An expandable shell-driven adaptive membrane protection mechanism

Abstract

The application discloses a deployable thin shell driven adaptive thin film protection mechanism and belongs to the technical field of space satellite protection. The deployable structure is composed of a carbon fiber thin shell and a thin film. Other components include a stepping motor, a bevel gear, a rotating shaft, a shell, a buckle and a roller. The thin shell is connected with a reset rubber band through structural design to realize automatic bending. One end of the thin film is connected with a storage component, and the other end is connected with a free end of the thin shell. The thin shell is automatically bent to drive the thin film to be unfolded and wrapped, so that satellite protection is realized. The application realizes lightweight protection mechanism design of an on-orbit satellite, can significantly reduce the damage of space debris to the satellite, improves the durability and working efficiency of the satellite, and improves the working safety of the satellite to a certain extent.

Description

Technical Field

[0001] This invention belongs to the field of space satellite protection technology, specifically, it relates to an adaptive thin-film protection mechanism driven by a deployable thin shell. Background Technology

[0002] In low Earth orbit, millimeter-sized debris travels at ultra-high speeds and can penetrate the outer shell of traditional spacecraft, threatening the safety of equipment and personnel; the temperature difference in space can reach ±200°C, requiring materials to have high thermal stability and low coefficient of thermal expansion; high-energy particles in solar wind and cosmic rays can damage electronic devices and threaten the health of astronauts.

[0003] The aluminum protective layer needs to be stacked in multiple layers, which significantly increases the launch cost; traditional structures are difficult to cope with impact, radiation and thermal control requirements at the same time, requiring multiple systems to be stacked, which is highly complex.

[0004] Deep space exploration and long-term stationary missions require lightweight and scalable structures, which traditional rigid structures cannot meet. The application of thin-film structures in the field of space protection technology stems from the urgent need for efficient and lightweight protection solutions, as well as the advancements in materials science and aerospace technology. Through material innovation and design optimization, thin-film structures have solved the quality and functional bottlenecks of traditional protection technologies, achieving functions such as ultra-lightweighting, impact resistance, radiation shielding, and thermal control. They have become a key technology for deep space exploration, space station expansion, and satellite protection. Summary of the Invention

[0005] In view of this, the technical problem to be solved by the present invention is to provide an adaptive thin-film protection mechanism driven by a deployable thin shell, which avoids the problems of large protective layer weight and high launch cost in the prior art, and achieves radiation and thermal control requirements.

[0006] To address the aforementioned technical problems, this invention discloses an adaptive thin-film protection mechanism driven by deployable thin shells. After the device is attached to a satellite, four thin shells are deployed in a cross-shaped arrangement, with each pair of shells forming a 90° angle. These shells are automatically bent into semicircles by a reset rubber band, enveloping the satellite to form an approximately spherical structure. Four thin films are stored at the four corners of the outer shell, with one end fixed and the other end connected to the free end of the thin shell. The deployment of the thin shells pulls the films to unfold and envelop the satellite, forming a spherical wrapping membrane. The device contains a built-in motor that provides driving force to rotate the shaft, thereby ensuring that the four rollers rotate simultaneously through bevel gears, causing the carbon fiber thin shells to curl or extend.

[0007] An adaptive thin-film protection mechanism driven by an deployable thin shell is rectangular in shape with rounded corners at the four corners. It consists of an outer shell, a rotating shaft system, a carbon fiber thin shell, and a thin film. The outer shell consists of two parts: an upper and a lower part; the bottom of the outer shell has a reserved space to store the film, and a motor is placed in the center. The space is completely slotted on all four sides for the thin shell and the film to stretch. The approximate formula for calculating the area of ​​a single thin film is as follows: in, This refers to the area of ​​a single thin film. The mean radius of curvature of the thin shell in its unfolded, bent state. in, The length of a single thin shell.

