US008047472B1
`
`(12) United States Patent
`Brand et al.
`
`(10) Patent N0.2
`(45) Date of Patent:
`
`US 8,047,472 B1
`Nov. 1, 2011
`
`(54) RAM BOOSTER
`
`(56)
`
`References Cited
`
`(75) Inventors: Vance D. Brand, Tehachapi, CA (US);
`Walter Ray Morgan: Slml Valley: CA
`
`US, PATENT DOCUMENTS
`3,063,240 A * 11/1962 Ledwith ,,,,,,,,,,,,,,,,,,, “ 60/225
`
`(Us)
`
`_
`
`(73) Ass1gnee: The United States ofAmerica as
`represented by the Administrator of
`
`‘he Natmnaléemmti“ and SP“
`Admlnlstratlons Washlngtons DC (Us)
`
`(
`
`) Not1ce.
`
`Subject to any d1scla1mer, the term of th1s
`patent is extended or adjusted under 35
`U'S'C' 1546)) by 612 days'
`
`(21) Appl_ No‘: 12/045’970
`
`(22) Filed:
`
`Mar. 11, 2008
`
`Related US. Application Data
`(63) Continuation-in-part of application No. 11/422,554,
`?led on Jun. 6, 2006, noW abandoned.
`
`(51) Int- Cl-
`(200601)
`364G 1/00
`(52) U-s- Cl- ~~~~~~~~~~~~~ ~~ 244/158-9; 244/158~1; 244/171-1;
`244/1713
`(58) Field of Classi?cation Search ............. .. 244/ 158.1,
`244/158.9,159.1,159.3,171.1,171.3,171.4
`See application ?le for complete search history.
`
`3,066,480 A * 12/1962 Buck . . . . . . .
`
`. . . .. 60/266
`
`3,215,372 A * 11/1965 Price . . . . . . . . . . . . . .
`
`5,593,110 A *
`5,740,985 A :
`
`1/1997 Ransom et a1.
`4/1998 Scott et a1. . . . . . . . . .
`
`. . . .. 244/74
`
`.. 244/323
`. . . . . .. 244/2
`
`iii/i332
`2213435 31* 3/588? 215331621625‘ .......
`636163092 B1 *
`9/2003 Barnes et a1, ,,,,,,,,,,,,,,,,,,, ,, 244/2
`6,817,580 B2 11/2004 Smith
`* Cited by examiner
`
`Primary Examiner * Joshua Michener
`
`Assistant Examiner * Philip J BonZell
`(74) Attorney, Agent, or Firm * Mark Homer
`
`ABSTRACT
`(57)
`The present invention is a space launch system and method to
`propel a payload bearing craft into earth orbit. The invention
`has tWo, or preferably, three stages. The upper stage has
`rocket engines capable of carrying a payload to orbit and
`provides the capability of releasably attaching to the loWer, or
`preferably, middle stage. Similar to the loWer stage, the
`middle stage is a reusable booster stage that employs all air
`breathing engines, is recoverable, and can be turned-around
`in a short time between missions,
`
`7 Claims, 6 Drawing Sheets
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`Space Exploration Technologies; NEW PETITION
`Exhibit 1010
`Page 1 of 13
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`Nov. 1, 2011
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`Sheet 1 of6
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`US 8,047,472 B1
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`Space Exploration Technologies; NEW PETITION
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`Space Exploration Technologies; NEW PETITION
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`Page 3 of 13
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`US. Patent
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`Nov. 1, 2011
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`Sheet 3 of6
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`US 8,047,472 B1
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`FIGURE 3
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`Space Exploration Technologies; NEW PETITION
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`US. Patent
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`Nov. 1, 2011
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`Space Exploration Technologies; NEW PETITION
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`Page 5 of 13
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`US. Patent
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`Nov. 1, 2011
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`Sheet 5 of6
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`US 8,047,472 B1
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`Fmune 4d
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`Space Exploration Technologies; NEW PETITION
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`Page 6 of 13
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`US. Patent
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`Nov. 1, 2011
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`Sheet 6 0f 6
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`US 8,047,472 B1
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`Space Exploration Technologies; NEW PETITION
`Exhibit 1010
`Page 7 of 13
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`US 8,047,472 B1
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`1
`RAM BOOSTER
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`RELATION TO OTHER APPLICATIONS
`
`This application is a continuation-in-part to application
`Ser. No. 11/422,554, ?led on Jun. 6, 2006 noW abandoned and
`applicants hereby request this priority date for all subject
`matter contained herein from said previously ?led applica
`tion.
