Self-supporting space environment protection device for space applications, and method of manufacturing device

Abstract

To provide a self-supporting space environment protection device, and a method of manufacturing the device.SOLUTION: The device includes a self-supporting polymer-based body manufactured for installation on a component of a space-based system and composed of a space radiation resistant polymer-based material. The device further includes a low-absorptivity finish applied to an external surface of the self-supporting polymer-based body, the low-absorptivity finish having a solar absorptivity (α) value lower than the space radiation resistant polymer-based material, and a low-emissivity finish applied to an internal surface of the self-supporting polymer-based body, the low-emissivity finish having an infrared emissivity (ε) value lower than the space radiation resistant polymer-based material.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The following generally relates to space environmental protection devices, and more particularly to space environmental protection devices for space-based applications and satellite systems.

Background Art

[0002] Space environmental protection is required for structures, components, or mechanisms in space-based applications when exposed to radiation and atomic oxygen, collisions with meteoroid dust and orbital debris (MMOD), and severe environments and environmental threats such as a significant temperature range and / or extremes.

[0003] An existing method for protecting such structures, components, or mechanisms includes a thermal blanket. Traditional thermal blankets are flexible and require a support structure having a plurality of attachment points between the blanket and the support structure. Thermal blankets are typically made using patterns developed by female seamstresses, where the patterns are created using aerospace antennas, and then the thermal blankets are manufactured and finally installed. Before manufacturing, the pattern maker for the thermal blanket is required to wait until the final assembly of the structure, component, or mechanism is complete. This requirement adds complexity to determining the exact shape of the thermal blanket before installation and results in multiple iterations and adjustments to the thermal blanket configuration. This process is costly, time-consuming, and schedule-dependent.

[0004] Insulation blankets are typically made of flexible polymer-based materials with very low thermal conductivity, reducing the transfer of thermal energy to the structure, component, or mechanism being protected. Due to the nature of insulation blankets and their variable configurations, effective thermal properties are not at all consistent. This is because thermal properties are quite dependent on the attachments used, the number of slits / discontinuities, and the number of folds. These factors combine to lead to a decrease in the insulation efficiency of the insulation blanket.

[0005] Insulation blankets are fragile and prone to tearing. Also, they can potentially catch or interfere with the proper operation of the structure, component, or mechanism being covered. Any damage to the insulation blanket may not be easily detectable and can potentially lead to mission failure. If already in space, any corrections may be difficult or impossible. Therefore, when attaching to a structure, component, or mechanism, it is typically necessary to keep a large distance and space, which ultimately results in significant attachment problems and a decrease in insulation efficiency.

[0006] Other existing methods for protecting structures, components, or mechanisms in space, such as heat-insulating metal sheets (e.g., aluminum sheets with insulating washers), may not be cost-effective and are heavy.

[0007] Particularly in the area of satellite placement, space operations are expanding more and more, and there is a growing urgent need to mass-produce structures, components, or mechanisms to support the industry. Therefore, the development of cost / schedule-efficient solutions for defending such structures, components, or mechanisms from the harshness of space has become an urgent issue. Summary of the Invention Problems to be Solved by the Invention

[0008] Accordingly, there is an urgent need for an improved space environmental protection device for structures, components, or mechanisms in space applications that overcomes at least some of the drawbacks of existing systems and methods.

Means for Solving the Problem

[0009] A self-supporting space environmental protection device is provided for covering components of a space-based system. The device is manufactured for attachment onto a component and includes a self-supporting polymer-based body composed of a space radiation resistant polymer-based material. The self-supporting polymer-based body includes an inner surface facing the component when the self-supporting space environmental protection device is attached and an outer surface exposed to the space environment.

[0010] In one embodiment, a low absorption finish is applied to the outer surface of the self-supporting polymer-based body, and the low absorption finish has a solar absorptance (α) value lower than that of the space radiation resistant polymer-based material.

[0011] In one embodiment, a low emissivity finish is applied to the inner surface of the self-supporting polymer-based body, and the low emissivity finish has an infrared emissivity (ε) value lower than that of the space radiation resistant polymer-based material.

