Catalyzed decomposing structural payload foam

• US 20090108139A1
• Filed: 12/17/2008
• Published: 04/30/2009
• Est. Priority Date: 08/18/2004
• Status: Active Grant

• Current Assignee: Quenten E. Duden
• Original Assignee: Quenten E. Duden
• Inventors: Duden, Quenten E.
• Granted Patent: US 7,661,628 B2
• Time in Patent Office: Days
• US Class Current: 244/173.300
• CPC Class Codes: B64G 1/002 Launch systems
• CPC Class Codes: B64G 1/641 Interstage or payload connectors docking systems B64G1/646
• CPC Class Codes: B64G 1/643 for arranging multiple satellites in a single launcher
• CPC Class Codes: C08K 5/14 Peroxides
• CPC Class Codes: F42B 15/08 for carrying measuring instruments; Arrangements for mounting sensitive cargo within a projectileadaptations for meteorology G01W1/08; Arrangements for acoustic sensitive cargo within a projectile
• CPC Class Codes: Y10T 428/249954 With chemically effective material or specified gas other than air, N, or carbon dioxide in void-containing component

Abstract

A high energy, e.g., ultraviolet (UV), catalyzed decomposing foam encapsulating a payload to be boosted in space provides an ultra-light weight, adaptable means to facilitate survival of much lighter, smaller satellites and space hardware under boost environment. The decomposable foam is to contain multiple satellites within a booster payload in lieu of the traditionally heavy and complex structural framework. The catalyzed decomposing foam significantly lowers the weight and structure of all space hardware. This packaging system is especially beneficial where several or even hundreds of satellites are required for a constellation system, thereby significantly benefiting all technologies applied in space, ranging from the telecommunication industry to DOD applications. In addition to weight and cost savings, advantages of this foam are many in that it is adaptable to any payload shape as it may be injected, sprayed, formed, molded, easily cut or manufactured to support any geometry required.

Claims

1. A payload structure for launching a plurality of satellites into space by a vehicle, said payload structure contained within said vehicle and including a mast supported on a base, the mast including a plurality of release mechanisms, each release mechanism associated with a said satellite, said payload structure at least partially surrounded by a foam decomposable by high energy electromagnetic radiation having a wavelength of less than about 10⁻

7 meters.

2. The payload structure of claim 1 wherein said high energy electromagnetic radiation is ultraviolet radiation.

3. The payload structure of claim 2 wherein said high energy electromagnetic radiation is low wave ultraviolet radiation of less than 290 nanometers.

4. The payload structure of claim 1 wherein said decomposable foam comprises a polymer selected from the group consisting of expanded polystyrenes, extruded polystyrenes, polyethylenes, polypropylenes, propylene copolymers, and polyurethanes.

5. The payload structure of claim 1 wherein said decomposable foam includes a free radical initiator.

6. The payload structure of claim 5 wherein said free radical initiator is selected from the group consisting of aluminum oxide, hydrogen peroxide, sulfur trioxide, sulfur fluoride, nitrous oxide, benzil dimethyl ketal, trimethylbenzophenone, α

-hydroxy ketone, benzophenone, benzoyl peroxide, di-iso-propyl peroxydicarbonate, di-sec-butyl peroxydicarbonate, tert-butylperoxy pivalate, caprylyl peroxide, lauroyl peroxide, acetyl peroxide, tert-butyl peroxyisobutyrate, p-chlorobenzoyl peroxide, hydroxyheptyl peroxide, di-tert-butyl diperphthalate, tert-butyl peracetate, t-butylperoxy iso-propyl carbonate, tert-butyl perbenzoate, dicumyl peroxide, tert-butyl hydroperoxide, methyl ethyl ketone peroxide, di-tert-butyl peroxide, p-menthane hydroperoxide, pinane hydroperoxide, cumene hydroperoxide, 2,5-dimethyl-2,5-dihydroperoxide, tert-butyl hydroperoxide-90, ammonium persulfate, potassium persulfate, azo compounds, tert-butyl peroxy-2-ethylhexanoate, and di(tert-butylcyclohexyl)peroxydicarbonate, and organic peroxides.

