A deformable liquid metal thermally controlled commercial aerospace flexible deployment mechanism

Abstract

This invention relates to the field of thermal control technology for commercial aerospace deployment mechanisms, and more particularly to a flexible deployment mechanism for commercial aerospace using deformable liquid metal thermal control. The mechanism includes a flexible deployment mechanism body, a flexible fluid circulation pipeline integrated inside or on the surface of the flexible deployment mechanism body, which retracts and deploys synchronously with the flexible deployment mechanism body; and a fluid drive and heat exchange unit located in a non-flexible area of ​​the spacecraft platform or body, connected to the flexible fluid circulation pipeline to form a closed loop. The flexible fluid circulation pipeline is filled with a liquid metal working fluid. This invention utilizes the high thermal conductivity and flow characteristics of the liquid metal working fluid, combined with a leaf vein / grid-like microtube array, to quickly equalize the temperature in different areas of the flexible deployment mechanism, effectively eliminating structural stress deformation caused by temperature gradients; and significantly improving the mechanism's adaptability to extreme space environments such as alternating high and low temperatures and strong radiation.

Description

Technical Field

[0001] This invention relates to the field of thermal control technology for commercial space deployment mechanisms, and in particular to a flexible commercial space deployment mechanism with deformable liquid metal thermal control. Background Technology

[0002] Flexible deployment mechanisms in commercial spaceflight are a core component of spacecraft in orbit, widely used in critical components such as solar panels, deployable antennas, and flexible radiators. Their design must simultaneously meet the requirements of compact folding during launch and reliable deployment during in-orbit operation. These mechanisms are typically manufactured using lightweight, flexible composite materials, enabling them to fold and retract during launch to reduce space requirements. Once in orbit, they are precisely deployed via a pre-programmed drive mechanism, thus fulfilling core functions such as energy harvesting, signal transmission, and thermal control. They are a key supporting technology for the lightweighting and scaling of commercial satellites, space station modules, and deep space probes.

[0003] However, flexible deployment mechanisms for commercial spaceflight face extremely harsh challenges from the space thermal environment. Throughout their on-orbit lifecycle, they must undergo cycles from the high temperatures of near-Earth orbit to the extremely low temperatures of shadowed regions, with temperature fluctuations reaching hundreds of degrees Celsius. On one hand, flexible composite materials have poor thermal conductivity, easily forming significant regional temperature gradients, leading to thermal stress that causes structural deformation, wrinkling, and even connection failure. On the other hand, materials are prone to embrittlement at low temperatures, severely affecting the mechanical properties and deployment reliability of the deployment mechanism. Traditional rigid thermal control structures are ill-suited to the folding-deployment deformation requirements of flexible mechanisms, and conventional flexible heat dissipation solutions can only achieve passive heat dissipation, failing to simultaneously address both low-temperature heating to prevent embrittlement and rapid temperature equalization, thus limiting the on-orbit stability and service life of flexible deployment mechanisms for commercial spaceflight. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing flexible composite materials, which have poor thermal conductivity and are prone to forming significant regional temperature gradients; and conventional flexible heat dissipation solutions can only achieve passive heat dissipation and cannot simultaneously address the functions of low-temperature heating to prevent embrittlement and rapid temperature equalization, thus restricting the on-orbit stability and service life of commercial aerospace flexible deployment mechanisms. Therefore, this invention proposes a deformable liquid metal thermal control commercial aerospace flexible deployment mechanism.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A deformable liquid metal thermally controlled commercial aerospace flexible deployment mechanism includes:

[0007] The flexible deployment mechanism body has a retracted state during launch and an deployed state during on-orbit operation;

[0008] The flexible fluid circulation pipeline is at least partially integrated inside or on the surface of the flexible deployment mechanism body, and retracts and unfolds synchronously with the flexible deployment mechanism body.

[0009] And a fluid drive and heat exchange unit, which is located in the non-flexible area of ​​the spacecraft platform or the body of the flexible deployment mechanism, and is connected to the flexible fluid circulation pipeline to form a closed loop;

[0010] The flexible fluid circulation pipeline is filled with a liquid metal working fluid.

[0011] The fluid drive and heat exchange unit includes:

[0012] An electromagnetic pump is used to drive the liquid metal working fluid to flow within a closed loop.

[0013] A heat exchanger is used to achieve heat exchange between the liquid metal working fluid and the thermal control system of the spacecraft platform or the space environment.

