Two-stage reusable earth-to-orbit aerospace vehicle and transport system

A reusable two-stage aerospace vehicle for conducting an Earth-to-orbit flight from a take-off and landing area on Earth to an orbit around the Earth and for returning to the take-off and landing area and landing, comprising:

• an upper stage movable along a first trajectory away from the take-off and landing area to the orbit and along a second trajectory from the orbit to the take-off and landing area, the upper stage including:
• an upper body structure having a first proximal portion, a first distal portion, and a first interior area extending therebetween;
• a first power plant connected to the first proximal portion and being activatable to propel the upper stage along a selected portion of the first trajectory to the orbit and being activatable to move the upper stage out of the orbit to the second trajectory;
• a first fuel tank assembly within the first interior area and being connected to the first power plant;
• a first landing system attached to the first body structure and being deployable as the vehicle stage moves along the second trajectory toward the take-off and landing area, the first landing system engaging the take-off and landing area and supporting the upper body structure upon landing;
• and
• a lower stage releasably connected to the upper vehicle stage, the lower stage being movable along the first trajectory away from the take-off and landing area to a separation portion along the first trajectory, the lower stage being separated from the upper stage at the separation portion and the lower stage being movable along a return trajectory after separation from the upper stage from the separation portion to the take-off and landing area, the lower stage being reconnectable to the upper stage and reusable for a second Earth-to-orbit flight after the lower stage returns to the take-off and landing area, the lower stage including:
• a lower body structure having a second proximal portion, a second distal portion, and a second interior area extending therebetween, the second distal portion being connected to the first proximal portion of the upper body structure;
• a second power plant connected to the lower body structure and being activatable to propel the upper and lower stages along the first trajectory from the take-off and landing area to the separation portion;
• a second fuel tank assembly positioned within the second interior area and connected to the second power plant;
• a separation sleeve attached to the upper and lower body structures, the proximal portion of the upper body structure and the distal portion of the lower body structure containing a gas therein when the upper and lower body structures are at the separation portion, the gas being at a pressure higher than ambient pressure at the separation portion of the first trajectory to exert a separating force on the upper and lower stages to move the upper and lower body structures apart from each other at the separation portion, the separation sleeve extending between the upper and lower body structures after the upper and lower body structures are initially separated at the separation portion, the separation sleeve having a fixed length and sealing the gas between the upper and lower body structures as the upper and lower body structures move apart from each other until a distance between the upper and lower body structures exceeds the fixed length of the separation sleeve;
• and
• a second landing system attached to the lower body structure and being deployable as the lower stage moves along the return trajectory toward the take-off and landing area, the second landing system engaging the take-off and landing area and supporting the lower body structure upon landing.

A reusable two-stage aerospace vehicle for use in carrying a payload on an Earth-to-orbit flight from a take-off and landing area on Earth to an orbit around the Earth and returning to the take-off and landing area, comprising:

• a wingless upper stage movable along a first trajectory away from the take-off and landing area to the orbit and along a second trajectory from the orbit through an outer atmosphere of the Earth and returning to the take-off and landing area, the upper stage generating frictional heat as the upper stage moves through the outer atmosphere, the upper stage being reusable to carry a payload along a second Earth-to-orbit flight after the upper stage returns to the take-off and landing area, the upper stage including:
• an upper body structure having a first distal portion and a first proximal portion;
• a payload support structure connected to the first distal portion;
• a single payload fairing connected to the first distal portion and positioned to cover the payload support structure and to enclose the payload therebetween, the payload fairing defining a leading portion of the upper vehicle stage as the upper stage moves along the first and second trajectories, the payload fairing being a heat shield to dissipate the frictional heat generated as the upper stage moves through the outer atmosphere;
• a first power plant connected to the upper body structure and being activatable to propel the upper stage from the separation portion of the first trajectory to the orbit;
• a first landing system attached to the upper body structure and being deployable as the upper stage moves along the second trajectory toward the take-off and landing area, the first landing system having a first landing member that engages the take-off and landing area and supports the upper body structure upon landing;
• and
• a wingless lower stage releasably connected to the wingless upper stage, the lower stage being movable along the first trajectory away from the take-off and landing area to a separation portion along the first trajectory, the lower stage being separable from the upper stage at the separation portion and being movable along a return trajectory to the take-off and landing area, the lower stage being reconnectable to the upper stage and reusable for the second Earth-to-orbit flight after the lower stage returns to the take-off and landing area, the lower stage including:
• a lower body structure coaxially aligned with the upper body structure and having a second proximal portion and a second distal portion, the second distal portion being connected to the first proximal portion of the upper body structure;
• a second power plant connected to the lower body structure, at least a portion of the second power plant being activatable to propel the upper and lower vehicle stages along the first trajectory from the take-off and landing area to the separation portion and a portion of the second power plant being activatable to direct the lower stage along the return trajectory;
• and
• a second landing system attached to the lower body structure and being deployable as the lower stage moves along the return trajectory toward the take-off and landing area, the second landing system having a second landing member that engages the take-off and landing area and supports the lower body structure upon landing.