7. The payload structure of claim 6 wherein said azo compounds are selected from the group consisting of 2,2′

-azobisiso-butyronitrile, 4,4′

-azobis(cyclohexanecarbonitrile), 4,4′

-azobis(4-cyano-valeric acid) and 2,2′

-azobis(2-methylpropane), and wherein said organic peroxides are selected from the group consisting of dicumyl peroxide, dioctanoyl peroxide, dimyristyl peroxide, dilauroyl peroxide, 1,1-di(tert-butylperoxycyclohexane), tert-butyl peroxydiethylacetate, and cumyl hydroperoxide

8. The payload structure of claim 5 wherein said free radical initiator is present in an amount sufficient to initiate decomposition of said decomposable foam upon exposure to said high energy radiation.

9. The payload structure of claim 1 wherein structural media are embedded within said decomposable foam.

10. The payload structure of claim 9 wherein said structural media are selected from the group consisting of glass, metal flakes, fibers, plastics, and rubber.

11. The payload structure of claim 1 wherein said foam structure has a base support, a plurality of lateral supports, and a top ring, where said base support provides support at a base of a group of satellites, and where said plurality of lateral supports, which attach to an inner support, provide lateral support.

12. A vehicle for launching a payload into space, said payload comprising a plurality of satellites supported within a payload structure, said payload structure contained within said vehicle and including a mast supported on a base, the mast including a plurality of release mechanisms, each release mechanism associated with a said satellite, said payload structure protected within said vehicle against launching forces by a decomposable foam that at least partially surrounds said payload, wherein said decomposable foam is decomposable by exposure to high energy electromagnetic radiation having a wavelength of less than about 10⁻

7 meters.

13. The vehicle of claim 12 wherein said high energy electromagnetic radiation is ultraviolet radiation.

14. The vehicle of claim 13 wherein said high energy electromagnetic radiation is low wave ultraviolet radiation of less than 290 nanometers.

15. The vehicle of claim 12 wherein said decomposable foam comprises a polymer selected from the group consisting of expanded polystyrenes, extruded polystyrenes, polyethylenes, polypropylenes, propylene copolymers, and polyurethanes.

16. The vehicle of claim 12 wherein said decomposable foam includes a free radical initiator.

17. The vehicle of claim 16 wherein said free radical initiator is selected from the group consisting of aluminum oxide, hydrogen peroxide, sulfur trioxide, sulfur fluoride, nitrous oxide, benzil dimethyl ketal, trimethylbenzophenone, α

-hydroxy ketone, benzophenone, benzoyl peroxide, di-iso-propyl peroxydicarbonate, di-sec-butyl peroxydicarbonate, tert-butylperoxy pivalate, caprylyl peroxide, lauroyl peroxide, acetyl peroxide, tert-butyl peroxyisobutyrate, p-chlorobenzoyl peroxide, hydroxyheptyl peroxide, di-tert-butyl diperphthalate, tert-butyl peracetate, t-butylperoxy iso-propyl carbonate, tert-butyl perbenzoate, dicumyl peroxide, tert-butyl hydroperoxide, methyl ethyl ketone peroxide, di-tert-butyl peroxide, p-menthane hydroperoxide, pinane hydroperoxide, cumeme hydroperoxide, 2,5-dimethyl-2,5-dihydroperoxide, tert-butyl hydroperoxide-90, ammonium persulfate, potassium persulfate, azo compounds, tert-butyl peroxy-2-ethylhexanoate, and di(tert-butylcyclohexyl)peroxydicarbonate, and organic peroxides.

18. The vehicle of claim 17 wherein said azo compounds are selected from the group consisting of 2,2′

-azobisiso-butyronitrile, 4,4′

-azobis(cyclohexanecarbonitrile), 4,4′

-azobis(4-cyano-valeric acid) and 2,2′

-azobis(2-methylpropane), and wherein said organic peroxides are selected from the group consisting of dicumyl peroxide, dioctanoyl peroxide, dimyristyl peroxide, dilauroyl peroxide, 1,1-di(tert-butylperoxycyclohexane), tert-butyl peroxydiethylacetate, and cumyl hydroperoxide

19. The vehicle of claim 16 wherein said free radical initiator is present in an amount sufficient to initiate decomposition of said decomposable foam upon exposure to said high energy radiation.