[0012] In one embodiment, the space radiation resistant polymer-based material is any one of a polymer composite, polyether ketone ketone (PEKK), a PEKK-based FDM thermoplastic, or polyetherimide (PEI).

[0013] In one embodiment, the space radiation resistant polymer is carbon filled to achieve conductivity and reduce the ESD risk associated with the use of the self-supporting space environmental protection device.

[0014] In one embodiment, the low absorption finish is a white paint.

[0015] In one embodiment, the low emissivity finish is a metal plating.

[0016] In one embodiment, the metal plating includes a plurality of plating layers, and the plurality of plating layers includes a silver plating layer on a nickel plating layer or a gold plating layer on a nickel plating layer.

[0017] In one embodiment, the metal plating includes a plurality of plating layers including a last metal plating layer that is nickel plating, gold plating, or silver plating.

[0018] In one embodiment, the low emissivity finish is a low emissivity coating.

[0019] In one embodiment, the device is configured to cover a partial segment of components used in space.

[0020] In one embodiment, a rigid polymer-based body is manufactured using any one of additive manufacturing, a molding process, or a subtractive machining process.

[0021] In one embodiment, a low absorption finish is applied to the outer surface of the self-supporting polymer-based body, a low emissivity finish is applied to the inner surface of the self-supporting polymer-based body, the low absorption finish has a lower solar absorptance (α) value than the space radiation resistant polymer-based material, and the low emissivity finish has a lower infrared emissivity (ε) value than the space radiation resistant polymer-based material.

[0022] A method of manufacturing a self-supporting space environmental protection device for covering components used in space is provided. The method includes recording the physical outer shape of a space component, manufacturing a self-supporting polymer-based body from a space radiation resistant polymer based on the recorded physical outer shape of the temperature sensitive device, applying a low absorption finish to the outer surface of the self-supporting polymer-based body, the low absorption finish having a lower solar absorptance (α) value than the space radiation resistant polymer-based material, and applying a low emissivity finish to the inner surface of the self-supporting polymer-based body, the low emissivity finish having a lower infrared emissivity (ε) value than the space radiation resistant polymer-based material.

[0023] In one embodiment, the rigid polymer body is manufactured using any one of additive manufacturing, a molding process, or a subtractive machining process.

[0024] In one embodiment, the self-supporting polymer-based body is manufactured to cover a partial section of a component used in space.

[0025] In one embodiment, the low absorption finish is a white paint.

[0026] In one embodiment, the low emissivity finish is a metal plating. The metal plating can include a plurality of plating layers. The plurality of plating layers can include a silver plating layer on a nickel plating layer. The plurality of plating layers can include a gold plating layer on a nickel plating layer.

[0027] In one embodiment, the metal plating includes a plurality of plating layers including a final metal plating layer that is nickel plating, gold plating, or silver plating.

[0028] In one embodiment, the low emissivity finish is a low emissivity paint.

[0029] Upon consideration of the following description of some exemplary embodiments, other aspects and features will become apparent to those skilled in the art.

[0030] The drawings included herein are for the purpose of illustrating various examples of the articles, methods, and apparatuses described herein. The drawings are as follows.

Brief Description of the Drawings

[0031]

Figure 1

Figure 2

Figure 3

Embodiments for Carrying Out the Invention

[0032] To provide examples of each claimed embodiment, various devices or processes are described below. The embodiments described below do not limit the claimed embodiments, and the claimed embodiments can cover processes or devices different from those described below. The claimed embodiments are not limited to a device or process having all the features of any one device or process described below, nor are they limited to features common to a plurality or all of the devices described below.

[0033] Furthermore, although process steps, method steps, algorithms, etc. may be described in sequential order (in this disclosure and / or the claims), such processes, methods, and algorithms can be configured to operate in an alternating order. In other words, any sequence or order of steps that may be described does not necessarily indicate that the steps must be performed in that order. The steps of the processes described herein can be performed in any practical order. Furthermore, some steps can be performed simultaneously.