[0014] Preferably, the flexible fluid circulation pipeline includes a pipe wall made of an elastic polymer with shape memory effect, so that the pipeline can return to a preset shape and flow cross section after the flexible deployment mechanism body is deployed.

[0015] Preferably, the microtube array is distributed in a leaf vein pattern within the plane of the flexible deployment mechanism body.

[0016] Preferably, the microtube array is distributed in a grid pattern within the plane of the flexible deployment mechanism body.

[0017] Preferably, it further includes:

[0018] A distributed temperature sensor array is arranged on the flexible deployment mechanism body;

[0019] A thermal control manager, connected to the distributed temperature sensor array and the electromagnetic pump signal, is used to actively adjust the power of the electromagnetic pump according to the temperature signal, thereby controlling the flow rate and heat transport capacity of the liquid metal, and realizing active heating or heat dissipation of the flexible deployment mechanism body.

[0020] Preferably, the liquid metal working medium is a gallium-based or indium-based low-melting-point alloy.

[0021] Preferably, the flexible deployment mechanism body is a solar panel substrate or a deployable antenna reflector.

[0022] Preferably, the flexible fluid circulation pipeline is arranged in the form of a microtube array on the surface of the flexible deployment mechanism body.

[0023] Preferably, the flexible deployment mechanism body is a composite material sandwich structure, and the flexible fluid circulation pipeline is embedded in the middle of the composite material sandwich in the form of a microtube array.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] 1. When in use, the liquid metal working fluid has high thermal conductivity and flow characteristics. Combined with the leaf vein-like / grid-like microtube array, it can quickly and evenly equalize the temperature of each area of ​​the flexible unfolding mechanism, effectively eliminating structural stress deformation caused by temperature gradient. In low-temperature environments, active heating prevents the composite material from becoming brittle and breaking. In high-temperature environments, it efficiently removes solar heat, achieving integrated control of "heating-heat dissipation-temperature equalization", which greatly improves the adaptability of the mechanism in extreme space environments such as alternating high and low temperatures and strong radiation.

[0026] 2. In use, this invention can collect temperature data of various parts of the mechanism in real time through a distributed temperature sensor array. The thermal control manager actively adjusts the power of the electromagnetic pump according to the temperature signal, and accurately controls the flow rate and heat transport capacity of the liquid metal to achieve "on-demand thermal control" and avoid energy waste. The closed loop design allows the liquid metal working medium to be recycled without additional replenishment. In conjunction with the thermal control system of the spacecraft platform, it can work together to exchange heat, further improve the long-term stability and reliability of the thermal control system, and reduce the risk of on-orbit failure.

[0027] 3. When in use, the flexible fluid circulation pipeline is made of an elastic polymer with shape memory effect. After being embedded in the composite material interlayer, it can complete the large deformation movement of shrinking and unfolding synchronously with the unfolding mechanism. It will not cause pipeline rupture or leakage due to deformation. After unfolding, it can automatically restore the preset flow section to ensure the stable operation of the thermal control circulation system. The integrated design of microtube array and composite material does not damage the original flexibility and structural strength of the mechanism, and takes into account both thermal control function and mechanical performance. Attached Figure Description

[0028] Figure 1 This is a three-dimensional structural schematic diagram of a deformable liquid metal thermal control flexible deployment mechanism for commercial aerospace proposed in this invention;

[0029] Figure 2 This is a three-dimensional structural diagram of the fluid drive and heat exchange unit of a commercial aerospace flexible deployment mechanism with deformable liquid metal thermal control proposed in this invention.

[0030] Figure 3 This is a schematic diagram of a microtube array structure for a commercial aerospace flexible deployment mechanism with deformable liquid metal thermal control proposed in this invention.

[0031] Figure 4This is a schematic diagram of the cross-sectional structure of the flexible deployment mechanism body of a commercial aerospace flexible deployment mechanism with deformable liquid metal thermal control proposed in this invention.

[0032] In the figure: 1. Flexible deployment mechanism body; 2. Flexible fluid circulation pipeline; 3. Fluid drive and heat exchange unit; 31. Electromagnetic pump; 32. Heat exchanger; 4. Distributed temperature sensor array. Detailed Implementation

[0033] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0034] Reference Figures 1-4 A deformable liquid metal thermally controlled commercial aerospace flexible deployment mechanism, comprising:

[0035] The flexible deployment mechanism body 1 has a retracted state during launch and an deployed state during on-orbit operation. The flexible deployment mechanism body 1 adopts a composite material sandwich structure, specifically including an upper functional surface layer, a middle functional layer, and a lower load-bearing support layer. Each layer is firmly connected into one piece through a hot-pressing composite process.

