Modular deployable space structures

Abstract

The systems and methods described herein include foldable and deployable structures that can be used as antennas, collectors, reflectors, or other larger structures. The systems and methods can use modular designs so that larger structures can be obtained for space applications.

Description

[Background technology]

[0001] Antennas, especially for space applications, are desirable to be lightweight and able to fit into as little storage space as possible. The main reason is cost: the lighter and smaller the space payload, the less it costs to launch it into space. For antennas, aperture size is paramount: the larger the aperture, the higher the antenna gain, efficiency, and, in imaging applications, the higher the resolution. Thus, there is a direct conflict between these opposing interests. Summary of the Invention [Means for solving the problem]

[0002] The batten-rest trusses described herein provide a foldable structure that reduces the storage volume of the deployable structure. Exemplary embodiments can include a structure for use as a perimeter truss for a reflector antenna and / or a solar concentrator.

[0003] Exemplary embodiments include trusses comprising an assembly of members, such as stringers, connected by nodes that form a rigid structure when deployed. Exemplary embodiments of batten-rest trusses can include stringers that are foldable between the nodes. The stringers can be hinged, can include shape memory composites, or can include other deformable materials.

[0004] The exemplary embodiments described herein involve combining modular component batten restraints to create larger deployed systems from smaller deployable sections. [Brief explanation of the drawings]

[0005] [Figure 1A] 1 illustrates an exemplary application of an antenna using a foldable truss frame. [Figure 1B] 1 illustrates an exemplary application of an antenna using a foldable truss frame. [Figure 1C] 1 illustrates an exemplary application of an antenna using a foldable truss frame. [Figure 2A] 1 illustrates an exemplary truss frame during an unfolding procedure from a folded configuration to an deployed configuration, according to embodiments described herein. [Figure 2B] 1 illustrates an exemplary truss frame during an unfolding procedure from a folded configuration to an deployed configuration, according to embodiments described herein. [Figure 2C] 1 illustrates an exemplary truss frame during an unfolding procedure from a folded configuration to an deployed configuration, according to embodiments described herein. [Figure 3A] 1 illustrates an exemplary deployment mechanism for use in a batten restraint system according to embodiments described herein. [Figure 3B] 1 illustrates an exemplary deployment mechanism for use in a batten restraint system according to embodiments described herein. [Figure 4A] 1 illustrates an exemplary support structure comprising an exemplary embodiment of a batten restrust according to embodiments described herein. [Figure 4B] 1 illustrates an exemplary support structure comprising an exemplary embodiment of a batten restrust according to embodiments described herein. [Figure 4C] 1 illustrates an exemplary support structure comprising an exemplary embodiment of a batten restrust according to embodiments described herein. [Figure 5A] 1 illustrates an exemplary modular structure in a completed configuration according to embodiments described herein. [Figure 5B] 5B is an exploded view of the exemplary modular structure of FIG. 5A, with modular components separated from the whole. [Figure 5C] 5C shows the module components removed from FIG. 5B. [Figure 6] 1 illustrates an exemplary wedge portion of a modular structure comprising a first substructure, a second substructure, and a third substructure comprising two portions. [Figure 7A] 1 illustrates different elements of a substructure according to embodiments described herein. [Figure 7B] 1 illustrates different elements of a substructure according to embodiments described herein. [Figure 7C] 1 illustrates different elements of a substructure according to embodiments described herein. [Figure 8] 1 illustrates one embodiment of a method for joining two substructures of a larger superstructure together. [Figure 9] 1 illustrates an exemplary portion of a mounting panel according to an exemplary embodiment. [Figure 10A] 1 illustrates an exemplary attachment method according to embodiments described herein. [Figure 10B] 1 illustrates an exemplary attachment method according to embodiments described herein. [Figure 10C] 1 illustrates an exemplary attachment method according to embodiments described herein. [Figure 10D] 1 illustrates an exemplary attachment method according to embodiments described herein. [Figure 10E] 1 illustrates an exemplary attachment method according to embodiments described herein. [Figure 11A] 1 illustrates an exemplary attachment method according to embodiments described herein. [Figure 11B] 1 illustrates an exemplary attachment method according to embodiments described herein. [Figure 11C] 1 illustrates an exemplary attachment method according to embodiments described herein. [Figure 12] 1 illustrates an exemplary mosaic reflective surface of an exemplary solar collector according to embodiments described herein. [Figure 12A] FIG. 2 is a close-up view of a single reflective portion of the reflective surface. [Figure 13] 1 illustrates an exemplary single piece-wise reflective element within a portion of a support structure for a mosaic reflective surface according to embodiments described herein. DETAILED DESCRIPTION OF THE INVENTION

[0006] The following detailed description illustrates the principles of the present invention by way of example, not by way of limitation. The description clearly enables those skilled in the art to make and use the invention and describes several embodiments, modifications, variations, alternatives and uses of the invention, including what is currently contemplated to be the best mode of carrying out the invention. It should be understood that the drawings are diagrammatic and schematic representations of exemplary embodiments of the invention, are not limiting of the invention, and are not necessarily drawn to scale.

[0007] Exemplary embodiments of the systems and methods described herein enable the construction of very large antenna apertures through a design that divides a large diameter antenna structure into sub-truss antenna structures. These sub-truss antenna structures can be configured to fit inside a rocket booster fairing when packaged and folded. Thus, the associated costs of deployment are made manageable by allowing large area antennas to be formed using modular components that fit inside more conventional, smaller payload areas for easier, piece-wise deployment.