[0034] When a single device or article is described herein, it will be readily apparent that more than one device / article can be used (whether or not they cooperate) instead of the single device / article. Similarly, when more than one device or article is described herein (whether or not they cooperate), it will be readily apparent that a single device / article can be used instead of the more than one device / article.

[0035] The following generally relates to space environmental protection devices, and more particularly to self - supporting space environmental protection devices for space - based applications and satellite systems.

[0036] Generally, the present disclosure provides a self - supporting space environmental protection device that can be applied to specific components of a space - based system (i.e., a system designed to be used in space). The types, functions, and structural features of the components to be (wholly or partially) covered can be diverse and are not particularly limited. For example, the components can be any mechanism, structure, or other infrastructure of a space - based system that requires protection realized by the self - supporting space environmental protection device and can benefit from the protection. Thus, it should be understood that references throughout this document to "components" protected or covered by the space - based environmental protection device can include the mechanisms, structures, or other infrastructure of a space - based system as described above.

[0037] The disclosed space environmental protection device includes a self - supporting body that, when the device is attached to a component, defines a cavity that (wholly or partially) contains the component to be used in space therein. The shape of the self - supporting body can be configured to entirely surround the shape or geometric profile of the component. In some cases, the shape of the self - supporting body can be configured to match, substantially follow, or mimic the outer profile of the component, such that the space occupied by the self - supporting space environmental protection device covering the component is reduced or minimized while still providing sufficient clearance for the covered component. In one embodiment, the self - supporting space environmental protection device is additionally manufactured from an additive - manufacturable and space - qualified polymer - based material that is resistant to cosmic rays and, in some cases, has ESD dissipation properties (e.g., carbon - filled or loaded). In various embodiments, the outer and inner surfaces of the self - supporting body can be bare or have a finish applied thereto. The outer surface facing space outside the self - supporting body can have a low - absorption finish applied thereto. The inner surface facing the component inside the self - supporting body can have a low - emissivity finish applied thereto, such as a metal plating or a low - emissivity paint.

[0038] In one embodiment, the present disclosure provides a space environmental protection device for covering a component (wholly or partially). The device includes a self - supporting polymer - based body manufactured for attachment to the component and composed of a cosmic - ray - resistant polymer - based material. The self - supporting polymer - based body includes an inner surface facing the component when attached and an outer surface exposed to the space environment. The device includes a low - absorption finish applied to the outer surface that has a lower solar light absorption rate value than the polymer - based material. The device further includes a low - emissivity finish applied to the inner surface of the self - supporting polymer - based body that has a lower infrared emissivity value than the polymer - based material.

[0039] In one embodiment, the radiation-resistant polymer is carbon-filled to achieve conductivity and reduce the ESD risk associated with the use of the device. The self-supporting polymer-based body is manufactured using an additive manufacturing technique.

[0040] While the present disclosure often focuses on embodiments of devices for use in thermal protection in a space environment, it should be noted that the devices of the present disclosure can be configured and used for protection from other space environmental factors as described herein, and such embodiments are intended by and form part of the present disclosure.

[0041] Referring now to FIG. 1, shown therein is a schematic view of a self-supporting space environmental protection device 100 according to one embodiment.

[0042] The self-supporting space environmental protection device 100 can be used in place of a blanket of complex shape in providing thermal protection to the components 102 for use in space applications.

[0043] In one embodiment, the component 102 is a mechanism. The term mechanism includes any temperature-sensitive structure or device intended for use in space. Examples of mechanisms include motors, antennas, electrical components, hold-release mechanisms, or other structures for use in space. The component 102 in FIG. 1 can be an actuator of an antenna, such as a rotary actuator. The rotary actuator can facilitate the movement of a boom (e.g., the reflector of the antenna) for operating the antenna. The component 102 can be a motor for implementing the sensitivity orientation of the hardware.