`
`STATEMENT OF GOVERNMENT INTEREST
`
`The invention described herein may be manufactured and
`used by or for the Government of the United States of
`America for governmental purposes Without payment of any
`royalties thereon or therefor.
`
`BACKGROUND OF THE INVENTION
`
`1. Field of the Invention
`The present invention relates generally to propelling a pay
`load into loW-earth orbit, more particularly to providing a
`booster ?rst stage for a payload bearing rocket second stage
`going to loW-earth orbit, and most particularly to providing a
`reusable, all air-breathing booster ?rst stage for a payload
`bearing rocket second stage going to loW-earth orbit.
`2. Description of The Related Art
`Most reusable space launch systems to date have employed
`tWo approaches: 1) Single stage to orbit (DCX or National
`Aero-Space Plane), or 2) Recoverable upper stage (Space
`Shuttle). Problems With the ?rst approach include the require
`ment for extremely high fuel mass fractions (>90% of gross
`liftoff Weight “GLOW”), plus the need to put all of the vehicle
`structural mass into orbit With a very small payload mass
`fraction (typically <1 % of GLOW). Problems associated With
`the second approach include expending or requiring refur
`bishment of a larger structural mass (external tanks expended
`and solid rocket boosters refurbished in the case of the
`shuttle). A heat resistant surface is required for the upper
`stage and there is still a need to place into orbit more than four
`times the actual payload mass. The recovered upper stage
`portion of the launch system must be designed for re-entry
`speeds up to Mach 25 and extreme heating. Also, as evi
`denced by the space shuttle, the high-speed re-entry tends to
`require extensive inspection and maintenance during tum
`around for subsequent launches.
`A third approach has also been suggested that employs a
`staged rocket system launched from a Winged platform (e.g.,
`Pegasus XL, launched from an L-1011 aircraft). While
`achieving reasonable payload mass fractions (relative to the
`expendable rocket launcher portion), because of physical siZ
`ing constraints, this concept currently is limited to about 1000
`lbs of payload to orbit, and a fairly high speci?c launch cost
`(YB/1b,").
`In a further effort to overcome some of these de?ciencies,
`another approach is a reusable booster stage using a combi
`nation of a rocket propelled main stage and a pair of turbojet
`engines mounted on the main stage (US. Pat. No. 6,817,580).
`HoWever, this concept still results in numerous de?ciencies
`including requirement for a plurality of different propellants,
`loW useable life for the main rocket stage, requirement for
`reaction control devices for the main stage, and increased
`turn-around time for reuse due to the rocket engine main
`stage.
`Therefore, it is desired to provide a reusable launch system
`that has a relatively loW launch cost, decreased tum-around
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`time betWeen launches, and improved ef?ciency and safety
`characteristics over current reusable launch systems.
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`SUMMARY OF THE INVENTION
`
`The invention proposed herein comprises a space launch
`system and method to propel a payload into earth orbit. The
`upper stage is a production, expendable rocket designed to
`carry a payload. The loWer stage is a booster that is reusable
`and poWered completely by air breathing propulsion. Prefer
`ably, the invention includes a middle stage that is also reus
`able and is also poWered completely by air breathing propul
`sion. A main objective of the system and method is to
`signi?cantly reduce the costs of propelling payloads, such as
`satellites, etc., into loW-earth orbit by employing a system that
`provides a reusable booster ?rst stage With signi?cantly
`increased user life and signi?cantly decreased turn-around
`time and maintenance compared to current systems.
