Spacecraft on-orbit self-connecting flexible composite material extension mechanism

Abstract

The application provides a spacecraft in-orbit self-connecting flexible composite material stretching mechanism, which comprises a flexible composite material stretching arm and a self-connecting unit. When the stretching arm unit is unfolded and stretched to a partially overlapped C type, two parts of the self-connecting unit contact each other and form self-connection through physical or chemical reaction. The application can realize self-connection of the stretching mechanism in a space environment, has the characteristics of anti-instability, high rigidity and light weight, and is an important development direction of large-area array winding type flexible solar wings, large-area off-orbit sails / solar sails, large-size deployable sunshields and large-scale deployable membrane antennas and other flexible mechanisms of spacecrafts.

Description

Technical Field

[0001] This invention belongs to the field of spacecraft, specifically relating to an on-orbit self-connecting flexible composite material extension mechanism for spacecraft. Background Technology

[0002] Space extension mechanisms are a primary means of resolving the conflict between large-scale spacecraft structures and rocket launch envelope constraints, with the retractability ratio being a core key characteristic. Currently, the flexibility and functional integration of satellite structural mechanisms is a crucial development direction. Flexible extension mechanisms utilize the large deformation and high strain resistance characteristics of their structural materials, offering greater retractability compared to rigid structures composed of hinges, bearings, and other rigid deployment mechanisms. Their structures are rollable, possessing a "rigid-flexible" capability, and utilize the strain energy stored in thin walls for deployment. They offer advantages such as fewer deployment components, simpler structure, lightweight yet high strength, and smaller retracted volume.

[0003] Internationally, in 2021, the United States began installing iROSA (Intelligent Roll-Up Flexible Solar Array) solar panels, using flexible composite material extension mechanisms as their drive source, on the International Space Station. Each iROSA has an unfolded size of 16m × 6m and a power output of 20kW. Furthermore, DSS and ATK jointly developed the ultra-high-power, modular Mega-ROSA. Compared to rigid fins, ROSAs with the same power output can reduce mass by 33% and folded volume by 75%. Meanwhile, the Hubble Telescope and the DART spacecraft employ flexible composite material extension mechanisms. These mechanisms utilize the strain energy stored within their roll-up structure to unfold in an orderly manner under the control and constraint of motors or mechanisms. They offer advantages such as simple structure, high unfold-to-fold ratio, and high stability. Their stiffness and strength depend on the deployment mechanism used, and with the development of flexible thin-film battery technology, they have become the main choice for future flexible solar array configurations.

[0004] Domestically, in 2024, the 5-meter-scale flexible composite material extension mechanism developed by the Shanghai Satellite Equipment Research Institute was applied to the Guangchuan 01 and 02 satellites, achieving the first on-orbit application in China. In 2025, the Shanghai Satellite Equipment Research Institute developed an 8-meter-scale flexible composite material extension mechanism, which was applied to the Internet technology experimental satellite and achieved on-orbit application.

[0005] Patent document CN119659987A discloses a flexible drive structure for a carbon fiber-based solar panel on a spacecraft and its control method. The flexible drive structure includes composite fibers, a fixing unit, and an electrical control unit; the composite fibers have an initial twist and include carbon fiber bundles and a polymer, the polymer including PDMS, with the space between adjacent monofilaments completely filled by the polymer; the fixing unit bundles and fixes the two ends of multiple composite fibers together as a whole and connects them to the solar panel and the spacecraft drive system; the electrical control unit is electrically connected to both ends of the fibers.

[0006] However, the area of ​​the new generation of large-area rollable flexible solar panels will reach 200m². 2 -500m 2 The core mechanism of the roll-up flexible solar array is a flexible composite material extension mechanism with an extension length of up to hundreds of meters and a length-to-diameter ratio of up to 100:1. Due to its open cross-section, it has disadvantages such as weak cross-sectional stiffness, weak torsional resistance, and poor local stability, which limits its further promotion and application.

[0007] To overcome the shortcomings of the prior art, the present invention aims to provide an on-orbit self-connecting flexible composite material extension mechanism to solve the technical problems of weak cross-sectional stiffness, weak torsional resistance, and poor local stability of existing flexible extension mechanisms. Summary of the Invention

[0008] To address the shortcomings of existing technologies, the purpose of this invention is to provide an on-orbit self-connecting flexible composite material extension mechanism for spacecraft.