[0044] The self - supporting space environmental protection device 100 covers, without limitation, the temperature - sensitive component 102 of an electromechanical system used for space applications. In a variant form, the device 100 can be used to cover components used in space and can cover the components either entirely or merely partially (e.g., a specific part of a component). The component 102 requires thermal protection in order to function properly and / or to meet the performance goals of a mission. The self - supporting space environmental protection device 100 thus helps to realize a relatively thermally favorable operating environment for the component 102. The self - supporting space environmental protection device 100 maintains the component 102 within a better temperature range than what the component 102 would have experienced if not protected. The component 102 in FIG. 1 is represented by a dotted line as a general cylindrical prism for illustrative purposes. In variant forms, the component 102 can have various shapes and sizes. In one embodiment, a rigid self - supporting polymer - based device 100 is designed or attached to cover a section or the entire surface of a component.

[0045] In one example, the electromechanical system may be an antenna. The antenna may be a movable antenna.

[0046] The self-supporting space environmental protection device 100 includes a self-supporting body 104. When the self-supporting space environmental protection device 100 is applied to the component 102, the self-supporting body 104 defines a cavity 106 in which the component 102 is included. The self-supporting body 104 can have any shape that can be achieved with the material from which the self-supporting body 104 is made. The shape of the self-supporting body 104 can be configured to entirely surround the shape or geometric profile of the component 102. In some cases, the shape of the self-supporting body 104 can be configured to match, or substantially follow, or mimic the outer profile of the component 102, such that the space occupied by the self-supporting space environmental protection device 100 covering the component 102 is reduced or minimized while still achieving a sufficient gap for the covered component 102. The device 100 can be effectively arranged to cover components of complex shapes for thermal protection.

[0047] The self-supporting body 104 includes a lower end piece 108. The lower end piece 108 can have a flat lower surface. The lower end piece 108 is used to position the self-supporting space environmental protection device 100 on the surface 110 of a spacecraft platform to which the component 102 is attached or disposed. In other embodiments, the lower end piece 108 may not be present. For example, the body 104 can be adhered into a groove.

[0048] The self-supporting space environmental protection device 100 includes mounting holes 112 for attaching the self-supporting space environmental protection device 100. The mounting holes 112 are used to receive a fixture (e.g., a screw) passing therethrough for attaching or fixing a thermal device to the platform 110 or the component 102. The mounting holes 112 may or may not have threads cut therein. While the self-supporting space environmental protection device 100 of FIG. 1 uses the mounting holes 112 and fixtures for attachment, in other embodiments, any other suitable form of fixing the self-supporting space environmental protection device 100 to the platform surface 110 or the component 102 can be used.

[0049] The self - supporting body 104 is composed of a self - supporting polymer - based material. The polymer may be an additionally manufacturable polymer. By using an additionally manufacturable polymer, a wider variation in the shapes that the self - supporting body 104 can take (e.g., using the shape outline or gap dimensions of components) can be enabled. In various embodiments, the self - supporting space environmental protection device 100 can be manufactured using an additive manufacturing process, a molding process (such as machining or injection molding), or a subtractive machining process.

[0050] The polymer - based material is a space - compatible material. The polymer is radiation - resistant. The polymer is an ESD - dissipative material.

[0051] The polymer may be polyetherketoneketone (PEKK) or a PEKK - based material. PEKK is a semi - crystalline, high - performance thermoplastic resin known for its strength, high - temperature resistance, and excellent chemical resistance properties. In one embodiment, the PEKK - based material is an additionally manufactured PEKK - based FDM (fused deposition modeling) thermoplastic. The polymer may be polyetherimide or a polyetherimide - based material. The polymer may be a thermoplastic or a thermoplastic - based material. The polymer may be any suitable additionally manufacturable and space - qualified polymer that realizes radiation resistance and ESD - dissipative properties (e.g., extracts charge).

[0052] In one embodiment, the polymer may be one or a combination of polymers within the polyaryletherketone (PAEK) family, such as polyetheretherketone (PEEK) or polyetherketoneketone (PEKK). Additionally, materials such as polyetherimide (PEI) or polyimide can be used.