`Accordingly, it is an objective of this invention to provide
`a space launch system that reduces turn-around time com
`pared to current systems betWeen launches.
`It is another objective to provide a space launch system of
`signi?cantly reduced cost to propel a payload into earth orbit
`compared to current systems.
`It is also an objective of this invention to provide loWer and
`middle stages that employ a single type of fuel using air
`breathing engines With a high speci?c impulse.
`It is a further objective of this invention to provide loWer
`and middle stages that do not require a reaction control sys
`tem.
`This invention meets these and other objectives related to
`propelling payloads into loW earth orbit by providing a reus
`able space launch system booster loWer stage and, preferably,
`middle stage, to help propel a payload bearing rocket upper
`stage into orbit around the earth. The loWer or ?rst stage
`comprises a cylindrical housing, having a fuel tank contain
`ing fuel Within the housing, that is releasably attached to the
`stage above it. A drogue parachute and a plurality of main
`parachutes are stored in and releasably attached to the hous
`ing. A plurality of ?ns are attached to the outer surface of the
`housing to provide aerodynamic stability and control. Also, a
`plurality of landing struts are attached to the ?ns for landing
`the reusable booster after each use. A plurality of air breathing
`engines are attached to the ?ns and struts, radiating outWards
`from the housing. A portion of these engines, located out
`board of the other engines, employ a system for de?ecting the
`exhausts in tangential directions relative to the circumference
`of the center tank, alloWing directional and roll control at loW
`speeds just after liftoff, and during recovery. The air breathing
`engines are provided fuel through a connection With the fuel
`tank in the housing. A preferable middle or second stage
`comprises a cylindrical housing, having a fuel tank contain
`ing fuel Within the housing, that is releasably attached to the
`loWer and upper stages. A plurality of ?ns are also attached to
`the outer surface of the housing to provide aerodynamic sta
`bility and control. The middle stage also has a drogue para
`chute and a plurality of main parachutes stored therein and
`either a plurality of air breathing engines attached circumfer
`entially around the housing or an annular air breathing engine
`surrounding the housing.
`
`Space Exploration Technologies; NEW PETITION
`Exhibit 1010
`Page 8 of 13
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`US 8,047,472 B1
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`3
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`In the drawings, Which are not necessarily to scale, like or
`corresponding parts are denoted by like or corresponding
`reference numerals.
`FIG. 1 depicts a side vieW of an embodiment of the present
`invention.
`FIG. 2 depicts a top vieW of a cut-aWay of the middle and
`loWer stage shoWn in FIG. 1.
`FIG. 3 depicts a side vieW of the upper stage of the launch
`system shoWn in FIG. 1.
`FIG. 4a depicts a cut aWay vieW of the aft end of the
`cylindrical housing on the loWer stage of the launch system
`shoWn in FIG. 1.
`FIG. 4b depicts a side cut aWay vieW of the aft end of the
`cylindrical housing on the loWer stage of the launch system
`shoWn in FIG. 1.
`FIG. 40 depicts a vieW of the drogue parachutes being
`released and the pilot parachutes deployed.
`FIG. 4d depicts a vieW of the main parachutes deployed.
`FIG. 5 depicts the launch and recovery sequence employ
`ing the system.
`
`DESCRIPTION OF PREFERRED
`EMBODIMENTS
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`The air breathing engines 116 should be con?gured so that
`propulsion, When all of the engines are actuated, is someWhat
`evenly distributed around the system 10. Those engines 116
`located furthest outboard from the system centerline also
`possess means for de?ecting the exhaust in tWo dimensions,
`such that directional and roll control of the system can be
`maintained, in loW speed ?ight for launch and recovery of the
`loWer stage 106.
