Solid grain structures, systems, and methods of forming the same

Abstract

Devices, methods, and systems for providing a solid grain fuel for a hybrid rocket. In one embodiment, the solid grain fuel includes a housing having a length extending between a first side and a second side. The housing defines a central axis and a bore extending from the first side to the second side. The bore of the housing extends with a helical configuration along the length of the housing. Further, the housing includes multiple segments configured to interlock together to form the bore along the length of the housing.

What is claimed is: 
     
         1 . A solid grain fuel for a hybrid rocket, comprising:
 a housing having a length extending between a first side and a second side, the housing defining a central axis and a bore extending from the first side to the second side, the bore extending with a helical configuration along the length of the housing, the housing including multiple segments configured to interlock together to form the bore along the length of the housing.   
     
     
         2 . The solid grain fuel of  claim 1 , wherein:
 each of the multiple segments comprises multiple flat layers and each flat layer defines a plane that is transverse relative to the central axis of the housing, and   the bore extends through each of the multiple flat layers   
     
     
         3 . The solid grain fuel of  claim 1 , wherein the housing is formed of acrylonitrile butadiene styrene (ABS). 
     
     
         4 . The solid grain fuel of  claim 1 , wherein the bore comprises a circular cross-section. 
     
     
         5 . The solid grain fuel of  claim 1 , wherein the multiple segments include opposite ends, at least one of the opposite ends including an orientation feature configured to couple to an end of another one of the multiple segments so that the bore in each of the multiple segments collectively defines the helical configuration within the coupled multiple segments. 
     
     
         6 . A solid grain fuel for a hybrid rocket, comprising:
 a housing having a length extending between a first side and a second side, the housing defining a central axis and a bore extending from the first side to the second side, the bore extending with a helical configuration along the length of the housing, the housing including acrylonitrile butadiene styrene (ABS).   
     
     
         7 . The solid grain fuel of  claim 6 , wherein the housing comprises multiple segments configured to interlock together to form the bore along the length of the housing. 
     
     
         8 . The solid grain fuel of  claim 7 , wherein the multiple segments include opposite ends, at least one of the opposite ends including an orientation feature configured to couple to an end of another one of the multiple segments so that the bore in each of the multiple segments collectively defines the helical configuration within the coupled multiple segments. 
     
     
         9 . The solid grain fuel of  claim 7 , wherein each of the multiple segments comprises multiple flat layers. 
     
     
         10 . The solid grain fuel of  claim 7 , wherein the bore comprises a circular cross-section. 
     
     
         11 . A method of forming a solid grain fuel for a hybrid rocket, the method comprising:
 forming multiple solid grain segments with additive layering with acrylonitrile butadiene styrene (ABS) wherein each of the multiple solid grain segments define a bore extending therethrough; and   coupling the multiple solid grain segments together to form an elongated housing such that the bore extending through each of the solid grain segments collectively defines a helically extending bore that extends along a length of the elongated housing between opposite first and second sides.   
     
     
         12 . The method according to  claim 11 , wherein the forming comprises:
 forming each of the multiple solid grain segments with multiple flat layers with fused deposition modeling.   
     
     
         13 . The method according to  claim 12 , wherein the forming comprises forming the multiple solid grain segments with acrylonitrile butadiene styrene (ABS). 
     
     
         14 . The method according to  claim 11 , wherein the forming comprises forming the multiple solid grain segments with inter-locking features to inter-lock the multiple solid grain segments together to form the elongated housing. 
     
     
         15 . The method according to  claim 11 , wherein:
 the forming comprises forming the multiple solid grain segments with a keying feature on at least one of the oppositely facing sides of the multiple solid grain segments, and   the coupling comprises orienting each one of the multiple solid grain segments relative to another one of the multiple solid grain segments with the keying feature to form the helically extending bore of the elongated housing.   
     
     
         16 . A hybrid rocket system, comprising:
 a container sized to contain liquid or gaseous fuel;   a solid grain portion having a length extending between a first side and a second side, the first side configured to receive fuel from the container, wherein:
 the sold grain portion defines a central axis and a bore extending between the first side and the second side; 
 the bore extends with a helical configuration along the length of the solid grain portion; and 
 the solid grain portion comprises multiple segments configured to interlock together to form the bore along the length of the housing; and 
   a nozzle coupled to the second side of the solid grain portion, the nozzle configured to manipulate thrust to the rocket system.   
     
     
         17 . The hybrid rocket system of  claim 16 , wherein each of the multiple segments comprises multiple flat layers and the bore extends through each of the multiple flat layers. 
     
     
         18 . The hybrid rocket system of  claim 16 , wherein the solid grain portion is formed of acrylonitrile butadiene styrene (ABS). 
     
     
         19 . The hybrid rocket system of  claim 16 , wherein the bore comprises a circular cross-section. 
     
     
         20 . The hybrid rocket system of  claim 16 , wherein the multiple segments include opposite ends, at least one of the opposite ends including an orientation feature configured to couple to an end of another one of the multiple segments so that the bore in each of the multiple segments collectively defines the helical configuration within the multiple segments.