[0009] According to the present invention, a spacecraft on-orbit self-connecting flexible composite material extension mechanism includes: a flexible composite material extension arm and a self-connecting unit; The self-connecting unit is divided into two parts and symmetrically arranged on both sides of the flexible composite material extension arm when the flexible composite material extension arm is in a coiled state. When the flexible composite material extension arm is unfolded and straightened back to a partially overlapping C-shape, the two parts of the self-connecting unit come into contact with each other and form a self-connection through physical or chemical reaction.

[0010] Preferably, the flexible composite material extension arm has a free-state structural form of a partially overlapping C-shaped slit long tube.

[0011] Preferably, the flexible composite material extension arm has a wall thickness ranging from 0.2 mm to 0.6 mm and a length ranging from 2 m to 100 m, and has an overlap formed by self-connecting units, with an overlap range of 5 mm to 50 mm.

[0012] Preferably, the overlapping method when the flexible composite material extension arm unfolds and straightens back to a partially overlapping C-shape is a partial overlap.

[0013] Preferably, the self-connecting unit is mainly composed of self-healing polymer materials, magnetic materials, or materials with connecting functions such as Velcro.

[0014] Preferably, the self-healing polymer material refers to a smart polymer with self-connection function, which can achieve self-connection by using contact pressure; the magnetic material refers to a flexible polymer magnetic material.

[0015] Preferably, the flexible composite extension arm is mainly composed of fiber-reinforced resin-based composite material; the resin is epoxy resin, cyanate ester resin or polyimide resin; the reinforcing fiber is carbon fiber, glass fiber or aramid fiber.

[0016] A method for manufacturing an on-orbit self-connecting flexible composite material extension mechanism for a spacecraft, according to the present invention, includes: (1) Prepreg preparation: The resin content of the prepreg is 30wt% to 60wt%, and the single layer thickness is 0.02mm to 0.06mm; (2) Use cutting equipment to cut the prepreg according to the design dimensions, and then lay it on the surface of the circular mold according to the layup requirements; (3) Vacuum the prepreg after it has been laid, with a vacuum degree ≤ -0.097MPa and a vacuuming time ≥ 4h; (4) Curing method: heat shrink film molding, autoclave molding or vacuum bag molding; curing temperature: 130℃~350℃; curing pressure: 0.05MPa~0.6Mpa. (5) Use machine tools and cutting tools to cut along the axis of the product for demolding, and after surface treatment, a flexible composite material extension arm is formed. (6) Prepare adhesives for post-treatment of flexible composite material extension arms; (7) Install self-connecting units on both sides of the axial overlap of the flexible composite material extension arm.

[0017] Preferably, it further includes: (8) Ground condition: Flatten the flexible composite material extension arm and roll it forward or backward onto the unfolding shaft; (9) After being in orbit, the flexible composite material extension arm is released, and the mechanism pushes the flexible composite material extension arm to unfold. The flexible composite material extension arm gradually returns to a partially overlapping C-shape, and the two parts of the self-connecting unit come into contact with each other and form an on-orbit self-connection through physical or chemical reactions.

[0018] According to a spacecraft of the present invention, the spacecraft includes an on-orbit self-connecting flexible composite material extension mechanism.

[0019] According to the present invention, a method for using a spacecraft on-orbit self-connecting flexible composite material extension mechanism is provided. In the ground state, the flexible composite material extension arm is flattened and rolled forward or backward onto the unfolding shaft. After being in orbit, the flexible composite material extension arm is released, and the mechanism pushes the flexible composite material extension arm to unfold. The flexible composite material extension arm gradually returns to a partially overlapping C-shape, and the two parts of the self-connecting unit come into contact with each other and form an on-orbit self-connection through physical or chemical reactions.

[0020] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention has the advantages of high storage ratio, light weight, long length, high rigidity, strong resistance to instability, strong axial compressive strength, strong torsional performance, high reliability, and low production cost.

[0021] 2. The flexible stretching mechanism of the present invention has a C-shaped structure and can be flattened and wound.

[0022] 3. The flexible extension mechanism of the present invention realizes the function of on-track self-connection.

[0023] 4. This invention can improve the overall stiffness of flexible solar panels. Attached Figure Description

[0024] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a schematic diagram of a conventional slotted circular tube that includes a straightening section, a transition section, and a winding section.

[0025] Figure 2 This is a schematic diagram of the partially overlapping C-shaped rod cross-section of the self-connecting material unit of the present invention.

[0026] Figure 3 This is a schematic diagram of the arrangement of the self-connecting material units of the present invention on a flexible composite material extension mechanism, wherein not all self-connecting material units are shown.

