic foam support 32 reinforces the ablative shell 30 but is also lightweight to reduce the overall weight of the fragmenting nozzle system 22.

[0034] The ignition system 34 is operable to trigger a controlled, low-energy pressure wave, to shed the first nozzle 26. For example, the ignition system 34 provides a low energy, deflagration-type, pressure wave. The term "deflagration," or variations thereof, refers to a rapid burn or combustion pressure wave that propagates at sub-sonic speeds. In contrast to deflagration, a "detonation" is a high-energy explosion shock wave that propagates at super-sonic speed. The ignition system 34 and fragmenting nozzle system 22 herein are designed for deflagration-type ignition. Hereafter, the controlled, low-energy pressure wave will thus be referred to as a deflagration pressure wave.

[0035] Both of the nozzles 26/28 are exposed to the deflagration pressure wave. The first nozzle 26 is formed of a fragmentable or fragmenting material with respect to the deflagration pressure wave and the second nozzle 28 is formed of a fragment- or pressure - resistant material with respect to the deflagration pressure wave. A fragmentable or fragmenting material substantially breaks apart into many small pieces or disintegrates to powder from the deflagration pressure wave. A fragment-resistant material does not break apart from the deflagration pressure wave. For example, the second nozzle 28 substantially maintains its geometric profile after the deflagration pressure wave.

[0036] Upon selective triggering of the deflagration pressure wave, the first nozzle 26 rapidly fragments and is shed or expelled from the rocket motor 20. For instance, the first nozzle 26 breaks apart into very small pieces that are no larger than approximately 3.5 inches and some of which are powder-sized; and within a period of less than 5 milliseconds the first nozzle 26 fragments and completely or substantially completely expels from the rocket motor 20. In further examples, the first nozzle 26 breaks apart into pieces that have a maximum dimension that is smaller than the minimum diametric size of the throat section 26b, to ensure that the pieces can be rapidly expelled.

[0037] The shedding of the first nozzle 26 rapidly exposes the different nozzle geometry of the second nozzle 28. Thus, the fragmenting nozzle system 22 can initially be used in a first operation mode, such as for a first operation pressure. The first nozzle 26 can then be removed or shed using the ignition system 34 such that the fragmenting nozzle system 22 can then be used in a second operation mode, such as for a second operation pressure. Moreover, since the fragmenting and expelling of the first nozzle is rapid, an operator can near-instantaneously change from the first mode of operation to the second. [0038] In further examples, the first mode is a rocket boost mode to accelerate the rocket or vehicle, and the second mode is a sustain mode to maintain thrust or speed. The boost mode may utilize the solid propellant grain 23, while the sustain mode may utilize ramjet combustion. For instance, a pyrotechnic ignitor lights the solid propellant grain 23. The grain 23 burns and sends hot gases through the first nozzle 26 to accelerate the rocket to cruise speed. As the grain burns out, the pressure of the hot gases flowing through the first nozzle 26 decreases. The decrease triggers the ignition system 34 to burn rapidly and generate the deflagration pressure wave. The deflagration pressure wave fragments the first nozzle 26 into small pieces, which are rapidly expelled from the back of the fragmenting nozzle system 22 to expose the geometry of the second nozzle 28 and transition into the sustain mode. In the sustain mode the second nozzle 28 serves as a combustion chamber where hot gases produced by a gas generator propellant mix with air from a port cover to generate hot combustion gases through the second nozzle 28. In this regard, the divergent section 28c of the second nozzle 28 serves as a ramjet nozzle.

[0039] In a further example, the ignition system 34 includes one or more one linear ignition cords 34a. As an example, the linear ignition cords 34a can be, but are not limited to, flexible tubes filled with an explosive, such as pentaerythritol tetranitrate (PETN). Such cords 34a can readily be incorporated within the syntactic foam support 32. One non- limiting example cord is ITLX®.

[0040] One or more annular grooves 34b are formed in the outer surface of the first nozzle 26 and the cord or cords 34a are situated in the grooves 34b. Covers 34c can be provided over the cords 34a for retention. For example, the covers 34c are split rings that include two or more arc segments. The cord or cords 34a can be provided at selected axial and radial positions in the syntactic foam support 32, to promote more uniform fragmentation and/or reduce the potential for damage to the second nozzle 28.

[0041] The fragmenting and fragment-resistant materials of the respective nozzles 26/28 are selected with regard to the deflagration pressure wave, operational design loads and the like. For example, phenolic-based materials can be used as the fragment-resistant material. One example phenolic material is silica-filled phenolic. Alternatively, if higher fragment-resistance is needed, other composite, ceramic or metal alloys may be used.

[0042] The fragmenting material or materials can include cyanate ester compositions. The cyanate ester compositions herein are tailored, for example, to provide good strain tolerance and shear strength at elevated temperatures for nozzles but also good fragmentation with respect to the deflagration pressure wave for complete, or near complete, removal and ejection from the rocket motor 20. The properties of the cyanate ester compositions also enable relatively small throat angles of 30° or less, which facilitates compactness of the fragmenting nozzle system 22.

[0043] For example, the syntactic foam support 32 includes a cyanate ester- containing syntactic foam. The cyanate ester-containing syntactic foam can include, by weight, 40 -70 of cyanate ester resin. In a further example, the cyanate ester-containing syntactic foam also includes, by weight, 10%-40% of microspheres. The microspheres can include, but are not limited to, silica glass microspheres, polymer microspheres, ceramic microspheres, or combinations thereof. In a further example, the cyanate ester-containing syntactic foam also includes, by weight, 5 -40 of glycidal ether. The glycidal ether serves as a viscosity modifier and aids in thermal decomposition (e.g., a burn rate modifier). This permits a higher amount of the microspheres to be used, to further decrease weight. In an additional example, the cyanate ester-containing syntactic foam also includes, by weight, up to 15% silica selected from fumed silica, amorphous silica powder, silica glass fibers, and combinations thereof. The fumed silica and/or silica powder can be added as a viscosity modifier. The silica glass fibers can be added to enhance strength.