[0008] The outer shell measures 200mm × 200mm × 80mm, and the diameter of the sphere enclosed by the structure after unfolding is 1m. The thin shell is divided into 5 sections, each section is 309mm long, and the total length is 1545mm. One end of the carbon fiber shell is connected to the film fixing device, and the other end is connected to the rotating shaft. The stepper motor provides power to the rotating shaft system. The carbon fiber shell, in its naturally extended state, is an arc-shaped rod-shaped shell with a central angle of 120 degrees (radius of 2cm in cross-section). It has openings on both sides of the edge and is threaded through with a reset rubber band, which allows the shell to automatically bend during the unfolding process. The shell can be rolled up under the action of the roller torque. The rotating shaft system includes a rotating shaft, a roller, bevel gears, a synchronous belt, a stepper motor, and a snap fastener. The rotating shaft passes through the roller and is fixed to the bevel gear at its end. Four pairs of bevel gears are located at the turning points of the four rotating shafts. The simultaneous rotation of the bevel gears ensures that the rollers rotate simultaneously and the thin shell unfolds synchronously. The synchronous belt is used for power transmission between the motor and the rotating shaft. The rotating shaft is fixed to the chassis of the outer shell by the snap fastener, and the motor is fixed by a slot on the chassis. The bevel gears are covered by gear covers to ensure stable gear operation.

[0009] The roller has snap-fit ​​edges on both sides, and the main body of the roller is an irregular cylinder. With the help of specific pins, it can fix the thin shell. The diameter of the roller was determined experimentally. A series of roller diameters were set, and the adhesion of the rolled-up part of the thin shell and the stability of the stretched part were measured and compared to select the optimal diameter. The rotating shaft passes through the roller and is supported at both ends by buckles. The stepper motor is fixed in the slot at the bottom of the housing, and the motor shaft and the rotating shaft transmit torque through a synchronous belt. The rotating shaft is fixed to the roller by a pin, and the synchronous pulley is fixed in conjunction with the rotating shaft.

[0010] The film comprises a polyimide matrix layer and an embedded metal microfilament array, which work together to form a composite structure with dual-mode protection functions of mechanical reinforcement and electromagnetic shielding.

[0011] Compared with the prior art, the present invention can achieve the following technical effects: 1. The main body of the rotating shaft system of the present invention is composed of bevel gears, which engage in four vertical directions to achieve synchronous and vertical unfolding of the thin shells on the four rotating shafts; a single motor and four sets of bevel gear linkage system are set inside the shell, and the output shaft of the motor drives the four rollers to rotate synchronously through the vertical meshing structure of the bevel gears; the bevel gear sets are isolated and fixed by a closed protective cover, and the four sets of rollers unfold from the side opening of the shell through the carbon fiber thin shell traction film, realizing synchronous control of the displacement of the thin shell and the film, and the transmission system is simplified and has high transmission efficiency.

[0012] 2. The arc-shaped carbon fiber thin shell is in the shape of an arc rod when naturally stretched. It has certain rigidity, bending strength, tensile strength and stability. When subjected to torque at one end, it can be rolled up or stretched along the rod direction. This characteristic meets the requirement that the part can be unfolded while having certain mechanical properties.

[0013] 3. The stepper motor drives the rotating shaft through the synchronous belt, and the rotating shaft drives the roller to rotate, realizing the synchronous unfolding of the thin shell and film, which simplifies the structure and reduces the overall weight.

[0014] 4. The stepper motor provides power to the rotating shaft, causing the thin shell to curl or extend, thereby changing the extension length of the carbon fiber thin shell. During transportation, each unit thin shell is completely curled up; after being connected to the satellite, the motor drives the four carbon fiber thin shells to gradually extend, the structure unfolds, and the space occupied is maximized. This unfoldable characteristic improves the space utilization and flexibility of the structure.

[0015] 5. A layer of highly effective adsorption material is attached to the bottom outer side of the device shell. This adsorption material is a nano-structured composite material designed based on biomimetic principles. This material can remain stable in the extreme temperature environment of the satellite surface and can automatically adjust the adsorption strength according to the material of the contact surface. Dynamic adsorption is achieved by combining smart materials in a pre-set installation area on the outer surface of the main structure of the satellite body.

[0016] 6. Through the elastic pre-tightening design of the thin shell structure, a reset rubber band is inserted into the pre-set perforation of the shell to achieve a self-bending shape by utilizing the material's springback characteristics. The curvature is controlled by adjusting the distribution of the perforation positions.

[0017] 7. The thin film structure is lightweight, easy to store, and has radiation shielding and heat protection functions. Compared with the traditional aluminum protective layer, it achieves lightweight, multi-functionality and significantly improves storage.

[0018] 8. The present invention stores four films at the bottom of the device, with one end fixed and the other end connected to the free end of the thin shell. The thin shell structure unfolds and pulls the films to unfold and wrap them, forming a spherical wrapping film. No other driving force is needed to drive the films to unfold, thus reducing energy consumption.