[0053] The polymer can be carbon-filled or loaded (with graphite nanotubes) to achieve the desired electrostatic discharge (ESD) dissipative properties (e.g., to extract charge). While carbon loading is one approach, in other embodiments, non-ESD materials with conductive finishes can be used to achieve the same purpose. In another embodiment, the polymer can be silver-filled.

[0054] In one embodiment, the polymer can be a non-ESD material to which a conductive finish is applied.

[0055] The self-supporting body 104 includes an outer or outward-facing surface 114 and an inner or inward-facing surface 116. In the embodiment of FIG. 1, when the self-supporting space environmental protection device 100 is attached, the outer surface 114 faces the external environment (e.g., deep space, exposed to space), and the inner surface 116 faces the component 102 (not exposed to space).

[0056] The inner surface 116 can be bare (i.e., a bare self-supporting polymer material), or a low-emissivity finish can be applied thereto. The low-emissivity finish can help reduce heat loss.

[0057] The low-emissivity finish can be a low-emissivity metal plating applied thereto. The metal plating can be electroless nickel plating. The metal plating can be gold plating. The plating can be silver plating. Preferably, the plating is a plating that does not react to oxidation (oxidation will affect the emissivity). In one embodiment, the metal plating can include multiple layers plated using a multi-layer plating process. For example, the multi-layer metal plating can include a layer of nickel and a layer of gold on the nickel. In another example, the multi-layer metal plating can include a layer of nickel and a layer of silver on the nickel. In one embodiment using multi-layer metal plating, the final layer can be silver, gold, or nickel.

[0058] In some cases, the inner surface 116 may be painted with an electrically conductive paint before plating the inner surface with a low emissivity metal. The electrically conductive paint is a primer for plating the low emissivity finish. In other embodiments, other types of catalysts may be used to plate the low emissivity finish.

[0059] The low emissivity finish on the inner surface 116 helps to retain the heat inside (heat insulation).

[0060] In one embodiment, the low emissivity finish is a low emissivity paint.

[0061] In one embodiment, the low emissivity finish has an ε lower than 0.7.

[0062] The outer surface 114 may be bare (i.e., a bare self-supporting polymer material). The outer surface 114 may include a low absorptivity finish applied thereto. The low absorptivity finish may be a white paint. The white paint can be applied with a spray gun. The low absorptivity finish reduces the acquisition of heat from the sun. In one embodiment, the low absorptivity finish may be a white paint having an α < 0.7.

[0063] Whether the finish is applied to the inner surface 116 or the outer surface 114 may depend on the application and the type of component to be protected or covered (e.g., a highly dissipative unit, a low dissipative unit).

[0064] In one embodiment, the polymer is a bare black polymer base material (ε ~ 0.9, α ~ 0.9) (either one or both of the inner surface 116 and the outer surface 114 are bare, or neither is bare). In one embodiment, the low emissivity finish is nickel plating (ε ~ 0.1, α ~ 0.4). In one embodiment, the low emissivity finish on the inner surface 116 is gold plating (ε ~ 0.03, α ~ 0.2). In one embodiment, the low emissivity finish on the inner surface 116 is silver plating. In one embodiment, the low emissivity finish on the inner surface 116 is a low emissivity paint. In one embodiment, the low absorptivity finish is a white paint (ε ~ 0.9, α ~ 0.17).

[0065] In one embodiment, the self - supporting space environmental protection device 100 realizes shielding for highly dissipative units that are exposed to the sun. A white coating is applied to the outer surface 114, and the inner surface 116 is bare so as to remove as much heat as possible.

[0066] In another embodiment, the self - supporting space environmental protection device 100 realizes insulation for low - dissipative units. The outer surface 114 is bare, and a low - emissivity finish is applied to the inner surface 116 to reduce heat loss.

[0067] The low - emissivity material can achieve temperature adjustment in order to control the temperature level and heat inside the component 102. The low - emissivity metal plating reduces radiative heat exchange and thus maintains the insulation performance of the self - supporting space environmental protection device 100. In one embodiment, the low - emissivity finish is a finish having an IR (infrared) emissivity (ε) lower than that of the bare base material of the self - supporting space environmental protection device 100. The bare base material includes the materials used in the manufacture of the self - supporting space environmental protection device 100. In one embodiment, the value of the IR emissivity (ε) is preferably 0.7 or less.