[0008] Exemplary embodiments described herein include a method for deploying a large aperture antenna structure using sub-antenna structures. In an exemplary embodiment, the method may include providing multiple sub-antenna structures as described herein. Each of the sub-antenna structures can then be launched into orbit. The sub-antenna structures may be launched separately and / or together in one or more payloads in one or more launch vehicles. Once all of the multiple sub-antenna structures are in orbit, they can be assembled into a single large antenna that would otherwise not fit even in the largest currently available booster fairing. For example, the antenna structure could even have an antenna diameter approaching one kilometer. In an exemplary embodiment of the method, a co-orbiting assembly robot may be used to join the multiple sub-antenna structures into a single large structure.

[0009] While embodiments of the present invention may be described and illustrated herein with respect to a particular support structure, it should be understood that embodiments of the present invention are not so limited and are further applicable to different configurations. Exemplary embodiments further disclosed herein include various combinations of flexible support options that can be used in modular configurations. Any combination of such support structures or alternative retractable options is contemplated for use herein. The exemplary embodiments described herein relate to antenna structures. However, the exemplary embodiments can also be used for reflectors, solar collectors, and the like and remain within the scope of the present application. To create a reflector or solar collector, the exemplary embodiments can include a reflective surface coupled to the net mesh support structure described herein and / or include a collector structure.

[0010] Any feature, component, configuration, and / or attribute described with respect to any example may be used in combination with any other example. Thus, any procedure, feature, component, configuration, and / or attribute may be used in any combination and remain within the scope of this disclosure. Features may be removed, added, duplicated, merged, subdivided, or otherwise recombined and remain within the scope of the present disclosure. The exemplary embodiments described herein are presented for illustrative purposes only. Thus, any antenna, collector, support structure, or other configuration may be used with or without any of the components described herein.

[0011] 1A-1C illustrate an exemplary application using a support structure comprising an exemplary embodiment of a truss frame according to embodiments described herein. FIG. 1C illustrates an exploded view of exemplary components of the application of FIGS. 1A-1B. FIG. 1A-1C illustrate an exemplary concept of a battenless space-deployable antenna. Other applications, such as reflectors, collectors, etc., are also contemplated herein.

[0012] Large area reflectors in space are commonly used as radio frequency (RF) reflector antennas for communications or radar imaging, as well as solar concentrators for generating solar-powered electrical power. Space-deployable reflector antennas or solar concentrators are preferably lightweight and can be folded into a volume small enough to fit within a rocket booster fairing. Exemplary embodiments described herein include a low-weight, low-storage-volume foldable reflector antenna / concentrator perimeter truss support made of modular substructures for separate storage and deployment. Larger structures are described herein with reference to FIGS. 1A-1C.

[0013] In this embodiment, the exemplary structure 100 includes a perimeter truss 102 that connects and supports a reflector 104 and inverted net domes 106, 108. The reflector 102 and inverted domes 106, 108, which can be combined with the perimeter truss 102, are net mesh surfaces made of rigid, non-conductive or conductive materials. The reflector domes may be designed to assume a specific shape, i.e., a surface of revolution, under appropriate tension. The surface of revolution may be any surface of revolution, such as a paraboloid of revolution, a sphere, or anything substantially similar thereto. The inverted dome 108 may be, but need not be, a mirror image of the reflector dome 106. Between the inverted dome 108 and the reflector dome 106 are tension ties 110 that are used to apply stress or tension to the mesh domes 106, 108. Thus, the reflector 104 and the inverted domes 106, 108 provide anchor points for these tension ties. When properly tensioned, the reflector dome 106 contacts the reflector 104 , causing the reflector to conform to the same shape as the reflector dome 106 .

[0014] In an exemplary embodiment, the reflector 104 may be a conductive mesh to form an antenna structure. The conductive mesh acts as a reflector of electromagnetic energy. For radio frequency (RF) applications, the conductive mesh may also be a thin metallized film of a few hundred angstroms of evaporated or sputtered aluminum or silver. For solar concentrator applications, the conductive mesh is replaced with a thin metallized film of a few hundred angstroms of evaporated or sputtered aluminum or silver. Thin films of other materials are also possible. The thin film may be, for example, a polyimide or polyester material. Other surface materials and structures are also contemplated herein. For example, mirrored surfaces, including glass structures, may be used.

[0015] As shown in FIGS. 1A-1C, an exemplary embodiment of a reflector 100 is presented. The reflector comprises a perimeter truss according to embodiments described herein. The perimeter truss 102 comprises stringers 112 as described herein. A reflective surface 106 is coupled to the perimeter truss 102. Support connections suspend a net perimeter (the outer portion of 106) and apply tension to the outer edge of the reflector surface, forming a tension drum. The perimeter truss 102 in this embodiment can couple to and support a reflector dome 106 and an inverted dome 108. The reflector dome 106 and the inverted dome 108 may comprise netting, mesh, cable, etc. Tension ties 110 (tensioning elements) may be present between the inverted dome 108 and the reflector dome 106, which are used to apply stress or tension to the conductive mesh.

[0016] The perimeter truss 102 shown in Figures 1A and 1C is generally circular, but the perimeter may also be made from piece-wise straight sections, as shown in Figure 1B.

[0017] 2A-2C illustrate an exemplary sequence of folded and unfolded configurations of an exemplary batten truss according to embodiments described herein that can be used as a frame in the truss structures described herein. In an exemplary embodiment, the truss can include multiple longerons and multiple diagonals. FIG. 2A illustrates an exemplary configuration in which the longerons are fully folded. The diagonals are shown vertically. The illustrated diagonals in this example do not extend or retract. FIG. 2B illustrates an exemplary configuration in which the longerons are not fully folded. FIG. 2C illustrates an exemplary configuration in which the truss components are fully deployed. The truss is configured as a Warren truss.