[0027] The diagram shows: Flexible composite material extension arm 1 Self-connecting unit 2 Detailed Implementation The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0028] This invention relates to an on-orbit self-connecting flexible composite material extension mechanism for spacecraft. This extension mechanism has advantages such as high packing ratio, light weight, large length, high stiffness, strong resistance to instability, strong axial compressive strength, strong torsional performance, high reliability, and low production cost.

[0029] According to the present invention, a spacecraft on-orbit self-connecting flexible composite material extension mechanism includes a flexible composite material extension arm and self-connecting units. Multiple self-connecting units are disposed on the flexible composite material extension arm, specifically at the edge of the flexible composite material extension arm.

[0030] The flexible composite material extension arm, in its free state, has a partially overlapping C-shaped slit tube structure and is mainly composed of fiber-reinforced resin-based composite material. The resin can be epoxy resin, cyanate ester resin, or polyimide resin; the reinforcing fibers can be carbon fiber, glass fiber, or aramid fiber.

[0031] The flexible composite material extension arm has a wall thickness ranging from 0.2mm to 0.6mm. Its length ranges from 2m to 100m, and its cross-section is C-shaped with partial overlap ranging from 5mm to 50mm.

[0032] The self-connecting unit is mainly composed of self-healing polymer materials, magnetic materials, or materials with connecting functions such as Velcro. When the flexible composite material extendable arm is in a coiled state, the self-connecting unit is divided into two parts symmetrically arranged on both sides of the flexible composite material extendable arm. When the flexible composite material extendable arm unfolds and straightens back to a partially overlapping C-shape, the two parts of the self-connecting unit come into contact with each other and form a self-connection through physical or chemical reactions. The self-healing polymer material refers to a smart polymer with self-connecting function, which can achieve self-connection using contact pressure. The magnetic material refers to a flexible polymer magnetic material. Therefore, this invention enables the self-connection of extendable mechanisms in a space environment, featuring anti-instability, high stiffness, and light weight. It represents an important development direction for flexible mechanisms such as large-area array coiled flexible solar panels, large-area array off-orbit sails / solar sails, large-size deployable sunshades, and large deployable thin-film antennas for spacecraft.

[0033] like Figure 2 , Figure 3 As shown, the on-orbit self-connecting flexible composite material extension mechanism has external dimensions of φ100mm × 50mm, an overlap of 30mm, and a thickness of 0.48mm. The self-connecting material is Velcro, with adhesive positions spaced 50mm apart. The composite material reinforcing fiber is T800, and the resin is cyanate ester resin.

[0034] The method of use is as follows: On the ground, flatten the flexible composite material extension mechanism and roll it forward or backward onto the deployment shaft. Once in orbit, release the composite material extension mechanism; the mechanism will push the components to unfold, achieving self-connection in orbit via Velcro fasteners on the flexible composite material extension arm.

[0035] The method for manufacturing an on-orbit self-connecting flexible composite material extension mechanism for spacecraft provided by this invention includes: (1) Preparation of prepreg. The resin content is 30wt% to 60wt%, and the single layer thickness is 0.02mm to 0.06mm. The resin can be epoxy resin, cyanate ester resin, or polyimide resin, and the reinforcing fiber can be carbon fiber, glass fiber, or aramid fiber.

[0036] (2) Prepreg cutting. The prepreg is cut to the design dimensions using a cutting device, and then laid on the surface of the circular mold according to the layup requirements; (3) Pre-vacuuming. Vacuuming is performed on the prepreg after it has been laid, with a vacuum degree ≤ -0.097MPa and a vacuuming time ≥ 4h; (4) Curing. Curing methods include heat shrink film molding, autoclave molding, or vacuum bag molding. The curing temperature is 130℃~350℃, and the curing pressure is 0.05MPa~0.6MPa. (5) Demolding. Using machine tools and cutting tools, cut along the axis of the product, demold manually, and after surface treatment, a flexible composite material extension arm is formed; (6) Prepare adhesives for post-treatment of flexible composite material extension arms; (7) Install self-connecting material. Install self-connecting material on both sides of the axial overlap of the flexible composite extension arm. This material can be a self-healing polymer, a magnetic material, or Velcro.

[0037] (8) In the ground state, flatten the flexible composite material stretching mechanism and roll it forward or backward onto the unfolding shaft.

[0038] (9) After being in orbit, the composite material extension mechanism is released, the mechanism pushes the component to unfold, and the composite material extension mechanism gradually returns to a partially overlapping C-shape. The two parts of the self-connecting unit come into contact with each other and form an in-orbit self-connection through physical or chemical reactions.