`Preferably, the invention also comprises a middle stage 130
`that is releasably connected to the upper stage 100 via the
`mating ring 104 and is releasably connected to the loWer stage
`106 via a second mating ring 105. A second release mecha
`nism 109 is employed to disable the second mating ring 105
`to stage or disconnect the middle stage 130 from the loWer
`stage 106. Preferably the second release mechanism 109 also
`comprises a pyrotechnic device that is actuated via computer
`control. The middle stage 130 comprises a housing 132 that is
`also preferably cylindrical in shape, and, most preferably,
`similar in shape to the loWer stage housing 110. A plurality of
`?ns, preferably With moveable tips, 112 are attached to the
`housing 132 to provide aerodynamic control and stability to
`the launch system 10. A plurality of air breathing engines 117
`are connected around the middle stage housing 132 so that
`propulsion, When all of the engines are actuated, is someWhat
`evenly distributed around the system 10. In the alternative, a
`single annular air breathing engine 117 surrounds the housing
`132. These airbreathing engines 116 Will preferably be Ram
`jets, With feW moving internal parts and capable of operation
`betWeen speeds of Mach 2.0 and Mach 4.0 or even higher.
`Referring to FIGS. 1, 2, and 4a-4d, the invention also
`comprises fuel tanks 400 Within the housings 110 and 132 that
`carry fuel for the engines 116, 117. Therefore, the fuel tanks
`400 are connected to the engines 116, 117 in a manner to
`alloW fuel from the fuel tanks 400 to How into the engines 116,
`117. The siZing and operation of the fuel tanks 400 may be
`selected by one skilled in the art, based upon the siZe of the
`housing, the Weight of the tanks 400 and fuel and other launch
`requirements.
`The loWer and middle stages 106, 130 contain a descent
`mechanism 401 to sloW the descent of each stage 106, 130 so
`that they can be recovered for later use. Preferably, the
`descent mechanism 401 includes at least one supersonic
`drogue parachute 402 (or alternatively ballute) that is releas
`ably attached Within the housings 110, 132. The number and
`siZe of drogue parachutes 402 employed in the invention may
`be selected by one skilled in the art based upon the Weight of
`the loWer and middle stages 106, 130. A pair of ?rst deploy
`ment mechanisms (preferably explosive mortars) 404 are
`used to deploy the drogue parachutes 402. The ?rst deploy
`ment mortars 404 are preferably located inside the drogue
`parachute cavity Within housings 110, 132. The aft cover 401
`is detached from the housings 110, 132 When the ?rst deploy
`ment mechanism 404 is initiated to alloW the drogue para
`chutes 402 to be deployed. The ?rst attachment/release
`mechanism 406 may be selected by one skilled in the art. One
`preferred example of an attachment/release mechanism is an
`electrically actuated initiator that contains an explosive
`charge driven guillotine for cutting parachute risers to release
`a drogue chute 402. The ?rst attachment/release mechanism
`406 alloWs for the drogue parachutes 402 to be jettisoned after
`use. The drogue parachutes 402 are used for initial reduction
`in the descent speed of the loWer and middle stages 106, 130
`as described further beloW.
`Regarding the preferable loWer stage 106 descent mecha
`nism, a plurality of main parachutes 408 are releasably
`attached to the aft end of the housing 110. In a preferred
`embodiment, four main parachutes 408 are used in the inven
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`The present invention is a space launch system and method
`to propel a payload bearing craft into earth orbit. The inven
`tion comprises tWo or three stages. The upper stage primarily
`includes rocket engines, propellant tanks, and a payload vol
`ume and the upper stage provides the capability of releasably
`attaching to a loWer or middle stage. The loWer stage is a
`reusable booster stage that employs all air breathing engines,
`is recoverable, and can be tumed-around in a short time
`betWeen missions. Preferably, a middle stage is employed
`that is a reusable booster stage that also employs all air breath
`ing engines that is also recoverable and can be turned around
`in a short time betWeen missions. The invention is capable of
`being practiced using a majority of parts that are currently
`available “off the shelf’ With minor modi?cations and these
`parts require signi?cantly less maintenance and preparation
`betWeen missions than current launch system par‘ts/ systems.
`This results in the ability to dramatically increase the number
`of missions over time and signi?cantly reduce the cost per
`mission.