[0018] Figure 2A shows how a battenless perimeter truss can be stowed in an exemplary configuration. As shown, the height of the folded / stowed configuration can be approximately the length of the diagonal members. By using telescoping diagonals, the stowed height can be made shorter.

[0019] The exemplary truss 200 is comprised of structural members 202 joined at nodes 204. The structural members may include diagonals 208 and stringers 206. The stringers are configured to extend longitudinally along the length of the truss in the deployed configuration according to embodiments described herein. The diagonals are configured to extend across and along the truss in the deployed configuration according to embodiments described herein, or to extend at an angle to the stringers in the deployed configuration. The diagonals of the truss can be configured to be non-perpendicular to the stringers in the deployed configuration.

[0020] In exemplary embodiments, the diagonal members may be rigid members that are not configured to substantially deform during stowing or deployment. The stringers may comprise deformable members configured to deform or have a different shape from the stowing configuration to the deployed configuration. As used herein, a deformable member may comprise any configuration that deforms as described herein. For example, the deformable member may be flexible so as to bend under the application of an external force.

[0021] As used herein, the terms rigidity and flexibility are intended to be relative terms. Thus, while it is understood that a rigid structure may still have some degree of bending under the application of sufficient external force, absolute rigidity is not required. Instead, those skilled in the art will understand that a rigid structure is intended to generally maintain its shape during normal operation and for its intended purpose. Flexible structures are considered to deform along their length. Deformation can occur with the application of sufficient external force without separating or destroying the structure, allowing the structure to return to its original form. Deformable structures are considered to deform at a point or along their length. Thus, deformable structures can include joints, hinges, living hinges, flexible members, or combinations thereof.

[0022] Exemplary embodiments described herein include a deformable structure that can still provide structural rigidity when the structure is fully deployed. For example, the deformable structure may be configured to deform under the application of a lateral or shear force applied to the structure. A structural lateral force can be applied by the system architecture to deform the deformable structure and place the structure in a stowed configuration. The deformable structure may be configured to maintain its shape or to maintain rigidity under the application of a compressive or longitudinal force applied to the structure. The structural rigidity can be maintained during normal use of the structure in its deployed configuration. Thus, the deformable structure can have both deformable and rigid properties depending on the direction of the applied force.

[0023] Exemplary embodiments of the deformable structure can include any combination of configurations to achieve the deformable configurations described herein.

[0024] For example, exemplary embodiments of the deformable structure may comprise a shape memory composite. These composites are flexible and can allow for unstructured deformation under the application of an external force. Shape memory composites may also be frozen or held in a deformed configuration, such as by a change in temperature. Shape memory composites may be configured to return to a memorized configuration. The memorized configuration may be due to a passive or active change. Shape memory composites may passively return to a memorized configuration for use in a deployed configuration by returning to the memorized configuration after the external force that caused the deformation is removed. Shape memory composites may actively return to a memorized configuration when a transition condition is met, such as a change in temperature or the application of an electric current or the removal of an external force.

[0025] Exemplary embodiments of the deformable structures described herein may comprise elastic shape memory carbon composites. Exemplary embodiments may also comprise other high strain materials. Exemplary embodiments of shape memory composites may be used as structural elements, such as the stringer members of the trusses described herein. The stringers may comprise structural fibers impregnated with an elastic resin or a shape memory metal, such as Nitinol. The structural fibers may be made of carbon, fiberglass, aramid (e.g., Kevlar), Vectran, or combinations thereof. The stringers may be wrapped in very thin films coated with SiO2 and / or Al2O3 to protect against atomic oxygen. The coating may comprise approximately 50 Å of SiO2 or 35 Å of Al2O3. These coatings at these thicknesses have been shown to provide protection from degradation by atomic oxygen present in low Earth orbit (LEO).

[0026] Exemplary embodiments of the deformable structures described herein can include thermally stable, shape-memory capable, high-strain superelastic shape memory alloy materials. Exemplary embodiments of the shape memory alloy materials can be made of Nitinol or other Ni-Ti composite alloys. Exemplary embodiments can include Ni-Ti ternary alloy types that add a third element for more stable performance in shape setting, shape precision, and durability in space environments. The properties of the shape memory composite alloy can be tailored by controlling the relative amounts of the alloying elements.

[0027] Exemplary embodiments of the deformable structures described herein can include rigid members with flexible or deformable portions. For example, the deformable structure can include rigid members joined by a hinge. Exemplary hinges can be folded by a socket, rod, flexible material, or other known hinge structures.

[0028] The deformation may be unstructured or structured. An unstructured deformation may allow deformation based on an applied force to deform the structure. An unstructured deformation may allow deformation of a member along its length in response to an applied force. Thus, the member may deform into different shapes or configurations under different applied forces. A structured deformation may allow deformation in a known or predetermined manner. An example of a structured deformation is a hinge.

[0029] As shown in Figures 2B-2C, exemplary embodiments of truss structures described herein include multiple structural members connected to one another by multiple nodes. The connections between the structural members and the nodes allow the structural members connected at the nodes to be repositioned relative to one another to transition between deployed and stowed configurations and vice versa. As shown, each node includes at least two structural members, i.e., at least one diagonal member and at least one longeron structural member. An internal node can include at least four structural members, i.e., at least two diagonal members and at least two longeron members connected to the same node. Thus, multiple nodes can include at least four structural members extending therefrom.

[0030] In exemplary embodiments, the diagonal structure members are rigid. The diagonal structure members may be rigid in the deployed configuration, the stowed configuration, and during transitions between the stowed and deployed configurations. In exemplary embodiments, the diagonal structure members may be elastic or non-elastic.

