GB2270089A - Producing metal coated propulsion tanks for aerospace applications - Google Patents
Producing metal coated propulsion tanks for aerospace applications Download PDFInfo
- Publication number
- GB2270089A GB2270089A GB9317363A GB9317363A GB2270089A GB 2270089 A GB2270089 A GB 2270089A GB 9317363 A GB9317363 A GB 9317363A GB 9317363 A GB9317363 A GB 9317363A GB 2270089 A GB2270089 A GB 2270089A
- Authority
- GB
- United Kingdom
- Prior art keywords
- tank
- metal layer
- propulsion
- shell
- array
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 47
- 239000002184 metal Substances 0.000 title claims abstract description 47
- 230000001464 adherent effect Effects 0.000 claims abstract description 21
- 239000002861 polymer material Substances 0.000 claims abstract description 15
- 229910052802 copper Inorganic materials 0.000 claims abstract description 14
- 238000000151 deposition Methods 0.000 claims abstract description 14
- 229910052737 gold Inorganic materials 0.000 claims abstract description 14
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 13
- 239000012779 reinforcing material Substances 0.000 claims abstract description 13
- 239000003822 epoxy resin Substances 0.000 claims abstract description 11
- 229920000647 polyepoxide Polymers 0.000 claims abstract description 11
- 229910001220 stainless steel Inorganic materials 0.000 claims abstract description 10
- 239000010935 stainless steel Substances 0.000 claims abstract description 10
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 8
- 239000004917 carbon fiber Substances 0.000 claims abstract description 8
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 8
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 7
- 238000001465 metallisation Methods 0.000 claims abstract description 5
- 238000005229 chemical vapour deposition Methods 0.000 claims abstract description 4
- 230000008021 deposition Effects 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 30
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 22
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 12
- 239000010949 copper Substances 0.000 claims description 12
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 12
- 239000010931 gold Substances 0.000 claims description 12
- 229920000642 polymer Polymers 0.000 claims description 12
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 10
- 239000010936 titanium Substances 0.000 claims description 10
- 239000000835 fiber Substances 0.000 claims description 8
- 239000004697 Polyetherimide Substances 0.000 claims description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 6
- 229920001601 polyetherimide Polymers 0.000 claims description 6
- 239000011248 coating agent Substances 0.000 claims description 2
- 238000000576 coating method Methods 0.000 claims description 2
- 238000005530 etching Methods 0.000 claims description 2
- 239000000126 substance Substances 0.000 claims description 2
- 230000003014 reinforcing effect Effects 0.000 claims 1
- 230000003381 solubilizing effect Effects 0.000 claims 1
- 239000000446 fuel Substances 0.000 abstract description 23
- 239000007800 oxidant agent Substances 0.000 abstract description 8
- 230000001590 oxidative effect Effects 0.000 abstract description 8
- 239000000463 material Substances 0.000 abstract description 4
- 230000004888 barrier function Effects 0.000 abstract 1
- 239000003380 propellant Substances 0.000 abstract 1
- 239000007789 gas Substances 0.000 description 13
- 239000002131 composite material Substances 0.000 description 7
- 229920001187 thermosetting polymer Polymers 0.000 description 5
- OAKJQQAXSVQMHS-UHFFFAOYSA-N Hydrazine Chemical compound NN OAKJQQAXSVQMHS-UHFFFAOYSA-N 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 229910001200 Ferrotitanium Inorganic materials 0.000 description 3
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229920001169 thermoplastic Polymers 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- WFPZPJSADLPSON-UHFFFAOYSA-N dinitrogen tetraoxide Chemical group [O-][N+](=O)[N+]([O-])=O WFPZPJSADLPSON-UHFFFAOYSA-N 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 239000001307 helium Substances 0.000 description 2
- 229910052734 helium Inorganic materials 0.000 description 2
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000000071 blow moulding Methods 0.000 description 1
- ZOMBKNNSYQHRCA-UHFFFAOYSA-J calcium sulfate hemihydrate Chemical compound O.[Ca+2].[Ca+2].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O ZOMBKNNSYQHRCA-UHFFFAOYSA-J 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 238000000454 electroless metal deposition Methods 0.000 description 1
- 150000002118 epoxides Chemical class 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000002828 fuel tank Substances 0.000 description 1
- 239000011507 gypsum plaster Substances 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000010720 hydraulic oil Substances 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 239000000543 intermediate Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- 238000001175 rotational moulding Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000004634 thermosetting polymer Substances 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