[0036] Upper functional surface layer: Select the appropriate material according to the application scenario - if it is a solar panel substrate, use a glass fiber cloth / polyimide film composite layer; if it is a deployable antenna reflector, use a composite structure of metal mesh reflector and polyimide film to ensure functionality while meeting flexibility requirements.

[0037] Intermediate functional layer: The flexible polymer matrix is ​​used as a carrier. The flexible polymer matrix is ​​selected from silicone rubber or flexible epoxy resin. The microtube array of flexible fluid circulation pipeline 2 is embedded inside. The microtube array and the flexible polymer matrix are integrated and encapsulated by casting, hot pressing or 3D printing embedding process, without relative displacement.

[0038] The lower load-bearing support layer is made of carbon fiber reinforced composite material thin plate with a thickness controlled between 0.8-1.5mm, which ensures the overall structural strength of the mechanism without affecting its flexible deployment and retraction performance.

[0039] The flexible fluid circulation pipeline 2 is at least partially integrated inside or on the surface of the flexible deployment mechanism body 1, and retracts and deploys synchronously with the flexible deployment mechanism body 1. The flexible fluid circulation pipeline 2 is arranged in the form of a microtube array, and the cross-section of the microtube is a rectangular or elliptical flat structure (major axis 5-8mm, minor axis 1-2mm). It is distributed in a leaf vein or grid pattern in the plane of the flexible deployment mechanism body 1. The leaf vein pattern is suitable for long strip solar wing substrates, and the grid pattern is suitable for large area antenna reflector surfaces to ensure uniform heat coverage.

[0040] The walls of the microtubes are made of elastic polymers with shape memory effect, specifically polyurethane shape memory polymers or silicon-based shape memory polymers, with a glass transition temperature of -20℃ to 10℃. After on-track deployment, they can recover to the preset flat shape and flow cross section under temperature triggering, and the dimensional tolerance of the flow cross section is controlled within ±0.1mm.

[0041] The liquid metal working medium filled in the microtube array is a gallium-based low-melting-point alloy (such as Ga-In-Sn alloy, melting point ≤15℃) or an indium-based low-melting-point alloy (such as In-Bi-Sn alloy, melting point ≤40℃). The working medium filling rate is 90%-95% of the microtube volume, with reserved space for volume compensation.

[0042] And the fluid drive and heat exchange unit 3 is located in the non-flexible area of ​​the spacecraft platform or body 100 and is connected to the flexible fluid circulation pipeline 2 to form a closed loop.

[0043] The fluid drive and heat exchange unit 3 includes:

[0044] Electromagnetic pump 31 is used to drive the flow of liquid metal working fluid in a closed loop. It is a miniature non-contact electromagnetic pump with a rated power of 5-20W and a flow rate adjustment range of 0.1-1L / min. It uses the conductivity of liquid metal to drive the working fluid circulation through electromagnetic force. The pump body shell is made of titanium alloy material, which is suitable for space vacuum environment.

[0045] Heat exchanger 32 is used to achieve heat exchange between the liquid metal working fluid and the thermal control system of the spacecraft platform or the space environment. It adopts a miniature plate-fin heat exchanger with a heat exchange area of ​​0.1-0.5m². 2 With a working pressure ≤0.5MPa, one end is connected to the outlet of electromagnetic pump 31 through a pipeline, and the other end is connected to the radiating plate or thermal control fluid loop of the spacecraft platform thermal control system to realize heat exchange between liquid metal and the space environment.

[0046] The circulation loop also includes a liquid storage tank and a compensation tank connected in series. The liquid storage tank and the compensation tank are sealed bladders made of flexible film (50-100mL in volume) and made of fluororubber material. They are used to compensate for the volume expansion / contraction of liquid metal due to temperature changes and to maintain the loop pressure at 0.1-0.3MPa.