[0019] Of course, any product implementing this invention does not necessarily need to achieve all of the technical effects described above at the same time. Attached Figure Description

[0020] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this invention, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the unfolded state of the adaptive thin-film protection mechanism driven by the unfoldable thin shell in an embodiment of the present invention; Figure 2 This is a schematic diagram of the retracted state of the adaptive thin-film protection mechanism driven by the deployable thin shell in an embodiment of the present invention. Figure 3 for Figure 2 A schematic diagram of the exploded parts from a different perspective; Figure 4 for Figure 1 A schematic diagram of the exploded parts from a different perspective; Figure 5 This is a schematic diagram of the carbon fiber thin shell bending structure of the adaptive thin-film protection mechanism with deployable thin shell drive in an embodiment of the present invention; Figures 6-18 for Figure 3 and Figure 4 A schematic diagram of each part.

[0021] Figure Labels

[0022] 1-Thin film; 2-Reset rubber band; 3-Carbon fiber shell; 4-Outer shell; 5-Bevel gear; 6-Roller; 7-Synchronous belt; 8-Snap fastener; 9-Shaft; 10-Stepper motor; 11-Interface disc; 12-Gear cover; 13-Long bolt; 14-Pin. Detailed Implementation

[0023] The following will describe in detail the implementation of the present invention with reference to the accompanying drawings and embodiments, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly. Example 1

[0024] It's important to understand that this protective mechanism achieves adaptive adsorption and connection with the outer surface of the satellite's main structure through a nanostructured composite material at the base of the substrate. This nanostructured composite material is designed based on biomimetic principles. During manufacturing, a special nanoprocessing technique is used to combine nanomaterials with different functions, giving it the ability to remain stable under extreme temperature environments. In practical applications, an installation area is first pre-defined on the outer surface of the satellite's main structure. After cleaning the installation area, the protective mechanism is placed in that area. At this point, the nanostructured composite material automatically adjusts its adsorption strength according to the material of the contact surface, tightly bonding with the microstructure of the satellite surface at the nanoscale, forming multi-scale adsorption and establishing a stable connection that meets the requirements of the space environment.

[0025] like Figure 1 As shown, an adaptive thin-film protection mechanism driven by an expandable thin shell is shown in its unfolded state. The thin shell unfolds, causing the thin film 1 to unfold and wrap around the structure, forming a spherical protective barrier. The thin-film structure is lightweight, easy to store, and has radiation shielding and heat protection functions. Compared with traditional aluminum protective layers, it achieves lightweight, multi-functionality and significantly improves storage capacity.

[0026] like Figure 2 As shown, an adaptive thin-film protective mechanism driven by an expandable thin shell is shown in its retracted state. The outer shell 4 is composed of upper and lower parts, and the thin film 1 is retracted at the bottom of the outer shell.

[0027] The outer casing 4 adopts a split design, with the upper and lower casings reliably connected by circumferentially evenly distributed long bolts 13. The connection point is equipped with a pre-threaded structure, which forms a precise fit with the bolts to ensure the structural integrity of the component under complex working conditions.

[0028] Specifically, the outer shell 4 measures 200mm × 200mm × 80mm and consists of two parts, upper and lower. During manufacturing, the upper and lower shells are machined separately. A space is reserved at the bottom for storing the film, and a space is provided in the center for placing the motor. All four sides of this space are slotted to ensure smooth expansion of the shell and film. The upper and lower shells are reliably connected by four circumferentially distributed long bolts 13. A pre-threaded structure is provided at the connection point between the upper and lower shells to form a precise fit with the bolts. During assembly, the long bolts 13 are passed through the corresponding bolt holes in the upper and lower shells, and the bolts are tightened to the specified torque using a special tool, ensuring good structural integrity of the component under complex spatial conditions.

[0029] The carbon fiber shell 3 of this invention, in its naturally extended state, is an arc-shaped rod-like shell with a central angle of 120 degrees (radius of 2cm in cross-section), and a thickness of 0.2mm. It possesses certain rigidity, bending strength, tensile strength, and stability. One end is fixed to the roller 6 by a pin 14, and the other end is connected to the rotating shaft 9. During manufacturing, advanced carbon fiber molding technology is employed to ensure that the shell's performance indicators meet design requirements. Holes are opened on both sides of the carbon fiber shell 3, through which reset rubber bands 2 pass. During the shell's unfolding process, the elasticity of the reset rubber bands 2 enables automatic bending. By changing the position of the holes, the degree of bending of the shell can be adjusted, thereby controlling the shell's curvature. In practical applications, the hole positions are pre-designed according to different protection requirements and satellite shapes to ensure that the carbon fiber shell 3 forms a suitable wrapping shape after unfolding. The film 1 comprises a polyimide matrix layer and an embedded metal microfilament array, which synergistically form a composite structure with dual-mode protection functions of mechanical reinforcement and electromagnetic shielding. Preferably, the thin shell is divided into 5 sections, each section is 309mm long, and the total length is 1545mm.