- B60K15/03—Fuel tanks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64G—COSMONAUTICS; VEHICLES OR EQUIPMENT THEREFOR
- B64G1/00—Cosmonautic vehicles
- B64G1/22—Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
- B64G1/40—Arrangements or adaptations of propulsion systems
- B64G1/402—Propellant tanks; Feeding propellants
- B64G1/4021—Tank construction; Details thereof
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/14—Metallic material, boron or silicon
- C23C14/20—Metallic material, boron or silicon on organic substrates
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/06—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Sustainable Energy (AREA)
- Transportation (AREA)
- Sustainable Development (AREA)
- Life Sciences & Earth Sciences (AREA)
- General Chemical & Material Sciences (AREA)
- Remote Sensing (AREA)
- Aviation & Aerospace Engineering (AREA)
- Filling Or Discharging Of Gas Storage Vessels (AREA)
Abstract
A lightweight space-deployed propulsion tank is produced by depositing an adherent metal layer on the desired surfaces of a lightweight tank shell produced by wrapping, and then curing on a disposable pattern, which may be coated with a polymeric material, having a desired shape an array of reinforcing material, such as carbon fibers, itself impregnated with a polymer material, eg an epoxy resin. The disposable pattern being removed before the metal layer is deposited. The metal layer serves as a leak barrier and protects the underlying polymer material from corrosive damage that may be produced by the propellant fuel or oxidant therein. The desired surfaces may either be on the inside wall of the tank or on the outside wall of the tank. The metal layer may be formed of Ni, Au, Cu, Ti, Al or stainless steel and be deposited by electroless deposition, vacuum metallization or chemical vapour deposition. A second metal layer of Ni, Au or Cu may be electrolytically deposited on top of the adherent metal layer.
Description
METHOD OF PRODUCING
PROPULSION TANKS FOR
AEROSPACE APPLICATIONS, AND
TANKS SO PRODUCED
Field of the Invention
The present invention is directed to propulsion tanks useful in space-borne applications and is particularly directed to lightweight, low cost storage tanks for fuel and the like used in space-deployed structures, such as satellites.
Background of the Invention
It is well known that satellites when orbiting a planet, such as earth, require a particular orientation with respect to the planet. This orientation is especially needed so that the satellite can perform the desired tasks. More importantly, it is known to provide satellite and orbiting space vehicles with altitude position and orientation controls which permit the correction and maintaining of particular positions in all directions of freedom of motion.
Generally, one uses mini-propulsion systems and small jets for that purpose; they provide very small but very accurately metered mechanical impulses so that requisite control and corrective motion can be obtained.
The miniature or mini-propulsion systems and control jets in a space vehicle require a certain amount of fuel and, therefore, it is necessary to store such a fuel in a suitable container within the satellite. The fuels used are generally in the liquid state. Known and conveniently used single component fuels include hydrazine and derivatives thereof. Decomposing hydrazine constitutes a very useful propulsion gas that can be used directly by the propulsion system for purposes of position and altitude control as mentioned above. A pressurant gas is also generally stored in a separate tank to supply pressure necessary to convey the propulsion fuel from the tank to the propulsion jets.
Multi-component fuel is also known and is often preferred because of a somewhat larger energy control and, thus, is a preferred choice in those cases in which the space vehicle can be refueled only infrequently or not at all.
However, it is a significant drawback of these multicomponent fuels that at least some of the more desirable components are highly chemically aggressive. A typical example of such a component is nitrogen tetroxide.
One of the typical approaches known in the art is to use forged titanium or stainless steel tanks to store propellent fuel, pressurant or oxidant. The minimum weight of each tank is fixed by the wall thickness, which in turn is determined by the size of the tank and practical limits of machining such a tank shape. Such tanks are typically about 100 cm. in diameter and about 4 mm. in thickness. The weight of forged titanium or stainless steel tanks constitutes a major portion1 typically about 67%, of the propulsion system weight. Due to the substantial weight of such tanks, the useful payload of a satellite has to be reduced, as the capacity of a launching rocket is substantially fixed.
Additionally, titanium or stainless steel tanks are difficult to fabricate and expensive. They also require long lead times, typically about 18 months. In some cases, such as tanks used for storing a pressurant gas, an aluminum liner is generally required to prevent leakage of the. pressurant gas. Such a liner not only complicates the manufacturing process but also increases the cost and weight of the propulsion system.
