IP Library › Granted Patent US 12687138
Granted Patent B1
US 12687138 · App. 19/205,845 · Granted Jul 21, 2026

Rocket nozzle assembly with separable nozzle extension

Inventors: Adam M. Wuerl (Seattle, WA); David Alan Degenhardt (Seattle, WA); Gary D. Grayson (Maple Valley, WA); James W. Nord (Jupiter, FL)
Assignee: Blue Origin Manufacturing, LLC
F02K9/978
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Quick Facts
Patent No.
US 12687138
App. No.
19/205,845
Granted
Jul 21, 2026
Kind
B1
Abstract

Rocket nozzle assembly having a separable outboard nozzle extension for transitioning from a vacuum-optimized to an atmospheric-optimized configuration. The nozzle assembly includes an inboard divergent nozzle section attached at an interface with a detachable outboard divergent nozzle extension. The nozzle and extension are removably attached via a connector, such as a clamp and strap. An actuator causes the connector to release and thereby allow the extension to separate from the nozzle in flight. The nozzle assembly may be used with a reusable second stage rocket that lands on the ground or an ocean platform. The nozzle extension may be replaced in between flights.

Claims (23)

1 . A rocket nozzle assembly comprising:

a nozzle having a frustoconical nozzle body that extends axially between a first inboard end and a first outboard end and defines a nozzle channel;

a nozzle extension having a frustoconical extension body that extends axially from a second inboard end to a second outboard end, wherein the second inboard end is releasably coupled to the nozzle assembly at an outboard interface via a frangible connector extending annularly about the outboard interface, and wherein the frustoconical extension body defines an extension channel that is axially aligned with the nozzle channel;

an intermediate nozzle extension having a second frustoconical extension body that extends axially between a third inboard end and a third outboard end and defines a second extension channel that is axially aligned with the nozzle channel, wherein the third inboard end is removably coupled to the first outboard end at an inboard interface via a second connector extending annularly about the inboard interface and the second inboard end is releasably coupled to the third outboard end at the outboard interface via the frangible connector; and

an actuator in physical communication with the frangible connector and configured to cause the nozzle extension to detach from the nozzle assembly along the outboard interface.

2 . The rocket nozzle assembly of claim 1 , wherein the actuator causes the frangible connector to break.

3 . The rocket nozzle assembly of claim 1 , wherein the frangible connector comprises a plurality of detachable fasteners.

4 . The rocket nozzle assembly of claim 3 , wherein the plurality of detachable fasteners are rivets.

5 . The rocket nozzle assembly of claim 1 , wherein the actuator is configured to cause the nozzle extension to detach from the intermediate nozzle extension during flight.

6 . The rocket nozzle assembly of claim 1 , wherein the intermediate nozzle extension is configured to remain attached to the nozzle along the inboard interface during flight.

7 . The rocket nozzle assembly of claim 1 , wherein the intermediate nozzle extension is configured to be removed from the nozzle along the inboard interface after landing.

8 . A rocket system comprising:

a second stage rocket comprising one or more second stage rocket engines having a nozzle assembly configured to transform from a vacuum-optimized configuration to an atmospheric-optimized configuration, wherein the nozzle assembly comprises:

a nozzle having a frustoconical nozzle body that extends axially between a first inboard end and a first outboard end and defines a nozzle channel;

a nozzle extension having a frustoconical extension body that extends axially from a second inboard end to a second outboard end, wherein the second inboard end is releasably coupled to the nozzle assembly at an outboard interface via a frangible connector extending annularly about the outboard interface, and wherein the frustoconical extension body defines an extension channel that is axially aligned with the nozzle channel;

an intermediate nozzle extension having a second frustoconical extension body that extends axially between a third inboard end and a third outboard end and defines a second extension channel that is axially aligned with the nozzle channel, wherein the third inboard end is removably coupled to the first outboard end at an inboard interface via a second connector extending annularly about the inboard interface and the second inboard end is releasably coupled to the third outboard end at the outboard interface via the frangible connector; and

an actuator in physical communication with the frangible connector and configured to cause the nozzle extension to detach from the nozzle assembly along the outboard interface.

9 . The rocket system of claim 8 , wherein the actuator causes the frangible connector to break.

10 . The rocket system of claim 8 , wherein the frangible connector comprises a plurality of detachable fasteners.

11 . The rocket system of claim 10 , wherein the plurality of detachable fasteners are rivets.

12 . The rocket system of claim 8 , wherein the actuator is configured to cause the nozzle extension to detach from the intermediate nozzle extension during flight.

13 . The rocket system of claim 8 , wherein the intermediate nozzle extension is configured to remain attached to the nozzle along the inboard interface during flight.

14 . The rocket system of claim 2 , wherein the intermediate nozzle extension is configured to be removed from the nozzle along the inboard interface after landing.