[0030] Furthermore, the approximate formula for calculating the area of ​​a single thin film is as follows: in, This refers to the area of ​​a single thin film. The mean radius of curvature of the thin shell in its unfolded, bent state. in, The length of a single thin shell.

[0031] Next, please refer to Figures 3-18 The rotating shaft system consists of several parts, namely, bevel gear 5, roller 6, synchronous belt 7, buckle 8, rotating shaft 9, stepper motor 10, interface disc 11, and gear cover 12.

[0032] The rotating shaft 9 is designed with two unequal-diameter arc surfaces on its sides, one of which has two symmetrical holes for fixing the carbon fiber shell 3. During manufacturing, precise machining ensures the dimensional accuracy and surface quality of the rotating shaft 9. The rotating shaft 9 passes through the roller 6, which has snap-fit ​​flanges on both sides. The roller body is an irregular cylinder, and with specific pins, the shell can be fixed to the roller 6. Snap-fit ​​8 is fixed to the outer casing chassis, and the two ends of the rotating shaft 9 are supported by snap-fit ​​8, ensuring the stability of the rotating shaft 9 during rotation. Bevel gears 5 connect to both ends of the rotating shaft 9, meshing at the corners. This vertical meshing structure ensures that the shells on the four rotating shafts can unfold synchronously and vertically. A synchronous motor 10, fixed in the middle of the outer casing, is connected to the rotating shaft 9 via a synchronous belt 7. An interface disc 11 is added to the synchronous motor 10 to increase the transmission torque. During operation, the stepper motor 10 rotates, driving the synchronous belt 7 to move. The synchronous belt 7 transmits power to the rotating shaft 9, which in turn drives the roller 6 to rotate, realizing the synchronous unfolding and retraction of the carbon fiber shell 3 and the film 1. At the same time, in order to ensure stable operation of the gears, the bevel gear is covered by the gear cover 12.

[0033] The deployment process is as follows: After the protective mechanism is connected to the satellite and receives the deployment command, the stepper motor 10 starts and transmits power to the rotating shaft 9 via the synchronous belt 7. When the rotating shaft 9 rotates, since it passes through the roller 6 and is fixed to the roller 6 by a pin, it drives the roller 6 to rotate as well. The torque generated by the rotation of the roller 6 acts on the carbon fiber shell 3, which is fixed to the roller 6 by the pin 14, causing the carbon fiber shell 3 to gradually extend under the action of the roller torque. In its naturally extended state, the carbon fiber shell 3 is an arc-shaped rod-shaped shell with a central angle of 120 degrees. Holes are pre-drilled on both sides of its curved section, and the reset rubber band 2 passes through these holes. During the shell's extension, the elasticity of the reset rubber band 2 is used to make the shell automatically bend into a semi-circle. As the four shells are distributed and deployed in a cross shape, with an angle of 90 degrees between each pair and bent into a semi-circle, they pull the film 1 connected to the free end of the shell to unfold. Finally, the four films form a spherical wrapping membrane, achieving protection for the satellite.

[0034] In the retracted state, the outer shell consists of two parts, upper and lower, with the film retracted at the bottom. When the protective mechanism needs to be retracted, the stepper motor 10 rotates in the reverse direction, driving the roller 6 to rotate in the reverse direction via the synchronous belt 7 and the rotating shaft 9, gradually rolling the carbon fiber shell 3 onto the roller 6. Since one end of the film 1 is connected to the free end of the carbon fiber shell 3 and the other end is fixed to the bottom of the outer shell 4, the film 1 is also stored in the reserved space at the bottom of the outer shell 4 during the rolling process of the carbon fiber shell 3.

[0035] In summary, this invention achieves a lightweight protective mechanism design for on-orbit satellites, which can significantly reduce damage to satellites from space debris, improve satellite durability and operational efficiency, and the thin film wrapping provides a certain degree of shielding against electromagnetic signals, thereby improving satellite operational safety.