Thus, it is desirable to produce a lightweight, inexpensive tank suitable for space-borne applications.
Lightweight, fiber reinforced, polymer composite tanks not only offer the advantage of a significant weight reduction but also offer the additional advantage of a significant reduction in cost of fabrication.
Furthermore, fabrication techniques used for producing polymer composite tanks are simple enough to significantly reduce lead times, typically by 12 or more months.
However, the aforementioned polymer composite tanks suffer from a major drawback. At present no effective method is available for providing the walls of such tanks with a puncture-resistant metal layer that can effectively protect such tanks from the corrosive action of multi-component fuels or prevent leakage of a pressurant gas.
It is known to position a non-adherent metallic film on the inner side of a polymer composite tank to protect the walls of such a tank from the corrosive action of- fuels or the components thereof. The thickness of a load-sharing metallic film in this situation is adjusted so that the combined structure achieves a desired strain when such tanks are pressurized to a targeted pressure (for example, in the case of the pressurant, about 300 k./cm.2, thereby preventing leakage of the pressurant gas). One example of such a metallic film is a titanium film with a thickness of about 350-500 microns. The strain within the aforementioned strain limit keeps the stretch of the metallic film below its ductility limit, i.e., the film deformation occurs only within the ductile range of the metallic film.As the fuel from the tank is consumed during propulsion maneuvers, the metallic film, stretched beyond its elastic limit, buckles inward. As a result, the sealing ability of the metallic film may be affected and seepage of the propellent fuel through damaged portion of the metallic film can damage the walls of the polymer composite tanks.
The present invention provides means for depositing lightweight, non-load bearing adherent metal layers on the walls of polymer composite tanks. Said layers are not damaged during pressurization and depressurization of such tanks. The invention also provides means for customizing the metal layers to substantially prevent chemical attack by the fuel components on the polymer tank walls. The invention further provides means for storing pressurant gases at high pressure without leakage.
Statement of the Invention
The invention is directed to a method of producing a tank which comprises producing a lightweight tank shell and depositing an adherent metal layer on desired surfaces of the shell.
The present invention is further directed to a tank, most often a lightweight space-deployed propulsion tank, which comprises a tank shell having a wall comprising an array of a reinforcing material impregnated with a polymer material and a substantially non-load bearing and substantially unyielding adherent metal layer disposed on the desired surfaces of the shell.
Detailed Description of the Preferred Embodiment
A propulsion system of a satellite generally comprises jet nozzles, various propulsion tanks and an operating system for providing precise impulses through the nozzles to accurately position an orbiting satellite. Since the weight of propulsion tanks forms a major portion of the overall propulsion system weight, a lightweight propulsion tank would be highly desirable for reducing the overall weight of the propulsion system. Generally, propulsion tanks are used for storing propulsion components, such as a fuel, an oxidant and/or a pressurant. The pressurant is typically an inert gas, such as helium, used to apply constant pressure to liquid oxidant or liquid fuel stored in the oxidant and fuel tanks, respectively. The pressurant gas forces the oxidant or the fuel into the propulsion operating system. Separate tanks are generally provided for storing the aforementioned components. However, a single tank having compartments to store the propulsion components could also be used.
Such a lightweight, structurally stable space deployed propulsion tank may be made from a composite shell of a reinforcing material impregnated with a polymer material. As the reinforcing material, such materials as carbon, glass or steel fibers are generally employed. Carbon fibers are preferred. However, other reinforcing materials.
such as woven cloth of carbon, glass or steel, can also be employed.
The polymer material suitable for use in the present invention may be a thermoplastic or a thermoset polymer, or a combination of both, i.e. two or more layers comprising a thermoset polymer and a thermoplastic polymer. A thermoset polymer is preferred. Suitable thermosetting polymers useful as intermediates therefor are the epoxy resins. For example, an epoxy resin or an epoxide, defined as any molecule containing more than one epoxy group (whether situated internally, terminally or in cyclic structures) capable of being converted to a useful thermoset form, may be used. Suitable thermoplastic polymers are polycarbonate and polyetherimide, including halogenated polyetherimide. Polyetherimide is preferred.
The aforementioned tank shell may be produced by a variety of methods. For example, an array of a reinforcing material, such as fibers or yarns, after being impregnated with a polymer material, such as an uncured epoxy resin, may be wrapped or wound on a disposable pattern of a desired shape, typically a spherical or torpedo shape, and the epoxy resin subsequently cured.