[0068] In one embodiment, the low - absorptivity finish is a finish having a solar absorptivity (α) lower than that of the bare base material of the self - supporting space environmental protection device 100. The bare base material includes the materials used in the manufacture of the self - supporting space environmental protection device 100. Alternatively, the bare base material includes the material profile of the outer surface of the self - supporting space environmental protection device 100.

[0069]

[0070] ​In another embodiment, a plurality of self - supporting space environmental protection devices 100 can be configured in a stackable arrangement to improve insulation. For example, a first self - supporting space environmental protection device 100 can be configured to cover components, and a second self - supporting space environmental protection device 100 can be configured to cover the first self - supporting space environmental protection device or stack on top of the first self - supporting space environmental protection device. In such an embodiment, the outer shapes of the first and second self - supporting space environmental protection devices 100 can be adapted, as needed, to facilitate stacking (e.g., having similar or complementary surface shapes). While an example of a stack configuration of two self - supporting space environmental protection devices 100 is described, it should be understood that a stackable configuration including any number of self - supporting space environmental protection devices 100 can be realized, and such a stack is explicitly contemplated by the present disclosure when it achieves acceptable thermal protection characteristics and fits within the size constraints for the application.

[0071] Advantageously, the composite of the self - supporting polymer - based device 100, in combination with one or more of the inner finish and the outer finish, can achieve temperature regulation, radiation shielding, atomic oxygen shielding, and MMOD (micrometeoroid and orbital debris) protection.

[0072] In one embodiment, a low - absorptivity finish on the outer surface and a low - emissivity finish on the inner surface are selected to achieve temperature regulation.

[0073] In one embodiment, a rigid self - supporting polymer - based device 100 includes a silicone - based finish on the outer surface. The silicone - based finish is configured to provide shielding from atomic oxygen resulting from the use of silicone.

[0074] In one embodiment, a rigid self - supporting polymer - based device 100 does not have a surface finish or coating on the inner surface 116 or the outer surface 114.

[0075] In one embodiment, the rigid self-supporting polymer-based device 100 has a surface finish or coating only on the outer surface 114. The inner surface 116 may be left exposed.

[0076] In one embodiment, the rigid self-supporting polymer-based device 100 has a surface finish or coating only on the inner surface 116. The outer surface 114 may be left exposed.

[0077] The following Table 1 summarizes some possible configurations of the rigid self-supporting polymer-based device 100 in various embodiments, some of which are described above. Embodiments include those directed to environmental protection (which can be combined with thermal management) and thermal management (which can be combined with environmental protection). Reference is made to the components of FIG. 1 (component 102, outer surface 114, and inner surface 116). This includes what is required of component 102 from a protection perspective in a given embodiment / use case and how the outer surface 114 and inner surface 116 are configured in a given embodiment / use case. In some cases, additional information about the embodiment or use case / content is provided (under "Other").

[0078] [Table 1]

[0079] Referring now to FIG. 2, shown therein is a stacked self-supporting space environmental protection device 200 including two self-supporting space environmental protection devices 100 of FIG. 1 according to one embodiment.

[0080] The reference numerals for the two self-supporting space environmental protection devices are given subscripts -1 and -2, respectively.

[0081] The stacked self-supporting space environmental protection device 200 includes a first self-supporting space environmental protection device 100-1 and a second self-supporting space environmental protection device 100-2, respectively. The first thermal protection device 100-1 and the second thermal protection device 100-2 are attached through their respective mounting holes 112-1, 112-2. The first thermal protection device 100-1 and the second thermal protection device 100-2 each include an outer surface 114-1, 114-2, and an inner surface 116-1, 116-2. The components are attached on the platform surface 110.

[0082] When attached, the outer surface 114-2 of the second self-supporting space environmental protection device 100-2 is the surface facing the only universe.

[0083] A low-emissivity finish is applied to the inner surface 116-1 of the first self-supporting space environmental protection device 100-1. A low-emissivity finish is applied to the outer surface 114-1 of the first self-supporting space environmental protection device 100-1.