`Referring to FIG. 1, the invention is a launch system 10
`comprising an upper stage 100 of a production rocket engine
`that is capable of carrying a payload. A mating, ring 104
`attaches releasably to the bottom of the upper stage 100. A
`?rst release mechanism 108 is employed to disconnect the
`50
`upper stage 100 from the loWer stage 106 or, preferably, the
`middle stage 130. Preferably the ?rst release mechanism 108
`comprises a pyrotechnic device that is actuated via computer
`control.
`The loWer stage 106 is a booster stage that launches and
`propels the system to a selected point in the atmosphere prior
`to ignition of the upper stage 100. The loWer stage 106 com
`prises a housing 110 that is preferably cylindrical in shape. A
`plurality of ?ns, preferably With moveable tips, 112 are
`attached to the housing 110 to provide aerodynamic stability
`and control to the launch system 10. A plurality of landing
`struts 114 are attached to the ?ns 112 to provide landing
`support to the loWer stage. Preferably, the landing struts
`employ shock attenuation and have landing pads 120 at the
`end of each strut 114.Also, a plurality of air breathing engines
`116 are connected to the ?ns 112, in a con?guration radiating
`outWards from the housing 110 and parallel to its center axis.
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`Space Exploration Technologies; NEW PETITION
`Exhibit 1010
`Page 9 of 13
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`US 8,047,472 B1
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`tion. A second deployment mechanism 410, preferably an
`electrically initiated pilot chute mortar, is used to deploy a
`pilot chute 405 that pulls a main parachute pack 407 from
`Within the housing 110. Each main parachute pack 407
`deploys into a main parachutes 408. Finally, a second attach
`ment/release mechanism 412, preferably similar to the ?rst
`attachment/release mechanism, is used to jettison the main
`parachutes 408.
`During descent, the deceleration and pitch rotation of the
`loWer stage 106 occurs as folloWs. The drogue parachutes 402
`are jettisoned and the main parachutes 408 opened at about
`15,000 feet altitude. At about 7,500 feet altitude, the loWer
`stage 106 is released from the deployed four main parachutes
`408. At the instant of release, a portion of the air breathing
`engines 116 are at idle thrust and a portion of the air breathing
`engines 1 1 6 have accelerated to partial thrust. The rotation for
`pitch-up is accomplished by thrust vector control of the out
`board turbofan engines 116, that have been accelerated to
`partial thrust, Which have exhaust vanes to de?ect the ?oW of
`exhaust gases. In addition to the thrust vector control of the
`loWer stage 106, the deceleration and pitch is augmented by
`aerodynamic control consisting of four all-movable surfaces
`on the tips of the ?ns 118. The number and location of air
`breathing engines 116 at idle thrust and at partial thrust may
`be determined by one skilled in the art. Preferably, tWelve air
`breathing engines 116 remain at idle thrust and six air breath
`ing engines 116 accelerate to partial thrust.
`At approximately 7,500 feet the pitch-up maneuver starts
`immediately after the main parachute strap 416 is pyrotech
`nically separated from its attach point at the aft end of housing
`1 1 0. A rapid pitch-up maneuver is instigated by cooperatively
`de?ecting the exhaust of the outboard fanj et engines 116 and
`simultaneously de?ecting the all-moving control surfaces
`comprising the outer tips of the ?ns 118.
`After the loWer stage 106 has pitched-up through an angle
`of more than 160 degrees to a tail doWn attitude, all of the air
`breathing engines 116 are accelerated to operating thrust
`(Without afterburner) for a controlled vertical descent to
`touchdoWn. The loWer stage 106 descends to touchdoWn on a
`barge in the ocean, or if su?icient fuel is allotted, returns to the
`launch site for touchdoWn. The drogue and main parachutes
`402, 408 all independently ?oat to earth for recovery and
`re-use.