The aforementioned disposable pattern may be made of any suitable moldable material that is solubilizable, etchable or breakable. Suitable materials are aluminum and hydrated calcium sulfate, such as plaster of
Paris. Aluminum is preferred. The aforementioned pattern may be formed by any well known process, such as rotational molding, blow molding, injection molding, die casting, spin forming and the like.
If necessary, the disposable pattern, which is generally hollow, may be pressurized with a fluid, such as hydraulic oil, to maintain its shape during the fiber winding process. Details of the aforementioned process are provided in Morris, E., et al., High-Pressure, High
Performance Filament-Wound Carbon/Epoxy Pressurant
Tanks With Seamless Aluminum Liners For Expendable
Launch Vehicles and Spacecraft, 34th International SAMPE
Symposium (1989), incorporated herein by reference. The aforementioned paper describes various fiber materials as well. as winding devices used in the fiber winding process.
Generally, the array of reinforcing material is produced by weaving, in various directions, long strands of fiber or yarn on a disposable pattern to achieve randomization of the reinforcing fiber. Such randomization significantly boosts the structural integrity and strength of the resulting propulsion tank shell.
Upon heating and curing the array, a reinforced structure is formed. The disposable pattern may be then broken off or removed by a solubilizing agent or an etching solution to form the tank shell. Any suitable etchant, such as base, may be used, for example, when a disposable pattern of aluminum is employed.
The propulsion tank shell may also be produced by coating a disposable pattern of a desired shape with a layer of a first polymer material, preferably polyetherimide. The thickness of the layer of the first polymer material is generally about 25-50 microns. The coated surface is then wrapped with an array of a reinforcing material, such as carbon fibers, typically preimpregnated with a second polymer such as an epoxy resin, and then cured to form a reinforced structure. It should be understood that the present invention contemplates additional polymer layers, if such layers are desired. Such a tank shell has the structural strength and stiffness characteristics of the employed polymer materials.It is contemplated that by adjusting the thicknesses of various polymer layers, the overall weight of the resulting propulsion tank can be maintained at a desired level with an increase in structural strength and stiffness. The underlying disposable pattern is then removed to form the tank shell.
Once the tank shell is produced, an adherent metal layer is then deposited on the desired surfaces thereof to prevent leakage of the stored fuel component as well as to protect the tank shell walls from degradation induced by the fuel component stored therein. The thickness of the adherent metal layer is adjusted to prevent leakage of the pressurant gas when the adherent metal layer is stretched along with the shell wall by the pressure of the pressurant gas.
The surfaces on which the metal layer is deposited are preferably on the inner side of the tank shell.
However, they may be on the outer side or on both sides of the tank shell. The metal layer may be provided on the outer side of the tank shell when the resulting propulsion tank is used as a pressurant tank containing pressurant gas, such as helium. Additionally, it is contemplated that a propulsion tank shell with a metal layer on both inner and outer sides will protect its contents from damage resulting from the action of ultraviolet or gamma rays.
The adherent metal layer is preferably applied on the desired surfaces of the tank shell by electroless deposition. Prior to electroless metal deposition, adhesion between the desired surfaces of the tank shell and the metal layer deposited thereon, may be improved by methods well known in the art. For example, U. S. Patents 4,959,121 and 4,999,251, both incorporated herein by reference, disclose suitable methods for improving adhesion of a metal layer to a polyetherimide surface.
The electrolessly applied adherent metal layer comprises gold, nickel, copper or various combinations thereof. A gold layer is preferred for propulsion tanks used to store a propulsion fuel or an oxidant, and a copper layer is preferred for propulsion tanks used for storing a pressurant gas. A total metal thickness of about 20-150 microns is sufficient to prevent leakage of the pressurant gas. Alternatively, the adherent metal layer may comprise an inner copper layer followed by an outer nickel or gold layer.
The adherent metal layer may be also applied on the surfaces of the tank shell by other well known methods, such as vacuum metallization or chemical vapor deposition.
Such an adherent metal layer may comprise gold, nickel, copper, titanium, stainless steel or various combinations thereof. In case of a propulsion tank used for storing fuel components, a final layer of stainless steel or titanium may be necessary to protect the inner metal layers from oxidation.
Preferably, the metal thickness is increased from about 1-2 microns to the desired thickness of about 20-150 microns by deposition of successive metal layers.