A reusable two-stage aerospace vehicle for moving in a first Earth-to-orbit flight from a take-off and landing area on Earth to an orbit around the Earth and returning to the take-off and landing area, comprising:

• a wingless upper stage movable along a first trajectory away from the take-off and landing area to the orbit and along a second trajectory from the orbit to the take-off and landing area, the upper stage being reusable for a second Earth-to-orbit flight after the upper stage returns to the take-off and landing area, the upper stage including:
• an upper body structure having a first proximal portion, a first distal portion and a first interior area therebetween;
• a first power plant connected to the upper body structure;
• a first fuel tank assembly positioned within the first interior area and connected to the first power plant;
• a first parachute assembly connected to the upper body structure and being deployable to reduce a velocity of the upper stage relative to the take-off and landing area as the upper stage moves along the second trajectory toward the take-off and landing area;
• a plurality of inflatable first airbag assemblies mounted to the upper body structure, each first airbag assembly having a first airbag and a first inflation device to inflate the first airbag as the upper stage moves along the second trajectory and prior to the upper stage landing at the take-off and landing area and cushioning and supporting the upper body structure upon landing;
• and
• a wingless lower stage releasably connected to the upper stage, the lower stage being movable with the upper stage along the first trajectory away from the take-off and landing area to a separation portion along the first trajectory, the lower stage being separable from the upper stage at the separation portion and being movable along a return trajectory from the separation portion to the take-off and landing area, the lower return stage being reconnectable to the upper stage and reusable for the second Earth-to-orbit flight, the lower stage including:
• a lower body structure having a second proximal portion, a second distal portion and a second interior area therebetween, the second distal portion being connected to the first proximal portion of the upper body structure;
• a second power plant connected to the lower body structure and being activatable to propel the upper and lower vehicle stages along the first trajectory from the take-off and landing area to the separation portion, the second power plant being activatable after separation of the upper and lower stages to move the lower stage from the separation portion to the return trajectory for return to the take-off and landing area;
• a second fuel tank assembly positioned in the second interior area and connected to the second power plant;
• a second parachute assembly connected to the lower body structure and being deployable to reduce a second velocity of the lower stage relative to the take-off and landing area as the lower stage moves along the return trajectory toward the take-off and landing area;
• and
• a plurality of inflatable second airbag assemblies mounted to the lower body structure, each second airbag assembly having a second airbag and a second inflation device to inflate the airbag as the lower stage moves along the return trajectory and prior to landing the inflated second airbag engaging the take-off and landing area and cushioning and supporting the second body structure upon landing.

A reusable two-stage aerospace vehicle for an Earth-to-orbit flight from a take-off and landing area on Earth to an orbit around the Earth and returning to the take-off and landing area, comprising:

• an upper stage movable along a first trajectory away from the take-off and landing area to the orbit and along a second trajectory from the orbit to the take-off and landing area, the upper stage being reusable for a second Earth-to-orbit flight after the upper stage returns to the take-off and landing area, the upper stage including:
• an upper body structure having a first proximal portion, a first distal portion, an interior area extending therebetween, and a first longitudinal axis extending through the first interior area;
• a first power plant connected to the upper body structure;
• a first fuel tank assembly positioned in the interior area and connected to the first power plant;
• a first landing system attached to the upper body structure and being deployable as the upper stage moves along the second trajectory toward the take-off and landing area, the first landing system having a first landing member that engages the take-off and landing area and supports the upper body structure upon landing;
• and
• a lower stage releasably connected to the wingless upper stage, the lower stage having a center of mass and being movable along the first trajectory away from the take-off and landing area to a separation portion along the first trajectory, the lower stage being separable from the upper stage at the separation portion and being movable along a return trajectory from the separation portion to the take-off and landing area, the lower stage being reconnectable to the upper stage and reusable for the second Earth-to-orbit flight, the lower stage including:
• a lower body structure having a second proximal portion, a second distal portion, and a second longitudinal axis extending through the second proximal and distal portions, the second longitudinal axis being coaxially aligned with the first longitudinal axis, the second distal portion being connected to the first proximal portion of the upper body structure;
• a separation system releasably interconnecting the upper and lower body structures, the separation system being activatable to separate the upper body structure from the lower body structure at the separation portion of the first trajectory;
• a vehicle redirection parachute connected to the lower body structure at an attachment portion away from the center of mass, the redirection parachute being deployable from a packed position to a deployed position, the redirection parachute in the deployed position exerting a drag force on the lower body structure at the attachment portion to rotate the lower body structure relative to the upper body structure after separation with the second longitudinal axis being rotated out of coaxial alignment with the first longitudinal axis to position the lower body structure to align with the return trajectory;
• a second power plant connected to the lower body structure and being activatable to propel the upper and lower stages along the first trajectory from the take-off and landing area to the separation portion, the second power plant being activatable after separation of the upper and lower stages to move the lower stage from the separation portion to the return trajectory for return to the take-off and landing area;
• and
• a second landing system attached to the lower body structure and being deployable as the lower stage moves along the return trajectory toward the take-off and landing area, the second landing system having a second landing member that engages the take-off and landing area and supports the lower body structure upon landing.