`In a preferred embodiment of the invention, the descent
`mechanism for the middle stage 130 is similar to that of the
`loWer stage 106, except that the four main parachutes remain
`attached through splashdoWn and landing struts are not
`included in the middle stage 13 0. The pitch rotation maneuver
`folloWing jettison of the main parachutes 408 is not required
`for the middle stage 130 because it splashes nose-doWn into
`the ocean With main parachutes 408 still attached. Middle
`stage drogue parachute cables and main parachute risers all
`attach to the aft end of the middle stage 130. All electronic
`boxes and electrical harnesses in the middle stage 130 are
`encased and Water-proofed for, protection from salt Water
`during and folloWing splashdoWn. The Ramjet engine(s) 116
`used on the middle stage 130 are relatively impervious to the
`effects of Water, With almost no moving parts. The fuel tanks
`Will be sealed off and slightly pressurized With inert gas after
`the ramjet engines shut doWn, such that they also are not
`damaged by exposure to seaWater, and also provide buoyancy
`to keep this stage a?oat until recovered.
`For the loWer and middle stages 106, 130, an onboard
`computer 414 Within the housing 110, 132 autonomously
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`controls guidance, navigation, and ?ight control, and onboard
`systems sequencing from pre-launch until after touchdoWn of
`the reusable portion of the system 10. In a preferred embodi
`ment of the invention, selected system controls may be
`backed up by remote manual command up-linked from the
`launch site. The speci?c control mechanisms and schemes
`may be selected by one skilled in the art employing currently
`used launch systems, and devices.
`Referring to FIG. 3, the upper stage 100 utiliZes a produc
`tion rocket engine, capable of propelling a payload, that pref
`erably employs cryogenic fuels for propulsion such as liquid
`hydrogen and liquid oxygen. A preferred second stage is the
`Centaur III Which is poWered by tWo rocket engines that
`provide 22,300 pounds of thrust each. Each of the tWo engines
`has a vacuum speci?c impulse of 451. In a prefened embodi
`ment, the upper stage 100 Will include a modi?ed payload
`fairing 300, Which is an adapter, to adjust the siZe of the
`payload compartment to carry a Weight of payload mass and
`volume that matches the thrust and propulsion capabilities of
`the launch system 10. Propellants employed in the upper
`stage are preferably cryogenic hydrogen and oxygen.
`Referring to FIGS. 1 and 2, in a preferred embodiment of
`the invention, there are three ?ns 112, evenly distributed
`around the housing 110. Preferably, each ?n 112 has a move
`able tip 118 that provides for aerodynamic control at higher
`speeds.
`The plurality of air breathing engines 116 preferably com
`prise turbofan engines 200. In a preferred embodiment, the
`turbofan engines 200 are con?gured in a star con?guration
`(Which, for the purposes of this application, is de?ned as the
`engines are positioned along each side of the ?ns 112, radi
`ating outWards from the housing 110). Preferably, there are
`three turbofan engines 200 positioned on each side of each ?n
`112, each turbofan engine 200 being parallel to the one on the
`opposite side of each ?n 112. In this con?guration, using
`current turbofan technology, there are preferably a total of l 8
`turbofan engines attached to the loWer stage 106. HoWever, in
`the event that turbofan technology improves, the number of
`turbofan engines 200 attached to the loWer stage 106 may be
`decreased. The turbofan engines 200 normally Will employ
`jet fuel, preferably JP-lO, for operation.
`The turbofan engines 200 preferably have the characteris
`tics of the F-l00-229 production engines, each With a ?xed,
`customiZed inlet. Such engines have a maximum installed net
`thrust of 35,000 pounds in afterbumer at sea level at Mach 1.
`In a preferred embodiment, vectored thrust vanes 120 are
`placed in the exhaust of the six outermost turbofan engines
`200. The vectored thrust vanes 120 are used for ?ight control
`of roll, pitch, and yaW from liftoff to about Mach 2.6. The
`turbofan inlets should be shaped and optimiZed for loW drag,
`thrust e?iciency, and capability to prevent engine stall in the
`rotation maneuver described beloW, before landing. The siZe
`and performance of the turbofan engines 200 may be selected
`by one skilled in the art dependent upon the performance
`characteristics of the middle and upper stages/payload 100,
`130 and the mass of the loWer stage 106.