[0047] The inlet and outlet manifolds of the flexible fluid circulation pipeline 2 converge at the root of the flexible deployment mechanism body 1. They are then sealed to the electromagnetic pump 31, heat exchanger 32, and liquid storage and compensation bladder via a flexible metal bellows (nominal diameter 8-12mm) and a high-strength polymer quick-connect fitting. The joints employ a double-ferrule sealing structure, with a leakage rate ≤1×10⁻⁶. -8 Pa・m 3 / s

[0048] Also includes:

[0049] A distributed temperature sensor array 4 is arranged on the flexible unfolding mechanism body 1; it consists of flexible thin-film platinum resistance sensors or thermocouple sensors, with the number of sensors arranged at a density of 10-15 per square meter. The sensors are attached to the inner side of the upper functional surface layer of the flexible unfolding mechanism body 1 in the form of a thin film, or embedded in the polymer matrix of the intermediate functional layer. The measurement accuracy is ±0.5℃, and the measurement range is -100℃ to 150℃.

[0050] The sensor's signal line runs along the edge of the flexible unfolding mechanism body 1 or the gaps in the microtube array, using polytetrafluoroethylene insulated wires, and converges to a waterproof and sealed connector at the root, establishing a signal connection with the thermal control manager through a flexible cable.

[0051] The thermal control manager, which is an embedded controller, integrates a temperature signal acquisition module and a pump drive module. It is connected to the distributed temperature sensor array 4 and the electromagnetic pump 31. It is used to actively adjust the power of the electromagnetic pump 31 according to the temperature signal, thereby controlling the flow rate and heat transport capacity of the liquid metal, and realizing active heating or heat dissipation of the flexible deployment mechanism body 1.

[0052] System assembly process

[0053] Microtube array prefabrication: Shape memory polymer microtubes are prepared by extrusion molding process, arranged according to a preset leaf vein or grid pattern, and fixed in the mold.

[0054] Intermediate functional layer molding: Liquid flexible polymer matrix material is injected into a mold to wrap the microtube array. After curing (temperature 60-80℃, time 2-4h) and demolding, an intermediate functional layer with embedded microtube array is formed.

[0055] Sandwich structure composite: The upper functional surface layer, the middle functional layer and the lower load-bearing support layer are stacked in sequence and then composited into one piece by hot pressing process (temperature 100-120℃, pressure 0.3-0.5MPa, time 1-2h) to form the flexible unfolding mechanism body 1.

[0056] Circulation system connection: In the rigid area at the root of the flexible deployment mechanism body 1, the inlet and outlet main pipes of the microtube array are connected to the flexible metal bellows and quick-connect couplings, and then the liquid storage and compensation bladder, electromagnetic pump 31 and heat exchanger 32 are connected in sequence to complete the assembly of the closed circulation loop. After assembly, the air tightness test is carried out (pressure 0.6MPa, pressure holding for 30min, pressure drop ≤0.02MPa).

[0057] Sensor and control system installation: attach or embed the distributed temperature sensor array 4 into the flexible deployment mechanism body 1, connect and fix the signal lines, install the thermal control manager in the non-flexible area of ​​the spacecraft platform, and complete the connection and debugging of the signal lines and power lines.

[0058] Working principle:

[0059] Launch phase (folding state): The flexible deployment mechanism body 1 folds and folds, and the microtube array bends and deforms with the shape memory polymer tube wall. At this time, the liquid metal working fluid partially flows back to the storage and compensation bladder, and the electromagnetic pump 31 is in a low-speed operation state (flow rate 0.1L / min), only maintaining a small amount of working fluid circulation in the circuit to avoid damage to the microtubes due to working fluid impact during the folding process.

[0060] In-orbit deployment phase: After the spacecraft enters orbit, the flexible deployment mechanism 1 is deployed under the action of the drive mechanism. The shape memory polymer tube wall of the microtube array is restored to the preset flat shape and flow cross section under the triggering of the space environment temperature. The electromagnetic pump 31 is started to preheat, and the working fluid begins to gradually fill the entire microtube array.

[0061] Low-temperature conditions (temperature ≤ -20℃): When the distributed temperature sensor array 4 detects that the temperature of the flexible deployment mechanism body 1 is lower than the set threshold, the thermal control manager receives the signal and controls the electromagnetic pump 31 to increase the power, increasing the flow rate of the liquid metal working fluid to 0.8-1L / min. The working fluid absorbs heat from the spacecraft platform thermal control system or auxiliary electric heater (optional) and quickly transfers it to the entire flexible deployment mechanism body 1 through the microtube array, so that the temperature of the mechanism is maintained at -10℃~0℃, avoiding the embrittlement of the composite material.