[0031] In exemplary embodiments, the stringer structure members are deformable. The stringer structure members may be deformable according to any configuration or embodiment described herein. The stringer structure members may be deformable during transitions from the stowed and deployed configurations as described herein. The stringer structure members may be rigid in the deployed configuration under expected and / or normal operating forces, such as compressive forces applied to the stringers.

[0032] 3A-3B illustrate an exemplary deployment system for use in a batten restraint system according to embodiments described herein. Figures 3A-3B illustrate an exemplary structure in the form of a pantograph truss.

[0033] The exemplary embodiments described herein can include a deployment system that can assist in transitioning the truss from a folded configuration to a deployed configuration or from a deployed configuration to a folded configuration.

[0034] The exemplary embodiment of truss structure 300 comprises a plurality of structural members 302 and nodes 304. The structural members and nodes may comprise structural members 202 or nodes 204 as illustrated in Figures 2A-2C or as described herein. The structural members 302 may comprise rigid and / or deformable structures as described herein. The stringers 306, as illustrated, may be deformable, while the diagonals 308, as illustrated, may be rigid or non-deformable.

[0035] As shown, the stringers comprise deformable members including a shape memory composite. The shape memory composite may be deformable under the application of an external force. The shape memory composite may have a memorized configuration to which it automatically or passively returns after the external force is removed. As shown, the memorized configuration is a straight configuration and the deformed configuration is bent.

[0036] The truss system 300 shown herein also provides a deployment system, which may include a cable 312 and a number of pulleys 310.

[0037] The system can have a deployed configuration as shown in Figure 3A. The cables may be arranged so that they are in neutral tension, i.e., they are not under tension so that they do not apply a shear force to the stringers. Because the cables are not applying an external force to the stringers, the stringers maintain their memorized configuration. Thus, the stringers are straight and deployed.

[0038] The system is in a stowed configuration in which the stringers are deformed and the structure is collapsed. Figure 3B illustrates an exemplary transition from the deployed configuration to the stowed configuration. A force is applied to cable 312, as indicated by the arrows in Figure 3B, placing the cable in tension. The cable is coupled to both sides of the truss and zigzags between adjacent longitudinal stringers on the same side of the truss and opposing stringers on the opposite side of the truss. For example, cable 312 can be coupled to a first stringer on a first side of the truss and then to a first opposing stringer on a second side of the truss. The second side of the truss is opposite the first side of the truss. The first stringer can be longitudinally offset from the first opposing stringer. The cable can then be coupled to a second stringer on the first side of the truss. The second stringer can be longitudinally adjacent to the first stringer. The second stringer can be longitudinally offset from the first opposing stringer. The cable can then be coupled to a second opposing stringer. The second opposing stringer can be longitudinally adjacent to the first opposing stringer or longitudinally offset from the second stringer. The cable can be cycled through "n" stringers and "m" opposing stringers in this manner to form a zigzag between opposite sides of the truss, where n and m are integers. When a force is applied to the cable, a force is applied to the deformable stringer member, causing the member to deform toward the center of the truss or toward the opposite side of the truss. Thus, the system can be configured to collapse and remain in a stowed configuration by continuously applying tension to the cable. When tension is removed from the cable, the stringer returns to the memorized configuration and can be deployed to the deployed configuration.

[0039] Exemplary embodiments may include alternative or additional features that can be used as storage forces to deform the stringers and maintain the truss in a deformed configuration for storage. Exemplary embodiments may also, or alternatively, use different or additional features within the overall structure or deployed device. For example, exemplary embodiments may include tear-off surfaces, removable retraction or storage materials or cords, a jacket, one or more antenna features, one or more sleeves or jackets, one or more support bases, a hub, one or more inflation mechanisms, a housing, an actuator, a controller, cables, pulleys, etc.

[0040] 4A-4C illustrate an exemplary portion of a frame comprising an exemplary embodiment of a batten-rest truss according to embodiments described herein. FIG. 4A illustrates an exemplary portion of a Warren perimeter truss-shaped structure. The truss can comprise multiple longerons and diagonals, as described herein. The truss sections may be joined together to form a closed shape, as shown in FIG. 4B. The closed shape can form an outer frame for supporting a net mesh and reflective surface, as described herein. As shown, the reflector and / or net mesh frame shape can comprise multiple piece-wise linear sections joined together at an angle between adjacent structures. In accordance with embodiments described herein, the piece-wise linear sections are joined together to form an overall, approximately circular structure. As described more fully herein, the piece-wise linear perimeter can form a portion for a modular structure according to embodiments described herein.

[0041] FIG. 4C illustrates an exemplary modular, strip-like frame comprised of closed-shaped partial frames that can be repeated multiple times to create a perimeter frame of a larger structure described herein. As illustrated, the closed-shaped partial frames can form a generally wedge-shaped structure. Each side of the wedge-shaped partial frame can include a batten truss according to embodiments described herein. As illustrated, each side of the wedge-shaped partial frame can be generally straight. The sides of the partial frames can form a generally triangular or truncated triangle, as shown and described with respect to other embodiments herein. The perimeter frame can include multiple partial frames. Each partial frame can be the same shape, a different shape, or can include a set of various shapes described herein. The partial frames can be positioned adjacent to one another to form a repeating pattern to form a larger overall structure. While wedge substructures are shown and described herein to create a generally circular overall larger structure, other partial and larger shapes can be created. For example, smaller square structures can be combined to create a larger square or rectangular structure. Wedge substructures can be used to create oval, circular, stepped circular, stepped oval, elliptical, or other structures. It will be understood by those skilled in the art that, as described herein, a generally circular or approximating shape may allow for deviations from the desired shape as required or permitted by the target design structure, but still resemble the desired shape. Thus, a generally circular shape may be a closed shape that does not include curved edges, but instead includes multiple striped, straight edges of approximately equal shape, creating a shape that closely resembles or approximates a circle, especially when viewed at a larger scale. For example, the multiple striped, straight portions may still approximate a circle, since when combined, the resulting closed shape can still be obtained, and the resulting total surface area approximates the surface performance of a circular closed shape for the desired purpose of use as a reflector, collector, and / or antenna.