[0044] In an additional example, the cyanate ester-containing syntactic foam includes, by weight, 40%-70% of cyanate ester resin, such as Primaset™ BA-200 by Lonza, up to 2% 2-ethyl 4-ethyl imidazole catalyst, 5%-40% of butyl glycidyl ether, cresyl glycidyl ether, neopentyl glycol diglycidyl ether, 1 ,4-butanediol diglycidyl ether, castor oil poly glycidyl ether, or combinations thereof, up to 5% of fumed silica, up to 5% amorphous silica powder, up to 5% milled fiberglass, and 10%-40% of silica glass microspheres, such as those under the trade names S-60, S-32, or K-15 by 3M™.

[0045] The cyanate ester-containing syntactic foam can be fabricated by mixing together the composition constituents. The mixture is poured into mold and cured to form the desired geometry of the syntactic foam support 32. Post-cure processes may also be used to modify the properties.

[0046] The ablative shell 30 can be fabricated of a non-foam, cyanate ester- containing material. In a further example, the cyanate ester-containing material includes, by weight, 30%-65% of cyanate ester resin. In a further example the cyanate ester-containing material also includes, by weight, up to 35% of chopped quartz fiber, and by weight, up to 35% of glass selected from chopped glass fiber, milled glass fiber, and combinations thereof. In a further example, the cyanate ester-containing material also includes, by weight, up to 15% of amorphous silica powder. In a further example, the cyanate ester-containing material also includes, by weight, up to 65% of silica fabric.

[0047] In an additional example, the cyanate ester-containing material includes, by weight, 30%-65% of cyanate ester resin, such as Primaset™ PT-30 by Lonza, up to 2% of 2-ethyl 4-ethyl imidazole catalyst, and up to 35% quartz chopped fiber, and up to 35% chopped or milled glass fiber and up to 15% of amorphous silica powder. The fibers provide reinforcement that permits the strength to be tailored. Rather than the quartz chopped fiber and chopped or milled glass fiber, the cyanate ester-containing composition can include up to 65% of silica fabric and up to 15% of amorphous silica powder. The silica fabric provides a better distribution of reinforcement to potentially enhance resin wetting and erosion resistance compared to chopper or milled fibers, which may be difficult to evenly disperse in the resin. The powder is a flow modifier that facilitates the reduction of viscosity.

[0048] In further examples, the cyanate ester-containing material of the ablative shell 30 may be provided as a molding compound that has all the compositional constituents expect the silica fabric, which produces a macerated fiber molding compound. Alternatively, the molding compound has all the compositional constituents except for the quartz and glass fiber, which produces a pre-preg broadgood that can be cut into desired geometries. The molding compound can be compression molded and cured in the desired geometry of the ablative shell 30. Post cure processes may also be used to modify the properties.

[0049] Figure 3 A illustrates another example of a first nozzle 126. In this disclosure, like reference numerals designate like elements where appropriate and reference numerals with the addition of one-hundred or multiples thereof designate modified elements that are understood to incorporate the same features and benefits of the corresponding elements. In this example, the first nozzle 126 includes the ablative shell 30, syntactic foam support 132, and ignition system 134. The syntactic foam support 132 is a multi-piece structure, and each piece can itself include multiple sub-pieces and/or arc-segments to facilitate assembly.

[0050] The multiple pieces of the syntactic foam support 132 include an inner shell 132a, an inner cap 132b, outer foam caps 132c/132d, and a foam junction box 132e. The inner shell 132a and inner cap 132b include, respectively, grooves 134bi/134b ₂ for receiving the ignition system 134. The multi-piece construction permits integration of the ignition system 134 into the syntactic foam support 132 at desired axial and radial locations, to promote more uniform fragmentation and/or reduce the potential for damage to the second nozzle 28. [0051] In this example, the ignition system 134 includes an ignition cord 134a, which is shown in isolated view in Figure 3B. The ignition cord 134a is shaped to promote more uniform fragmenting. The ignition cord 134a spans between terminal ends E1/E2 and includes annular portions 134ai/134a ₂ and wave portions 134a ₃ /134a ₄ . The annular portions 134ai/134a ₂ include, respectively, the terminal ends E1/E2 and extend approximately 360°. The wave portions 134a ₃ /134a ₄ are located serially along the ignition cord 134a between the annular portions 134ai/134a ₂ . The wave portion 134a ₃ is radially outwards of wave portion 134a ₄ . In this example, each of the wave portions 134a ₃ /134a ₄ extends in a three-dimensional pattern, i.e., circumferentially, axially, and radially.

[0052] Figures 4A, 4B, 4C, and 4D illustrate the serial assembling of the first nozzle 126. In Figure 4A the ignition cord 134a is assembled into the groove 134bi of the inner shell 132a. In Figure 4B the inner cap 132b is assembled such that the wave portion 134a ₃ of the ignition cord 134a is received in the groove 134b ₂ . In Figure 4C, the foam junction box 132e is assembled around the terminal ends E1/E2, and in Figure 4D the outer foam caps 132c/132d are assembled to cover the exposed ignition cord 134a. The first nozzle 126 is thus easily assembled and the ignition system 134 provides more uniform fragmenting.

[0053] Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.

[0054] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.