A reusable two-stage aerospace vehicle for use in an Earth-to-orbit flight from a take-off and landing area on Earth to an orbit around the Earth and returning to the take-off and landing area, comprising:

• a wingless upper stage movable along a first trajectory away from the take-off and landing area to the orbit and along a second trajectory from the orbit to the take-off and landing area, the upper stage being reusable for a second Earth-to-orbit flight after the upper stage returns to the take-off and landing area, the upper stage including:
• an upper body structure having a first proximal portion, a first distal portion, and a first interior area extending therebetween;
• a first power plant connected to the upper body structure and being activatable to propel the upper body structure along a selected portion of the first trajectory to the orbit and being activatable to move the upper stage out of the orbit to the second trajectory;
• a first fuel tank assembly positioned within the first interior area and connected to the first power plant;
• a first landing system attached to the upper body structure and being deployable as the upper stage moves along the second trajectory toward the take-off and landing area, the first landing system having a first landing member that engages the take-off and landing area and supports the upper body structure upon landing;
• a first flight control computer assembly mounted to the upper body structure, and having a plurality of first sensors mounted to the upper body structure, the first power plant, and the first landing system;
• and
• a wingless lower stage releasably connected to the wingless upper stage, the lower stage being movable with the upper stage along the first trajectory away from the take-off and landing area to a separation portion along the first trajectory, the lower stage being separable from the upper stage at the separation portion and being movable along a return trajectory from the separation portion to the take-off and landing area, the lower stage being reconnectable to the upper stage and reusable for the second Earth-to-orbit flight after the lower stage returns to the take-off and landing area, the lower stage including:
• a lower body structure coaxially aligned with the upper body structure and having a second proximal portion, a second distal portion, and a second interior area extending therebetween, the second distal portion being connected to the first proximal portion of the upper body structure;
• a second power plant connected to the lower body structure, at least a portion of the second power plant being activatable to propel the upper and lower stages along the first trajectory from the take-off and landing area to the separation portion and a portion being activatable to direct the lower stage along the return trajectory;
• a second fuel tank positioned within the second interior area and connected to the second power plant;
• a separation system releasably interconnecting the upper and lower body structures, the separation system being activatable to separate the upper body structure from the lower body structure at the separation portion of the first trajectory;
• a second landing system attached to the lower body structure and being deployable as the lower stage moves along the return trajectory toward the take-off and landing area, the second landing system having a second landing member that engages the take-off and landing area and supports the lower body structure upon landing;
• and
• a second flight control computer assembly mounted to the lower body structure and having a plurality of second sensors mounted to the lower body structure, the second power plant, the separation system, and the second landing system.

A reusable two-stage aerospace vehicle for a first Earth-to-orbit flight from a take-off and landing area on Earth to an orbit around the Earth and returning to the take-off and landing area, comprising:

• a wingless upper stage movable along a first trajectory away from the take-off and landing area to the orbit and along a second trajectory from the orbit to the take-off and landing area, the upper stage being reusable for a second Earth-to-orbit flight after the upper stage returns to the take-off and landing area, the upper stage including:
• an upper body structure having a first proximal portion, a first distal end portion and a first interior area therebetween;
• a payload support structure connected to the upper body structure;
• a first power plant connected to the first body structure and being activatable to propel the upper stage along a selected portion of the first trajectory to the orbit;
• a first microprocessor assembly connected to the first power plant and a plurality of first sensors attached to the first power plant, the first sensors being operatively connected the first microprocessor to transmit first data between the first sensors and the first microprocessor;
• a first fuel tank assembly positioned within the first interior area and being connected to the first power plant;
• a second microprocessor and a plurality of second sensors connected to the first fuel tank assembly, the second sensors being operatively connected to the second microprocessor to transmit second data between the second sensors and the second microprocessor;
• a first landing system attached to the upper body structure and being deployable as the upper stage moves along the second trajectory at a first velocity toward the take-off and landing area, the first landing system having a first landing member that engages the take-off and landing area and that supports the upper body structure off of the Earth upon landing;
• a third microprocessor connected to the first landing system and a plurality of third sensors connected to the first landing system and being operatively connected to the third microprocessor to transmit third data to the third microprocessor;
• a first flight control computer assembly attached to the upper body structure and having a fourth microprocessor, a first data storage device, a first inertial measurement device, a first positioning system receiver, and a first power supply;
• a first data bus connected to the first flight control computer and being connected to each of the first, second, and third microprocessors, the first data bus transmitting the first, second, and third data between the first flight control computer assembly and the respective first, second, and third microprocessors;
• and
• a wingless lower stage releasably connected to the upper stage, the lower stage being movable along the first trajectory away from the take-off and landing area to a separation portion along the first trajectory, being separable from the upper stage at the separation portion, and being movable along a return trajectory from the separation portion to the take-off and landing area, the lower stage being reconnectable to the upper stage and reusable for the second Earth-to-orbit flight after the lower stage returns to the take-off and landing area, the lower stage including:
• a lower body structure coaxially aligned with the first body structure, and having a second proximal portion and a second distal portion, the second distal portion being connected to the first proximal portion of the upper body structure;
• a second power plant connected to the lower body structure and being activatable to propel the upper and lower stages along the first trajectory from the take-off and landing area to the separation portion, the second power plant being activatable after separation of the upper and lower stages to move the lower stage from the separation portion to the return trajectory for return to the take-off and landing area;
• a second fuel tank assembly connected to the lower body structure and connected to the second power plant;
• and
• a second landing system attached to the lower body structure and being deployable as the lower stage moves along the return trajectory toward the take-off and landing area, the second landing system having a second landing member that engages the take-off and landing area and supports the lower body structure.

A method of transporting a payload from a take-off and landing area on Earth to an orbit around the Earth using a reusable two-stage aerospace vehicle and returning the aerospace vehicle to the take-off and landing area, comprising the steps of:

• releasably attaching the payload to the aerospace vehicle, the aerospace vehicle having an upper stage and a lower stage separately connected together, the upper stage including an upper body structure with a first proximal portion and a first distal portion, a payload support structure mounted to the first distal portion, a payload fairing mounted to the first distal portion, and a first power plant connected to first body structure, the lower stage including a second body portion with a second proximal portion and a second distal portion and a second power plant connected to the second body structure, the payload fairing being movable between an open position with the payload support structure being exposed and a closed position with the payload support structure being covered;
• positioning the aerospace vehicle on a take-off area;
• activating the second power plant and propelling the upper and lower stages upwardly away from the take-off area along a first trajectory away from the Earth to a separation portion of the first trajectory, the payload fairing being in the closed position and defining a leading portion of the aerospace vehicle as the aerospace vehicle moves along the first trajectory;
• separating the lower stage from the upper stage at the separation portion of the first trajectory and moving the upper and lower stages apart from each other;
• activating the first power plant of the upper stage after separation of the stages and propelling the upper stage from the separation portion along the first trajectory to the orbit;
• activating a portion of the second power plant of the lower stage after separation of the upper and lower stages and propelling the lower stage to the return trajectory;
• moving the second stage along the return trajectory and landing the second stage on the take-off and landing area;
• activating the second landing system as the lower stage approaches the take-off and landing area and landing the lower stage on the landing area with the first landing members engaging the landing area with the lower stage being reusable for a second Earth-to-orbit flight;
• moving the upper stage along the orbit and moving the payload fairing from the closed position to the open position to expose the payload;
• deploying the payload to a selected Earth orbit from the payload support structure when the payload fairing is in the open position and moving the payload fairing to the closed position after deployment of the payload;
• moving the upper stage from the orbit to a second trajectory from the Earth orbit toward the Earth, through an outer atmosphere of the Earth, and to the landing area, the upper stage generating frictional heat at the payload fairing as the upper stage moves through the outer atmosphere;
• and
• landing the upper stage on the take-off and landing area with the upper stage being reconnectable to the lower stage after returning to the landing area and being reusable for the second Earth-to-orbit flight.