[0042] The exemplary embodiments described herein can be used to design lightweight, low-packed-volume space-deployable structures for antennas and concentrators. The exemplary embodiments described herein can include stringers and diagonals. In exemplary embodiments, there are no cross members or battens. The exemplary truss or frame embodiments described herein can be in any configuration, including those with batten members extending perpendicular to the stringers between upper and lower stringers between separate adjacent diagonals. The battens can cut the equilateral triangles formed by the diagonals in half.

[0043] In an exemplary embodiment, the stringers and diagonals may be made of rigid members such as steel, aluminum, or titanium. They may also or alternatively be made of materials such as: (a) carbon, (b) fiberglass, (c) Kevlar, (d) Vectran, (e) elastic shape memory carbon composite (SMCC), (f) Sub-T g (f) a stiffenable composite material made from a resin-impregnated structural fabric, or (g) a composite of similar materials, or a combination thereof. g The structural fabric for the composite can be (a) carbon, (b) fiberglass, (c) Kevlar, (d) Vectran, (e) similar materials, or (f) combinations thereof. The stringers may be configured to bend, such as through flexible materials or with hinges.

[0044] If the member is made of a shape memory composite (SMCC) structural fabric, the resulting composite can be folded for packaging and, when the restraint is removed, unfolds and moves to its memorized shape. On the other hand, if the stringer is made of a rigid material, such as a composite of steel, aluminum, titanium, (a) carbon, (b) fiberglass, (c) Kevlar, and (d) Vectran, a locking hinge may be present at its midpoint or along its length. The hinge can be used to bend the stringer at its midpoint or at another desired length for storage. If a shape memory carbon composite (SMCC) material is used, a hinge is not necessary because the material is flexible when a point load is applied perpendicular to its length; the stringer can be bent at its midpoint or at a desired location. When the SMCC member is unfolded, it can become a compression-tension member. Other shape memory composites can also be used and remain within the scope of this disclosure.

[0045] Sub-T as described herein g The resin is heated to its glass transition temperature T g The resin may be a polymer resin or polyurethane resin having a rigidity below 0.5.

[0046] Shape memory composites allow the exemplary embodiments described herein to collapse under the application of an external force in a non-structural manner. Thus, the collapsed configuration can be dynamically determined based on the storage compartment or the applied external force. For example, a shape memory composite can be flexible or deformable along its length when a force is applied. However, the shape memory composite returns to a memorized configuration when the force is removed. In other words, the memorized or biased configuration may be the deployed configuration (antenna, collector, or other large-area shape) in which the structure or frame is configured for use. In exemplary embodiments, the shape memory composite can bend in any direction under the application of an external force. In exemplary embodiments, the shape memory composite may bend at multiple locations along the length of the member or along the entire length of the member. In exemplary embodiments, the shape memory composite can return to a memorized configuration, such as a straight line, circle, ellipse, curve, parabola, helix, spiral, or other predetermined shape, when the external force is removed.

[0047] Exemplary shape memory composite materials include a substrate of one or more of carbon fiber, Vectran, Kevlar, fiberglass, fiberglass, plastic, and / or fiber metal. The substrate comprises strands. The strands may be generally aligned along the length of the structure, may include one or more aligned configurations, may be wrapped, helically arranged, woven, or any combination thereof. The shape memory composite material includes a matrix around and / or between the substrates. The matrix may be silicone, urethane, or epoxy. Exemplary shape memory composite materials are described in co-pending patent application U.S. Patent Application Publication No. 2016 / 0288453, entitled "Composite Materials." High strain materials allow for deformation. High strain materials generally have the property of not undergoing plastic deformation beyond 3% strain. In other words, the material does not yield beyond 3% strain.

[0048] In an exemplary embodiment, the shape memory composite has a fiber-to-resin volume fraction ratio that can be controlled to achieve desired shape memory retention even after extended storage in a folded / packaged state. An exemplary fiber-to-resin volume fraction ratio is 52 to 65, i.e., 52% to 65% fiber or 48% to 35% matrix or resin. The average fiber-to-matrix ratio is about 58%. The fiber may be carbon, Kevlar, Vectran, nylon, or others described herein, and the resin may be urethane, silicone, or epoxy, or others described herein as a matrix.

[0049] Regardless of the truss structure used to frame the reflecting surface, antenna reflectors over 100 meters in diameter will not fit inside the rocket fairing of current or known rocket boosters. Therefore, the exemplary embodiments described herein allow the structure to be broken down into multiple smaller substructures, each of which can fit into the rocket fairing or other desired containment structure. Following this, the substructures are launched into orbit, and then the substructures are assembled into a single, much larger antenna.

[0050] 5A-5C illustrate exemplary modular structures according to embodiments described herein. FIG. 5A illustrates an exemplary overall structure for use in an unfolded and assembled configuration. FIG. 5B is an exploded view of the larger embodiment of FIG. 5A with selected modular subassemblies removed. FIG. 5C illustrates a modular subassembly removed for closer examination of its component parts. As shown, the overall reflective surface may be separated into modular portions. Some or all of the modular portions may be the same, or some or all of the modular portions may be different. The modular structures may be joined together to create the overall superstructure.