`In one embodiment of the invention, the plurality of air
`breathing engines 116 may employ the turbofan engines 200
`described above in a star shaped pattern along the ?ns 1 12 and
`also a plurality of ramjet engines 202 placed circumferen
`tially along the cylinder portion of the housing 110. In this
`con?guration, a preferred number of ramjet engines are posi
`tioned equally around the periphery of the cylinder portion of
`the housing 110. Preferably, the ramj et engines 202 can be a
`single annular engine encircling the cylinder portion of the
`housing 110.
`
`Space Exploration Technologies; NEW PETITION
`Exhibit 1010
`Page 10 of 13
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`US 8,047,472 B1
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`7
`In a preferred embodiment, rather than placing the ramjet
`engines 202 on the loWer stage 106, the ramjet engines 202
`Will be placed on a middle stage 130. The ramjet system may
`be a plurality of ramj et engines positioned around the cylinder
`portion of the housing 132 at equal intervals or may be a
`single annular ramj et engine 202 placed along the cylinder of
`the housing 132. In this con?guration, the ramjet engines 202
`operate from about Mach 2 to Mach 4. The ramj et engines 202
`Would be operating in parallel With the turbofan engines 200
`attached to the loWer stage 106 from about Mach 2 to Mach
`2.6. After the speed of the launch system reaches the Mach
`limit for the turbofan engines 116 on the loWer stage 106
`(assumed to be Mach 2.6), the loWer stage 106 is separated
`from the middle stage 130 and the engines 116 are reduced to
`idle for descent under a parachute to a loWer altitude.
`The ramj et engines 202 may be designed using engine
`manufacturer’s analytical models representing current tech
`nology and preferably have ?xed geometry inlets and may
`have moveable inlet covers. Therefore, While these are pref
`erably custom engines, they employ current techniques for
`siZing and manufacture, preferably, making use of ceramics
`and composite materials to reduce the Weight of the ramj ets
`202 to about half that for similar thrust engines Which may
`have been designed in the 1970 and 1980 time frame. Prefer
`ably, the ramjet engines 202 also burn JP-lO fuel.
`Referring to FIG. 5, the invention also includes a mobile
`launch gantry 500 that alloWs the system 10 to be launched in
`any area containing a concrete pad or similar base. Preferably
`the gantry 500 has tilt up capability to position the system for
`launch and alloWs fueling lines for the upper, middle, and
`loWer stages 100, 130, 106 to run through the gantry 500 from
`mobile support vehicles (not depicted), including fuel trucks,
`that may surround the gantry 500. The gantry 500 provides
`ground poWer for fueling, systems check, and the payload
`until about three minutes from launch of the system 10. The
`gantry 500 may also include feed tanks to replenish cryogenic
`fuels in the upper stage 100 until right before launch of the
`system.
`The invention also includes a method of launching and
`propelling a rocket bearing payload into earth orbit that is
`depicted in FIG. 5 and described more fully beloW.
`In general, the method includes using the system described
`herein by using the turbofan engines attached to the loWer
`stage and ramjet engines attached to the middle stage in series
`to launch and propel the rocket until a predetermined speed
`and/ or altitude is reached (this speed/altitude may be
`selected/calculated by one skilled in the art based upon sys
`tem performance and Weight). First, the turbofan engines are
`reduced to idle after the ramjet engines have stabiliZed at
`operating thrust in the supersonic regime. The loWer and
`middle stages are separated and after the maximum Mach
`Number is reached using the ramjet engines of the middle
`stage, the middle and upper stages are separated. The rocket
`propelled upper stage is then ignited and propelled into earth
`orbit. The loWer stage is then recovered by using the drogue
`and main parachutes to sloW its descent, releasing the main
`parachutes, then pitching, around and controlling the thrust of
`the turbofan engines to enable a vertical descent and touch
`doWn. The middle stage is recovered after a Water splashdoWn
`aided by the drogue and main parachutes to sloW its descent.
`More particularly, the steps of employing the system are as
`folloWs:
`1. Hours before the launch, the mobile launch gantry is tilted
`up and the fueling lines are connected through the gantry to
`the system to fuel the system.