20. The vehicle of claim 12 wherein structural media are embedded within said decomposable foam.

21. The vehicle of claim 20 wherein said structural media are selected from the group consisting of glass, metal flakes, fibers, plastics, and rubber.

22. The vehicle of claim 13 wherein said foam structure has a base support, a plurality of lateral supports, and a top ring, where said base support provides support at a base of a group of satellites, and where said plurality of lateral supports, which attach to an inner support, provide lateral support.

23. A method for protecting a payload during launch into space, said payload comprising a plurality of satellites, said method comprising:

providing a payload structure

supporting said plurality of satellites within said payload structure, said payload structure contained within a launch vehicle and including a mast supported on a base, the mast including a plurality of release mechanisms, each release mechanism associated with a said satellite,

at least partially surrounding said payload with decomposable foam that is decomposable by high energy electromagnetic radiation having a wavelength of less than about 10<sup>−

7</sup> meters; and

decomposing said foam once said payload is in space by exposure to said high energy electromagnetic radiation.

24. The method of claim 23 wherein said high energy electromagnetic radiation is ultraviolet radiation.

25. The method of claim 24 wherein said high energy electromagnetic radiation is low wave ultraviolet radiation of less than 290 nanometers.

26. The method of claim 23 wherein said decomposable foam comprises a polymer selected from the group consisting of expanded polystyrenes, extruded polystyrenes, polyethylenes, polypropylenes, propylene copolymers, and polyurethanes.

27. The method of claim 26 wherein said decomposable foam is provided with a free radical initiator.

28. The method of claim 27 wherein said free radical initiator is selected from the group consisting of aluminum oxide, hydrogen peroxide, sulfur trioxide, sulfur fluoride, nitrous oxide, benzil dimethyl ketal, trimethylbenzophenone, α

-hydroxy ketone, benzophenone, benzoyl peroxide, di-iso-propyl peroxydicarbonate, di-sec-butyl peroxydicarbonate, tert-butylperoxy pivalate, caprylyl peroxide, lauroyl peroxide, acetyl peroxide, tert-butyl peroxyisobutyrate, p-chlorobenzoyl peroxide, hydroxyheptyl peroxide, di-tert-butyl diperphthalate, tert-butyl peracetate, t-butylperoxy iso-propyl carbonate, tert-butyl perbenzoate, dicumyl peroxide, tert-butyl hydroperoxide, methyl ethyl ketone peroxide, di-tert-butyl peroxide, p-menthane hydroperoxide, pinane hydroperoxide, cumene hydroperoxide, 2,5-dimethyl-2,5-dihydroperoxide, tert-butyl hydroperoxide-90, ammonium persulfate, potassium persulfate, azo compounds, tert-butyl peroxy-2-ethylhexanoate, and di(tert-butylcyclohexyl)peroxydicarbonate, and organic peroxides.

29. The method of claim 28 wherein said azo compounds are selected from the group consisting of 2,2′

-azobisiso-butyronitrile, 4,4′

-azobis(cyclohexanecarbonitrile), 4,4′

-azobis(4-cyano-valeric acid) and 2,2′

-azobis(2-methylpropane), and wherein said organic peroxides are selected from the group consisting of dicumyl peroxide, dioctanoyl peroxide, dimyristyl peroxide, dilauroyl peroxide, 1,1-di(tert-butylperoxycyclohexane), tert-butyl peroxydiethylacetate, and cumyl hydroperoxide

30. The method of claim 27 wherein said free radical initiator is added in an amount sufficient to initiate decomposition of said decomposable foam upon exposure to said high energy radiation.

31. The method of claim 23 wherein structural media are embedded within said decomposable foam.

32. The method of claim 31 wherein said structural media are selected from the group consisting of glass, metal flakes, fibers, plastics, and rubber.