[0036] The foregoing description illustrates and describes several preferred embodiments of the present invention. However, as previously stated, it should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept described herein through the foregoing teachings or techniques or knowledge in related fields. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. An adaptive thin-film protection mechanism driven by a deployable thin shell, comprising a shell (4), a protection component, and a rotating shaft system, characterized in that: The outer shell (4) is composed of an upper shell and a lower shell, which are connected by four long bolts (13). The bottom of the outer shell (4) is provided with a film storage space. The center of the outer shell (4) is provided with a stepper motor (10) installation space. The four sides of the outer shell (4) are respectively provided with slots for the carbon fiber shell (3) and the film (1) to extend out. The protective assembly includes four carbon fiber shells (3) and four films (1). The four carbon fiber shells (3) are distributed in a cross shape and the included angle between two adjacent carbon fiber shells (3) is 90°. The winding end of each carbon fiber shell (3) is connected to the corresponding roller (6). One end of each film (1) is fixed to the bottom of the outer shell (4) and the other end is connected to the free end of the corresponding carbon fiber shell (3). The carbon fiber shell (3) is an arc-shaped rod-shaped shell with a central angle of 120° and a thickness of 0.2 mm in its natural extended state. Multiple holes are provided on both sides of the carbon fiber shell (3). The position distribution of the multiple holes matches the target bending curvature required for the carbon fiber shell (3) to form a semi-circle after unfolding. The reset rubber band (2) passes through the multiple holes. The rotating shaft system has a built-in stepper motor (10) and is configured to drive the four rollers (6) to rotate synchronously in the unfolding or retracting direction. When the four rollers (6) rotate in the unfolding direction, the four carbon fiber shells (3) are released from the corresponding rollers (6) and bend into a semi-circle along the length direction under the rebound of the reset rubber band (2). The four carbon fiber shells (3) together define an approximately spherical envelope. The four films (1) are unfolded under the traction of the corresponding carbon fiber shells (3) and together form a spherical wrapping film. When the four rollers (6) rotate in the retracting direction, the four carbon fiber shells (3) are rolled up to the corresponding rollers (6) and drive the four films (1) to be recycled into the film storage space. The film (1) includes a polyimide matrix layer and a metal microfilament array embedded in the polyimide matrix layer. The polyimide matrix layer and the metal microfilament array together form a composite structure with mechanical reinforcement and electromagnetic shielding functions.

2. The deployable thin-shell driven adaptive thin-film protection mechanism according to claim 1, characterized in that, The cross-sectional radius of the carbon fiber shell (3) is 2 cm. The carbon fiber shell (3) is divided into 5 sections, each section is 309 mm long, and the total length is 1545 mm.

3. The deployable thin-shell driven adaptive thin-film protection mechanism according to claim 1, characterized in that, The outer shell (4) has dimensions of 200 mm × 200 mm × 80 mm, and the spherical wrapping film formed by the unfolding of the four films (1) has a diameter of 1 m.

4. The deployable thin-shell driven adaptive thin-film protection mechanism according to claim 1, characterized in that, The rotating shaft system also includes four rotating shafts (9), four rollers (6), four pairs of bevel gears (5), a timing belt (7), and a buckle (8); the carbon fiber shell (3) is fixed to the corresponding roller (6) by a pin (14), the rotating shaft (9) passes through the corresponding roller (6) and the end is fixedly connected to the bevel gear (5), the four pairs of bevel gears (5) are respectively set at the turning positions of the four rotating shafts (9) and cooperate with each other so that the four rollers (6) rotate synchronously; the timing belt (7) is set between the stepper motor (10) and the rotating shaft (9), the rotating shaft (9) is supported on the chassis of the outer shell (4) by the buckle (8), the stepper motor (10) is installed in the slot of the chassis, and the bevel gear (5) is provided with a gear cover (12) on the outside.

5. The deployable thin-shell driven adaptive thin-film protection mechanism according to claim 4, characterized in that, The roller (6) has snap-on retaining edges on both sides. The main body of the roller (6) is an irregular cylindrical shape. The snap-on retaining edges are fixed to the chassis of the outer shell (4) by the snap-on (8).

6. The deployable thin-shell driven adaptive thin-film protection mechanism according to claim 4, characterized in that, The stepper motor (10) is provided with an interface disk (11) for increasing the transmission torque. The stepper motor (10) is connected to the rotating shaft (9) via the synchronous belt (7).

7. The deployable thin-shell driven adaptive thin-film protection mechanism according to claim 4, characterized in that, The side of the rotating shaft (9) includes two arc surfaces with unequal radii, one of which has two holes symmetrically provided for fixing the carbon fiber shell (3).

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