[0062] High-temperature operating conditions (temperature ≥ 60℃): During the sunshine period, the flexible deployment mechanism body 1 absorbs solar radiation heat and the temperature rises to the set threshold. The thermal control manager instructs the electromagnetic pump 31 to maintain a medium-high flow rate (0.6-0.8L / min). The liquid metal working fluid transfers the heat absorbed by the mechanism to the heat exchanger 32 at the root. The heat is then dissipated to the space environment through the radiant plate of the spacecraft platform, so that the temperature of the mechanism is controlled at 40℃~50℃.

[0063] Temperature control stage: Under non-extreme temperature conditions, the thermal control manager adjusts the flow rate of the electromagnetic pump 31 (0.3-0.6L / min) according to the temperature gradient detected by the distributed temperature sensor array 4 (if the gradient is ≥5℃). The temperature difference is smoothed out by the circulation of liquid metal working fluid, ensuring the temperature uniformity of the flexible unfolding mechanism body 1 (temperature difference ≤3℃) and avoiding thermal deformation from affecting the accuracy of the mechanism.

[0064] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A deformable liquid metal thermally controlled flexible deployment mechanism for commercial aerospace applications, characterized in that, include: The flexible deployment mechanism body (1) has a retracted state during launch and an deployed state during on-orbit operation; The flexible fluid circulation pipeline (2) is at least partially integrated inside or on the surface of the flexible deployment mechanism body (1) and retracts and unfolds synchronously with the flexible deployment mechanism body (1); And a fluid drive and heat exchange unit (3) is provided in the non-flexible area of ​​the spacecraft platform or the flexible deployment mechanism body (1) and connected to the flexible fluid circulation pipeline (2) to form a closed loop; The flexible fluid circulation pipeline (2) is filled with liquid metal working fluid; The fluid drive and heat exchange unit (3) includes: An electromagnetic pump (31) is used to drive the liquid metal working fluid to flow in a closed loop; Heat exchanger (32) is used to realize heat exchange between the liquid metal working fluid and the thermal control system of the spacecraft platform or the space environment; The flexible fluid circulation pipeline (2) includes a pipe wall made of an elastic polymer with shape memory effect, so that the pipeline can be restored to a preset shape and flow cross section after the flexible deployment mechanism body (1) is deployed.

2. The deformable liquid metal thermally controlled commercial aerospace flexible deployment mechanism according to claim 1, characterized in that, The flexible fluid circulation pipeline (2) is arranged in the form of a microtube array on the surface of the flexible deployment mechanism body (1).

3. The deformable liquid metal thermal control commercial aerospace flexible deployment mechanism according to claim 2, characterized in that, The flexible deployment mechanism body (1) is a composite material sandwich structure, and the flexible fluid circulation pipeline (2) is embedded in the middle of the composite material sandwich in the form of a microtube array.

4. The deformable liquid metal thermal control commercial aerospace flexible deployment mechanism according to claim 2, characterized in that, The microtube array is distributed in a leaf vein pattern within the plane of the flexible deployment mechanism body (1).

5. A deformable liquid metal thermally controlled commercial aerospace flexible deployment mechanism according to claim 2, characterized in that, The microtube array is distributed in a grid pattern within the plane of the flexible deployment mechanism body (1).

6. The deformable liquid metal thermally controlled commercial aerospace flexible deployment mechanism according to claim 1, characterized in that, Also includes: A distributed temperature sensor array (4) is arranged on the flexible deployment mechanism body (1); The thermal control manager is connected to the distributed temperature sensor array (4) and the electromagnetic pump (31) by signal, and is used to actively adjust the power of the electromagnetic pump (31) according to the temperature signal, thereby controlling the flow rate and heat transport capacity of the liquid metal, and realizing active heating or heat dissipation of the flexible unfolding mechanism body (1).

7. The deformable liquid metal thermal control commercial aerospace flexible deployment mechanism according to claim 1, characterized in that, The liquid metal working medium is a gallium-based or indium-based low-melting-point alloy.

8. The deformable liquid metal thermal control commercial aerospace flexible deployment mechanism according to claim 1, characterized in that, The flexible deployment mechanism body (1) is a solar panel substrate or a deployable antenna reflector.

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