[0084] A low-emissivity finish is applied to the inner surface 116-2 of the second self-supporting space environmental protection device 100-2. A low-absorptivity finish is applied to the outer surface 114-2 of the second self-supporting space environmental protection device 100-2.

[0085] The self-supporting space environmental protection device has the advantages of low cost and low mass, and realizes an improvement in schedule / lead time in development compared with alternative forms. This may be particularly applicable when manufactured additionally.

[0086] Generally, the self-supporting space environmental protection device of the present disclosure can reproduce the thermal and mechanical functions of a flexible blanket while achieving significant advantages. Such advantages include, for example, reproducible thermal characteristics compared with blankets of complex shapes with multiple discontinuities, slits, or bends, and adjustable performance by using low-emissivity finishes and / or white coatings.

[0087] Furthermore, the device reduces manufacturing costs and assembly time. The device can be designed early in the program (e.g., in CAD) and ordered at the same time as other parts (therefore, the device does not affect critical schedules). The device achieves improved robustness / reduced risk (a flexible thermal blanket can be easily torn and potentially catch on components). The device avoids the need for additional supports and thus realizes a lighter option. The device achieves more predictable thermal efficiency (a small, flexible thermal blanket with multiple bends and slits is efficiency-sensitive and thus it is impossible to accurately predict the impact on performance).

[0088] In one embodiment, compared to a thermal blanket that may require a 150 g aluminum cage mass and a 75 g blanket mass, the additionally manufactured self-supporting space environmental protection device 100 can require only approximately 50% of the mass of an aluminum cage having a minimum print thickness of 0.05 inches.

[0089] Referring now to FIG. 3, shown therein is a method of manufacturing the self-supporting space environmental protection device 100 of FIG. 1 according to one embodiment.

[0090] At 302, method 300 includes recording the physical profile of a temperature-sensitive component that is used in a space-based electromechanical system and is protected or covered by a self-supporting space environmental protection device.

[0091] Accurate measurements of the component can be recorded to create a digital representation of the shape of the component and the degrees of freedom in which the component operates.

[0092] The measurements can be recorded by 3D scanning, manual measurement, or photogrammetry.

[0093] In one embodiment, the shape of the self - supporting space environmental protection device is determined based on the dimensions of the space - based equipment intended to be covered. In one embodiment, the self - supporting space environmental protection device is designed using computer - aided design (CAD) software, or a similar system (e.g., CAD) based on the physical outer shape of the temperature - sensitive components to be covered.

[0094] In 304, method 300 includes manufacturing a self - supporting space environmental protection device from a polymer qualified for space applications that is resistant to cosmic rays, based on the physical outer shape of the components recorded in 302. The self - supporting space environmental protection device can be manufactured using a CAD model.

[0095] In one embodiment, the manufacturing process includes the step of adopting additive manufacturing techniques.

[0096] In one embodiment, the self - supporting space environmental protection device is manufactured using a molding process such as machining or injection molding.

[0097] In 306, method 300 includes the step of applying a low - emissivity metal plating on the inner surface of the self - supporting space environmental protection device (e.g., surface 116 in FIG. 1).

[0098] In 308, method 300 includes the step of applying a low - absorptivity finish on the outer surface of the self - supporting space environmental protection device (e.g., surface 114 in FIG. 1).

[0099] While the above description provides examples of one or more devices, methods, or systems, it will be understood that other devices, methods, or systems may fall within the scope of the claims, as would be interpreted by one of ordinary skill in the art.