The additional thicknesses can comprise nickel, gold, copper or various combinations thereof and are preferably electrolytically deposited. Electrolytic metal deposition is well known to those skilled in the art. However, other deposition methods, such as vacuum metallization or chemical vapor deposition, could be used.
Another aspect of the invention is a spacedeployed propulsion tank produced by any one of the aforementioned methods. The tank of the present invention comprises a propulsion tank shell having a wall made from an array of a reinforcing material, such as carbon fibers, impregnated with a polymer material, such as an epoxy resin, and an adherent metal layer disposed on the desired surfaces of the tank shell. The metal layer comprises one or more layers of nickel, gold, copper, titanium, stainless steel, or combinations thereof. Since the thickness of the adherent metal layer disposed on the desired surfaces of the tank shell is of the order of about 20-150 microns, it is essentially incapable of bearing any structural loads. Thus, as the metal layer is very thin, the overall weight of the tank is low. Additionally, since the metal layer adheres to the surfaces of the tank shell, it is substantially unyielding.
Thus, damage, such as cracking or pinholes, to the metal layer resulting from expansion and contraction of the tank shell during its working cycle is significantly minimized.
The present invention is also directed to a tank having compartments for storing propulsion components, such as an oxidant, a pressurant and a fuel.
Claims (21)
1. A method of producing a tank which
comprises producing a lightweight tank shell and depositing an adherent metal layer on desired surfaces of the shell.
2. The method of claim 1 wherein said step of producing said tank shell comprises wrapping an array of a reinforcing material impregnated with a polymer material on a disposable pattern of a desired shape to form a reinforced structure, and removing said pattern.
3. The method of claim 2 wherein said array comprises carbon fibers impregnated with an epoxy resin.
4. The method of claim 1 wherein said metal depositing step comprises electroless deposition.
5. The method of claim 4 wherein said metal layer comprises nickel, gold, copper or combinations thereof.
6. The method of claim 1 wherein said metal depositing step comprises vacuum metallization or chemical vapor deposition.
7. The method of claim 6 wherein said metal layer comprises nickel, gold, copper, titanium, aluminum, stainless steel or combinations thereof.
8. The method of claim 1 further comprising electrolytically depositing a second metal layer on top of said adherent metal layer.
9. The method of claim 8 wherein said second metal layer comprises nickel, gold, copper, or combinations thereof.
10. The method of claim 1 wherein said step of producing said tank shell comprises coating a disposable pattern with a layer of a first polymer material, wrapping an array of a reinforcing material impregnated with a second polymer material on a top of said layer of said first polymer material to form a reinforced structure and removing said pattern.
11. The method of claim 10 wherein said first polymer is polyetherimide, said second polymer is an epoxy resin and said reinforcing material is carbon fibers.
12. The method of claim 1 wherein said desired surfaces are on the inside wall of said tank.
13. The method of claim 1 wherein said desired surfaces are on the outside wall of said tank.
14. A method of producing a lightweight tank comprising:
wrapping an array of reinforcing carbon fibers impregnated with an epoxy resin on a disposable pattern of a desired shape to form a fiber reinforced structure;
etching or solubilizing said pattern to remove said pattern from said fiber reinforced structure to form a propulsion tank shell;
vacuum metallizing or chemical vapor depositing an adherent metal layer of nickel, gold, copper, titanium, stainless steel or combinations thereof on the desired surfaces of said shell to form said propulsion tank.
15. The method of claim 14 further comprising electrolytically depositing a second layer of nickel, gold, copper or combinations thereof on top of said adherent metal layer.
16. A lightweight tank, which comprises:
a propulsion tank shell having a wall comprising an array of a reinforcing material impregnated with a polymer material;
a substantially non-load bearing and substantially unyielding adherent metal layer disposed on desired surfaces of said shell.
17. The tank of claim 16 wherein said array comprises carbon fibers impregnated with an epoxy resin.
18. The tank of claim 16 wherein said metal layer comprises nickel, gold, copper, titanium, stainless steel or combinations thereof.
