The innovative solution with Teflon PTFE

Citation

(2007), "The innovative solution with Teflon PTFE", Aircraft Engineering and Aerospace Technology, Vol. 79 No. 4. https://doi.org/10.1108/aeat.2007.12779daf.007

The innovative solution with Teflon PTFE

The innovative solution with Teflon PTFE

Based on the IRS design, ElringKlinger Kunststofftechnik GmbH has developed a manufacturing process for solid propellant with Teflon PTFE in a helix shape that is suitable for this mission. It fulfills all requirements regarding internal stress minimization and dimensional stability in harsh environments. Owing to its helix shape it is possible to feed the propellant into the thrusters using a torsion spring. To space efficiently store the propellant, IRS designed the propellant to be fed into the thruster bi-directionally.

Inherently, I-MPDs can be restarted on demand as often as needed until the system is empty. Further, such I-MPDs using solid Teflon PTFE propellant significantly extend the overall lifetime and function of a satellite. They can either be used to maintain satellites in orbit in the correct position or as primary propulsion system on long- term missions. ElringKlinger describes its joint IRS development as “totally new, with a possibly big impact on the future”.

The thruster makes multi-time ignition possible and allows for thrust control. With the helix-shaped Teflon PTFE propellant, they will be able to fulfill their mission for a much longer duration of time. For satellites in general, the new helix-shaped system is applicable for positioning systems, and makes minor orbit corrections possible. It can be used as the main engine for smaller satellites. Since, I-MPDs using solid propellant with Teflon PTFE make low energy demands they can be applied to smaller satellites with limited solar panel surface area.

The I-MPD system developed by IRS offers a superior exhaust velocity of over 12,000m/s using solid propellant Teflon PTFE. As a comparison, a conventional chemical thruster would need about 150kg, three times the amount of the I-MPD thruster, in order for the satellite to reach the moon. The lunar mission BW1 will need over 50kg of solid propellant Teflon PTFE. These will be distributed on a cluster of more than four I-MPDs resulting in an average propellant load per engine of 10kg.

Commercial future

The first test units of helix-shaped solid propellant Teflon PTFE were produced in early 2006 and are currently running successfully at 1:1 scale in tests conducted by the Institute of Space Systems, the institute at the Stuttgart University that designs, tests and qualifies Pulsed Plasma Thrusters.

The first satellites to utilize the new positioning system will be launched by the end of this decade. ElringKlinger Kunststofftechnik GmbH expects all nations engaged in space satellite technology to use the system in future, with possible applications in other industries, e.g. the adoption of high speed PTFE plasma for laser functions.

Its development by ElringKlinger recently won second prize in the Europe, Middle East and Africa section of the Du Pont Plunkett Awards 2006 for innovation in fluoropolymers. Held for the tenth time, the competition first ran in 1988 to mark the 50th anniversary of the discovery of Teflon PTFE fluoropolymer resin by Du Pont scientist Dr Roy J. Plunkett.