[0051] 5A illustrates an exemplary superstructure 500, such as a large collector, reflector, antenna, or the like. The illustrated superstructure 500 comprises multiple substructures 602, 604, 606. The superstructure comprises multiple frames 502, such as trusses as described herein. The frames are configured to support multiple surfaces 504. The surfaces can be configured according to the desired application, such as meshes, nets, sheets, membranes, etc., which may be conductive and / or reflective as described herein.

[0052] As shown, the superstructure can include multiple substructures. In an exemplary embodiment, the substructures are configured to be wedge-shaped, and may be triangular and / or trapezoidal, such that the wedges are separated. The substructures may be positioned adjacent to one another to form arcs around the perimeter of the superstructure. For larger structures and / or to control the storable size of the substructures, rings of substructures can be created. As shown, three sets of substructures are formed, with each substructure within a set being identical to the other substructures within the same set. However, the substructures may differ from one set to another. The sets of substructures may be configured to form concentric rings, such that a first set of substructures forms a first ring, a second set of substructures forms a second ring, and a third set of substructures forms a third ring. As shown, the first ring may be interior to and concentric with the second and third rings, and the second ring may be interior to and concentric with the third ring. The height of each of the different rings may vary between rings. As seen in FIG. 5C, the height of the frame may be at least large enough to correspond to or support the normal vector of the reflective surface and / or overlap adjacent substructures in order for adjacent substructures to couple to each other. Therefore, the size of the shape can be determined based on the surface of each substructure that needs to be supported. Thus, an inner ring of substructures may have a height lower than the second ring, which may have a height lower than the outermost ring of substructures, or the next radially larger ring. The bottom edge of each set of substructures may be the same across different sets of substructures. A common reference exists so that each substructure can be coupled and / or aligned to each other during the build process.The height of each of the different sets of substructures can have a different base reference level (i.e., "ground level" or bottom edge), so that the height of each of the different sets can be adjusted according to the minimum need to support the surface of a given modular substructure, and each ring or set of substructures can be offset relative to adjacent sets or rings. As shown in Figure 5C, the bottom edge of each frame of the different sets of substructures is the same, but the top edge of each frame of the different sets of substructures is different, with the inner sets being lower than the substructures on the outer ring or outer sets of substructures.

[0053] In an exemplary embodiment, the upper structure can comprise multiple substructures. A first substructure can be radially inward of a second substructure, which can be radially inward of a third substructure. In an exemplary embodiment, the third substructure comprises two third substructures. In an exemplary embodiment, the first substructure, the second substructure, and the third substructure(s) form a wedge across the upper structure. As a result, multiple wedges are repeated circumferentially to form the upper structure.

[0054] In an exemplary embodiment, each substructure comprises a frame, a reflector, and a support base, as described herein. For example, the frame can comprise a truss with longerons and diagonals, as described herein. The reflector can be any structure, such as a mesh, a conductive material, a reflective material, a membrane surface, or a sheet. The support base can comprise a net mesh, as described herein, including a reflective dome and an inverted dome, and tensioning elements therebetween, as described herein. Because the modular portions of the structure may not comprise circular objects but may instead comprise wedge or other shapes for the modular components, the term "dome" is used merely to identify the structures described herein with other embodiments. The support base does not necessarily have a dome shape, as will be understood by those skilled in the art. Instead, the shape of the dome is formed by the frame and the tension applied to each dome with the tensioning elements. In other words, the dome can be a support mesh and an inverted support mesh coupled to each other via tensioning or tensioning elements such that each support mesh assumes a desired contour. The resulting dome (or portion thereof) can therefore be made as a continuous surface, a mesh structure, or other material structure that closely approximates the general surface shape applicable to a desired application such as an antenna, collector, reflector, etc.

[0055] FIG. 6 illustrates an exemplary wedge portion of a modular structure comprising a first substructure 606 having a first frame 610-6, a second substructure 604 having a second frame 610-4, and a third substructure 602 having a third frame 610-2. The substructures are arranged radially outward from one another and are configured to couple together to form a wedge (or other portion) of the upper structure. As shown, each radially outer substructure may comprise the same number of substructures as the radially inner structure, or may comprise more substructures. Substructures configured to be arranged further radially outward from the upper structure may be larger. Accordingly, the substructures may be divided into smaller pieces or additional substructures to control the size of the substructures and corresponding storage configurations. As shown, the first substructure and the second substructure comprise the same number of substructures (one as shown), while the third substructure forms an overall substructure radially outward from the second substructure and comprises two substructures spanning the arc formed by the second substructure. Thus, each outer substructure can comprise one, two, three, four, or more substructures to correspond to the same or fewer corresponding inner substructures. Corresponding substructures are understood to be groupings of substructures configured to align to delimit a portion of the upper structure that can be repeated and attached to each other around the upper structure.

[0056] As shown, each of the substructures has a wedge shape. Each substructure comprises a frame having two opposing frame sides that diverge (one end closer to each other than the other end). In exemplary embodiments, such as the radially innermost substructure, the two opposing frame sides can meet at an apex to form a true geometric wedge shape. In exemplary embodiments, the frame can have two other opposing frame sides extending between the two opposing frame sides. In exemplary embodiments, the two other opposing frame sides are parallel to each other. In exemplary embodiments, one of the two other opposing frame sides is shorter than the second of the two other opposing frame sides. Where two opposing frame sides meet, the frame may have a single third frame side extending between the two opposing frame sides at an end opposite the apex. Thus, the frame can have a three-sided structure, a four-sided structure, or other shape. Each side may be straight and / or curved. For example, the radial portion of the substructure may be straight, while the circumferential portion of the larger structure may be curved. Curved structures can be created using curved stringers between the nodes.