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`8
`2. The bulk of Cryogenic upper stage fueling is completed
`about tWenty minutes before launch, but top-off continues, up
`until the gantry is moved aWay from the system (launch
`vehicle) a feW minutes prior to launch.
`3. The turbofan engines are started and run at idle about ten
`minutes prior to launch.
`4. Cryogenic propellant top-off is terminated and the gantry is
`moved aWay from the system about three minutes prior to
`launch.
`5. The turbofan engines are ?red at full afterburner thrust
`about ten seconds before liftoff.
`6. Liftoff occurs at the programmed launch time assuming all
`systems are operating correctly.
`7. The system reduces its pitch angle With respect to the
`horiZon after liftoff, thereafter folloWing the appropriate
`launch trajectory.
`8. The ramj ets are started about one minute after liftoff, after
`reaching minimum ignition Mach Number (estimated at
`Mach 2.0).
`9. The turbofan engines are shut doWn When the turbofan
`engine limit Mach Number limit is reached (estimated at
`Mach 2.6).
`10. The loWer and middle stages are disconnected by means
`of pyrotechnic devices and the drogue parachutes are
`deployed from the loWer stage.
`11. The ramjet engines are shut doWn When the staging con
`ditions (altitude and Mach Number) are reached.
`12. The middle and upper stages are disconnected by means
`of pyrotechnic devices.
`13. The upper stage engines are ignited and the stage contin
`ues to loW-earth orbit.
`14. Drogue parachutes are deployed from the middle stage.
`15. The turbofan engines are maintained at idle.
`16. The loWer stage drogue parachutes are jettisoned.
`17. The loWer stage main parachutes are deployed at about
`15,000 feet.
`18. Main parachutes are released at about 7,500 feet.
`19. The loWer stage is rotated by thrust vector control in
`concert With the control surfaces on the ?ns until the engines
`are thrusting doWnWards.
`20. The thrust of the turbofan engines is adjusted to further
`sloW the descent of the loWert stage.
`21. The turbofan engines are employed to land the loWer stage
`(the loWer stage may land on a to reasonably ?at, metallic
`surface).
`22. The middle stage drogue parachute(s) are jettisoned.
`23. The middle stage main parachutes are deployed.
`24. The middle stage makes a Water landing.
`Due to the launch trajectory of the system, recovery of the
`loWer and middle stages normally Will occur some tens of
`miles from the launch site. This is because of the launch
`trajectory of the system and due to the fact that it may require
`too much fuel to “?y” the loWer stage back to the launch site.
`A barge or ship Will be employed as a landing site for the
`loWer stage. This Will alloW the loWer stage to easily be
`returned to the launch site for turn-around. A ship Will also be
`employed to recover the middle stage after its Water landing.
`The beloW charts depict a theoretical mission employing
`one embodiment of the present invention. Many other con
`?gurations and trajectories may be employed using the
`present invention.
`
`Space Exploration Technologies; NEW PETITION
`Exhibit 1010
`Page 11 of 13
`
`

`
`US 8,047,472 B1
`
`9
`
`10
`
`Event
`
`Time
`
`Altitude
`
`Mach No. Comment
`
`LH2 and LOX
`fuelers disconnect
`from gantry
`and clear area
`
`Start fanjets,
`thrust at idle
`Gantry disconnects
`and moves aWay
`Full military poWer
`
`Full Afterbumer
`poWer — Liftoff
`
`Tilt to 6.4 degrees
`doWnrange
`gamma angle
`
`L — 20 min
`
`0 ft
`
`L — 10 min
`
`L — 3 min
`
`L — 10 sec
`
`0 ft
`
`0 ft
`
`0 ft
`
`L + 0 sec
`
`0 ft
`
`L + 2 sec
`
`100 ft
`
`Ramjet start
`
`L + 46 sec
`
`32,000 ft
`
`L + 53 sec
`
`40,000 ft
`
`0
`
`0
`
`0
`
`0
`
`0
`
`Gantry retains topping
`capabi