[0039] In a preferred embodiment, a prepreg with a single-layer thickness of 0.02 mm and a resin content of 40 wt% is prepared using T800 fiber and cyanate ester resin. The prepreg is cut to the designed dimensions and then manually laid up on the mold surface, with a total of 24 layers. After laying, the prepreg is vacuumed to a vacuum degree ≤ -0.097 MPa for 8 hours. A heat-shrink film is wound around the prepreg using a heat-shrink film forming process with a winding tension of 50 N. The prepreg is then cured using a vacuum bag compression molding process at a curing temperature of 210℃ and a curing pressure of 0.15 MPa. After curing, the prepreg is manually cut along the axial direction using a tool and demolded. Nylon Velcro is attached at 50 mm intervals along the axial overlap area of ​​the flexible extension arm to complete the self-connecting flexible composite material extension mechanism. The layup uses prepreg, and the layup method can be manual or wound.

[0040] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0041] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A spacecraft on-orbit self-connecting flexible composite material extension mechanism, characterized in that, include: Flexible composite material extension arm, self-connecting unit; When the flexible composite material extension arm is in a coiled state, the self-connecting unit is divided into two parts and symmetrically arranged on both sides of the flexible composite material extension arm. When the flexible composite material extension arm is unfolded and straightened back to a partially overlapping C-shape, the two parts of the self-connecting unit come into contact with each other and form a self-connection through physical or chemical reactions. The flexible composite material extension arm has a free-state structural form of a partially overlapping C-shaped slotted long tube.

2. The spacecraft on-orbit self-connecting flexible composite material extension mechanism according to claim 1, characterized in that, The flexible composite material extension arm has a wall thickness ranging from 0.2mm to 0.6mm and a length ranging from 2m to 100m. It has an overlap formed by self-connecting units, with an overlap range of 5mm to 50mm.

3. The spacecraft on-orbit self-connecting flexible composite material extension mechanism according to claim 2, characterized in that, The overlapping method when the flexible composite telescopic arm unfolds, straightens, and returns to a partially overlapping C-shape is called partial overlap.

4. The spacecraft on-orbit self-connecting flexible composite material extension mechanism according to claim 1, characterized in that, The self-connecting unit is mainly composed of materials with connecting functions, including self-healing polymer materials, magnetic materials, or Velcro.

5. The spacecraft on-orbit self-connecting flexible composite material extension mechanism according to claim 4, characterized in that, Self-healing polymers refer to intelligent polymers with self-connecting functions, which can achieve self-connection by using contact pressure; magnetic materials refer to flexible polymer magnetic materials.

6. The spacecraft on-orbit self-connecting flexible composite material extension mechanism according to claim 1, characterized in that, The flexible composite extension arm is mainly composed of fiber-reinforced resin-based composite material; the resin is epoxy resin, cyanate ester resin or polyimide resin; the reinforcing fiber is carbon fiber, glass fiber or aramid fiber.

7. A method for manufacturing an on-orbit self-connecting flexible composite material extension mechanism for a spacecraft, characterized in that, include: (1) Prepreg preparation: The resin content of the prepreg is 30wt% to 60wt%, and the single layer thickness is 0.02mm to 0.06mm; (2) Use cutting equipment to cut the prepreg according to the design dimensions, and then lay it on the surface of the circular mold according to the layup requirements; (3) Vacuum the prepreg after it has been laid, with a vacuum degree ≤ -0.097MPa and a vacuuming time ≥ 4h; (4) The curing method is heat shrink film molding, autoclave molding or vacuum bag molding, the curing temperature is 130℃~350℃, and the curing pressure is 0.05MPa~0.6Mpa; (5) Use machine tools and cutting tools to cut along the axis of the product for demolding, and after surface treatment, a flexible composite material extension arm is formed. (6) Prepare adhesives for post-treatment of flexible composite material extension arms; (7) Install self-connecting units on both sides of the axial overlap of the flexible composite material extension arm; Also includes: (8) Ground condition: Flatten the flexible composite material extension arm and roll it forward or backward onto the unfolding shaft; (9) After being in orbit, the flexible composite material extension arm is released, and the mechanism pushes the flexible composite material extension arm to unfold. The flexible composite material extension arm gradually returns to a partially overlapping C-shape, and the two parts of the self-connecting unit come into contact with each other and form an on-orbit self-connection through physical or chemical reactions.

8. A spacecraft, characterized in that, The spacecraft includes an on-orbit self-connecting flexible composite material extension mechanism according to any one of claims 1 to 6.

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