19. A method according to Claim 1 and substantially as hereinbefore described.
20. A tank according to Claim 16 and substantially as hereinbefore described.
21. A tank made by the method of any one of Claims 1 to 15 or 19.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US93383492A | 1992-08-24 | 1992-08-24 |
Publications (2)
Publication Number | Publication Date |
---|---|
GB9317363D0 GB9317363D0 (en) | 1993-10-06 |
GB2270089A true GB2270089A (en) | 1994-03-02 |
Family
ID=25464584
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB9317363A Withdrawn GB2270089A (en) | 1992-08-24 | 1993-08-20 | Producing metal coated propulsion tanks for aerospace applications |
Country Status (1)
Country | Link |
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GB (1) | GB2270089A (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1055013A1 (en) * | 1998-02-14 | 2000-11-29 | Phygen Inc. | Cathode arc vapor deposition |
GB2486427A (en) * | 2010-12-14 | 2012-06-20 | Converteam Technology Ltd | A layered material for a vacuum chamber |
EP2502829A1 (en) * | 2011-03-21 | 2012-09-26 | Hamilton Sundstrand Corporation | Demisable fuel supply system |
EP2644511A3 (en) * | 2012-03-28 | 2017-02-22 | Keystone Engineering Company | Demisable fuel supply system |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB504362A (en) * | 1936-10-14 | 1939-04-21 | Huettenwerke Siegerland Ag | Method of coating vessels with zinc |
US3909368A (en) * | 1974-07-12 | 1975-09-30 | Louis W Raymond | Electroplating method and apparatus |
GB1443170A (en) * | 1972-07-26 | 1976-07-21 | Hoechst Ag | Fuel tanks and their manufacture |
GB2085474A (en) * | 1980-10-15 | 1982-04-28 | Metal Box Co Ltd | Electrocoating |
EP0056922A1 (en) * | 1981-01-19 | 1982-08-04 | UNION SIDERURGIQUE DU NORD ET DE L'EST DE LA FRANCE par abréviation "USINOR" | Method of producing asymmetrically lead-clad sheets |
US4436594A (en) * | 1981-05-18 | 1984-03-13 | Daiwa Can Company, Limited | Method of treating the surface of a metal container |
GB2181744A (en) * | 1985-09-11 | 1987-04-29 | Larcum Kendall Limited | Surface treating hollow objects |
-
1993
- 1993-08-20 GB GB9317363A patent/GB2270089A/en not_active Withdrawn
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB504362A (en) * | 1936-10-14 | 1939-04-21 | Huettenwerke Siegerland Ag | Method of coating vessels with zinc |
GB1443170A (en) * | 1972-07-26 | 1976-07-21 | Hoechst Ag | Fuel tanks and their manufacture |
US3909368A (en) * | 1974-07-12 | 1975-09-30 | Louis W Raymond | Electroplating method and apparatus |
GB2085474A (en) * | 1980-10-15 | 1982-04-28 | Metal Box Co Ltd | Electrocoating |
EP0056922A1 (en) * | 1981-01-19 | 1982-08-04 | UNION SIDERURGIQUE DU NORD ET DE L'EST DE LA FRANCE par abréviation "USINOR" | Method of producing asymmetrically lead-clad sheets |
US4436594A (en) * | 1981-05-18 | 1984-03-13 | Daiwa Can Company, Limited | Method of treating the surface of a metal container |
GB2181744A (en) * | 1985-09-11 | 1987-04-29 | Larcum Kendall Limited | Surface treating hollow objects |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1055013A1 (en) * | 1998-02-14 | 2000-11-29 | Phygen Inc. | Cathode arc vapor deposition |
EP1055013A4 (en) * | 1998-02-14 | 2005-06-15 | Phygen Inc | Cathode arc vapor deposition |
GB2486427A (en) * | 2010-12-14 | 2012-06-20 | Converteam Technology Ltd | A layered material for a vacuum chamber |
GB2486427B (en) * | 2010-12-14 | 2013-08-07 | Converteam Technology Ltd | A layered material for a vacuum chamber |
EP2502829A1 (en) * | 2011-03-21 | 2012-09-26 | Hamilton Sundstrand Corporation | Demisable fuel supply system |
CN102691592A (en) * | 2011-03-21 | 2012-09-26 | 哈米尔顿森德斯特兰德公司 | Demisable fuel supply system |
US8511504B2 (en) | 2011-03-21 | 2013-08-20 | Hamilton Sundstrand Corporation | Demisable fuel supply system |
CN102691592B (en) * | 2011-03-21 | 2016-08-31 | 吉斯通工程公司 | The fuel system that can wither away |
EP2644511A3 (en) * | 2012-03-28 | 2017-02-22 | Keystone Engineering Company | Demisable fuel supply system |
Also Published As
Publication number | Publication date |
---|---|
GB9317363D0 (en) | 1993-10-06 |
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