[0057] 7A-7C show various perspective views of exemplary substructure elements according to embodiments described herein. FIG. 7A shows diagonals and stringers. These elements may be designed to be hinged and foldable for packaging. FIG. 7B shows an RF reflecting surface, which may be parabolic, spherical, or flat. Also shown is an inverted dome with tension ties attached from the RF reflecting surface to keep the RF surface taut and extended. FIG. 7C is a conceptual packaging concept in which the front and rear plates rotate as shown to achieve the desired compactness to fit within available storage space.

[0058] 7A-7B illustrate an exemplary substructure 700 according to embodiments described herein. The exemplary substructure 700 comprises a frame. The frame may comprise stringers 702 and diagonals 706 in a truss configuration. In an exemplary embodiment, the frame 702 may comprise multiple frame sections along each side of the substructure. The frame sections may comprise stringers and diagonals. The stringers of the frame sections may extend generally linearly along their lengths forming two extensions (along the top and bottom of the sides of the substructure), with the diagonals crossing between the two extensions. In an exemplary embodiment, the stringers are configured to bend or deform to fold the diagonals together, as shown schematically in FIG. 7C. The stringers 704 and diagonals 706 are connected to each other at nodes 708. As shown, multiple frame sections may be connected to each other to create a frame. The frame may be a closed perimeter outer support structure for a reflective surface.

[0059] The exemplary substructure 700 can include a reflective surface 710. The reflective surface can be any surface described herein, including a mesh surface, a continuous surface, a mosaic surface, etc. In an exemplary embodiment, the surface 710 is supported on a first support structure 712. The first support structure 712 supports the reflective surface 710 and can form the same shape or structure as the reflective surface. The shape of the support structure 712 can be created by attaching it to an inverted structure 714 using a tensioning element 716. By tightening or selecting the length and / or tension of the tensioning element 716, a tensioning force can be applied between the inverted structure 714 and the support structure 712 to create a desired shape. In an exemplary embodiment, the support structure 712 and the inverted structure 714 are net meshes coupled to each other, such as by the tensioning element 716. The tensioning element can be configured as an elastic or stretchable structure that acts as a spring to apply a desired tension to the resulting surface or structure in the deployed configuration.

[0060] As shown in FIG. 7B, the exemplary embodiment described herein supports the individual reflective members 710 with a support structure. The exemplary embodiment of the support structure (102, 106, 108, 110) includes flexible members for easy storage, as described with respect to FIG. 1. In the exemplary embodiment, the support structure may include one or more strings joined together at nodes. As described herein, when strip-shaped reflective members, such as those in FIGS. 12-13, are used, nodes 1312 of the support structure may be located adjacent to vertices 1314 of the individual strip-shaped reflective members 1302. Nodes may be intersections, knots, or other attachments of strings to one another. Nodes may create connection points for the individual strip-shaped reflective members.

[0061] An exemplary embodiment of the support structure comprises a mesh string frame 718. The strings can be coupled to the outer frame 702 and run in a pattern across the interior of the outer frame. When the outer frame is deployed, the mesh string frame is unfolded and positioned in a desired configuration. The nodes of the mesh string can be used to position the reflective surface 710 in a desired shape by forming the desired surface structure 712.

[0062] As shown, the modular substructures can include mounting panels 718. The mounting panels can be configured to attach adjacent substructures together. The adjacent substructures can be radially adjacent and / or circumferentially adjacent. As shown in FIG. 7C, the mounting panels 718 can be rotatably coupled to the frame 702 to collapse the substructures into a stowed configuration and extend the mounting panels in a deployed configuration.

[0063] Figure 8 shows an embodiment of how two substructures of a large superstructure antenna can be joined together in space. The two substructures can be identical and joined together at the forward and aft plates. Attachment points on each plate can include mating surfaces to facilitate precise alignment between adjacent substructures.

[0064] 9 illustrates an exemplary portion of a mounting panel according to an exemplary embodiment. A portion of one mounting panel of a first substructure and a portion of a second mounting panel of a second substructure are shown to illustrate how an exemplary connection can be made between adjacent substructures. As described herein, a first mounting panel 902 (which can be coupled to a first frame of the first substructure) can be configured to be attached to a second mounting panel 904 (which can be coupled to a second frame of the second substructure). The first and second mounting panels 902, 904 may include mating structures or surfaces 906, 908 to align the mounting panels with one another.

[0065] In an exemplary embodiment, the mating cone structure can form a mating surface to improve alignment accuracy of an in-space assembler robot. As shown, a first mounting panel 902 can include a conical hole 906 where the opening of the hole is wider (has a larger diameter) than the hole away from the opening. Thus, the opening can taper from a larger diameter near the surface of the mounting panel adjacent to a second mounting panel that is coupled to the first mounting panel, and narrow (to a smaller diameter) away from the surface. A second mounting panel 904 can include a conical protrusion 908 configured to mate with the conical hole 906. Thus, the protrusion 908 can taper from a larger diameter near the surface of the second mounting panel 904, and can be narrower or have a smaller diameter toward the end of the protrusion away from the surface of the second mounting panel 904.

[0066] As shown, when a first mounting panel 902 is brought closer to a second mounting panel 904 (see arrows), the mating surfaces 906, 908 allow the mounting panels to align to the desired position, improving precision between the panels. Thus, even if there is a slight initial misalignment between the conical pin and the conical slot, the tapered surfaces of both mating surfaces allow them to slide relative to one another. Once the plates are mated together, the panels can be joined together.