Description of Reference Numerals

[0100] 100 Self - supporting space environmental protection device, rigid self - supporting polymer - based device 100 - 1 First self - supporting space environmental protection device, first thermal protection device 100-2 Second Self-Supporting Space Environmental Protection Device, Second Thermal Protection Device 102 Component 104 Self-Supporting Body 106 Cavity 108 Lower End Piece 110 Platform Surface, Surface, Platform 112 Mounting Hole 112-1 Mounting Hole 112-2 Mounting Hole 114 Outer Surface 114-1 Outer Surface 114-2 Outer Surface 116 Inner Surface 116-1 Inner Surface 116-2 Inner Surface 200 Self-Supporting Space Environmental Protection Device

Claims

1. 1. A self-supporting space environmental protection device for covering a component of a space-based system, comprising: a self-supporting polymer-based body constructed for mounting on said component and constructed from a cosmic radiation resistant polymer-based material; A self-supporting space environment protection device, wherein the self-supporting polymer-based body has an inner surface that faces the component when the self-supporting space environment protection device is attached, and an outer surface that is exposed to the space environment.

2. 10. The device of claim 1, wherein a low absorptivity finish is applied to the exterior surface of the self-supporting polymer-based body, the low absorptivity finish having a lower solar absorptivity (α) value than the cosmic ray resistant polymer-based material.

3. 10. The device of claim 1, wherein a low-emissivity finish is applied to the interior surface of the self-supporting polymer-based body, the low-emissivity finish having a lower infrared emissivity (ε) value than the cosmic radiation resistant polymer-based material.

4. 2. The device of claim 1, wherein the cosmic ray resistant polymer-based material is one of a polymer composite, polyetherketoneketone (PEKK), a PEKK-based FDM thermoplastic, or polyetherimide (PEI).

5. 10. The device of claim 1, wherein the space ray resistant polymer is carbon filled to provide electrical conductivity and reduce ESD risks associated with use of the self-supporting space environmental protection device.

6. The device of claim 1 , wherein the low absorption finish is a white paint.

7. The device of claim 1 , wherein the low-emissivity finish is a metallic plating.

8. 8. The device of claim 7, wherein the metal plating comprises a plurality of plating layers, the plurality of plating layers comprising a silver plating layer on a nickel plating layer or a gold plating layer on a nickel plating layer.

9. 8. The device of claim 7, wherein the metal plating comprises multiple plating layers with a final metal plating layer being a nickel plating, a gold plating, or a silver plating.

10. The device of claim 1 , wherein the low-emissivity finish is a low-emissivity paint.

11. The device of claim 1 configured to cover a partial section of the component used in space.

12. The device of claim 1 , wherein the rigid polymer-based body is manufactured using any one of an additive manufacturing, a molding process, or a subtractive machining process.

13. 2. The device of claim 1, wherein a low absorptivity finish is applied to the exterior surface of the self-supporting polymer based body and a low emissivity finish is applied to the interior surface of the self-supporting polymer based body, the low absorptivity finish having a lower solar absorptivity (α) value than the cosmic ray resistant polymer based material, and the low emissivity finish having a lower infrared emissivity (ε) value than the cosmic ray resistant polymer based material.

14. 1. A method of manufacturing a self-supporting space environmental protection device for covering a component for use in space, comprising: recording the physical outline of the space component; fabricating a self-supporting polymer-based body from a cosmic ray resistant polymer based on said recorded physical contour of the temperature sensitive device; applying a low absorptivity finish to an exterior surface of the self-supporting polymer-based body, the low absorptivity finish having a lower solar absorptivity (α) value than the cosmic radiation resistant polymer-based material; applying a low-emissivity finish to an interior surface of the self-supporting polymer-based body, the low-emissivity finish having a lower infrared emissivity (ε) value than the cosmic radiation resistant polymer-based material; A method comprising:

15. 15. The method of claim 14, wherein manufacturing of the rigid polymer body is performed using any one of an additive manufacturing, a mold process, or a subtractive machining process.

16. The method of claim 14 , wherein the self-supporting polymer-based body is manufactured to cover a partial section of the component for use in space.

17. The method of claim 14, wherein the low absorption finish is a white paint.

18. The method of claim 14, wherein the low emissivity finish is a metallic plating.

19. 20. The method of claim 18, wherein the metal plating comprises multiple plating layers with a final metal plating layer being a nickel plating, a gold plating, or a silver plating.

20. The method of claim 14, wherein the low-emissivity finish is a low-emissivity paint.

Images