[0067] In an exemplary embodiment, a robotic claw maintains the pressure, and in one embodiment, ultrasonic welding is used to bond the two plates together, which can be made of metal, composite, or other weldable materials. Other attachments, such as clamps, pins, rivets, etc., can also be used.

[0068] 10A-10E illustrate an exemplary attachment method according to embodiments described herein having mating surfaces and a locking device according to embodiments described herein.

[0069] In an exemplary embodiment, a locking device can be used to couple and hold a first mounting panel to a second mounting panel. As shown, the mounting panels include conical mating surfaces, i.e., openings and protrusions or pins and slots as described herein. When the mating surfaces contact each other and a compressive force is applied between the mounting panels, the surfaces can mate and align.

[0070] One of the mounting panels may include a locking device 1002. The locking device may have a configuration that can pass through an opening in the other mounting panel and then expand outwardly of the other mounting panel away from the mounting panel having the locking device. The locking device 1002 may be tethered 1004 or coupled to the mounting panel and configured to compress the other mounting panel toward the mounting panel. As shown, the locking device has a deployable structure. The deployable structure may have a first configuration that can fit through an opening in the other mounting panel. The locking device 1002 may include an arm or guard 1006 that extends longitudinally through the opening to pass through the opening. Once through the opening, the deployable structure may have a biased configuration in which the cross-section of the deployable structure is larger than the diameter of the opening in the other mounting panel so that the locking device cannot re-enter the opening in the other mounting device. The locking device may include an elastic tether 1004 or other compression or spring structure such that the locking device applies pressure to the other mounting panel to hold the other mounting panel in a fixed position relative to the mounting panel. In an exemplary embodiment, the locking device may simply be crimped or otherwise attached to the tether when pressure is applied to the tether and the panel to which it is coupled, similar to a drawstring cord lock. Cord locks can include stops, spring catches, cord toggles, etc.

[0071] 11A-11C illustrate alternative attachment methods by which the mounting panels 1102, 1104 can be welded together. As shown, the mounting panels can have the same or different mating surfaces. The mounting surfaces can be brought together as shown in FIG. 11B, where the surfaces may be welded together (indicated by the enclosed dashed area 1106 in FIG. 11B). The mounting panels 1102, 1104 may be held together with a clamping force (as shown applied between an anvil 1108 and a weld tip or horn 1110) or the like, such that the mounting panels are maintained in a desired position when joined together.

[0072] 12A shows an exemplary mosaic reflective surface of an exemplary solar collector according to embodiments described herein, where FIG. 12A is a close-up view of a single reflective portion of the reflective surface. In the exemplary embodiment, the reflective surface 1200 comprises a plurality of individual strips 1202. Ultrasonic vibrations (indicated by arrows 1112) can then be applied to weld the surfaces together.

[0073] In an exemplary embodiment, the reflective surface 104, 710 may be tessellated. Thus, the reflective surface 1200 may comprise individual strips 1202 that may be shaped, oriented, and arranged to approximate the desired shape of the reflective structure. In an exemplary embodiment, the individual strips 1202 may be flat. The individual strips 1202 may also be curved about one or two axes or have any desired shape. The strips 1202 may include a shape-memory material such that they are flat in a stored configuration and / or curved in a deployed configuration.

[0074] 13 illustrates exemplary individual strip reflective elements 1300 within a portion of a support structure for a mosaic reflective surface according to embodiments described herein. The exemplary strip reflective elements may be supported by a support structure described herein. For example, the first support structure 712 may include a plurality of mesh strings 1306 configured to support the strip reflective surface 1302. The first support structure may be configured based on an arrangement of mesh strings to support the plurality of strip reflective surfaces.

[0075] In an exemplary embodiment, the reflective surface is tessellated into individual reflective strips. An exemplary tessellated strip 1300 of the overall reflective surface may include reflective strips 1302 and a support structure 1306. The support structure 1306 may be configured to tension the reflective strips 1302 via couplers 1308 between the reflective strips 1302 and the support structure 1306. Tensioning the reflective strips can reduce deformation of the surface and improve solar collection.

[0076] As shown, the strip reflective member 1302 can have a geometric shape. As shown, the strip reflective member 1302 is generally triangular with three vertices. Other shapes are contemplated herein, including square, rectangular, pentagonal, hexagonal, etc. In an exemplary embodiment, the strip reflective member 1302 has multiple vertices, and the vertices of the individual reflective members are coupled from the strip reflective member 1302 to the support structure 1306 via couplers 1308. In an exemplary embodiment, the couplings can include springs 1310 or other tensioning elements to tension the individual reflective members 1302 within the support structure in the deployed configuration.

[0077] As shown in FIG. 13, an exemplary strip-shaped reflective member can include a generally triangular metal-coated membrane. The edges of the metal-coated membrane can be curved inward. The metal-coated membrane can form a reflective surface for use as part of an antenna, collector, mirror, reflector, or other surface described herein. The metal-coated membrane can be bonded to a mesh support structure at the membrane's apex. The metal-coated membrane can be supported by a mesh made of strings that cross or knot with each other. The mesh strings can be on different sides of the metal-coated membrane.

[0078] As shown, the periphery 1304 of each strip 1302 may be curved. In an exemplary embodiment, the edge 1304 is formed as a catenary curved edge. Other configurations may include straight edges. An exemplary embodiment of triangular strips with catenary edges may be configured to allow attachment at the corners (vertices) of each triangle to provide a flat reflective surface. Springs may be coupled to the support structure at one or more corners (vertices) of the triangle to tension the reflective triangular element when the solar collector is fully deployed. In an exemplary embodiment, only a single vertex of the strip reflective element has a tensioning member, such as a spring, coupled to it. The spring may be based on a wound structure and / or a longitudinally elastically stretchable structure and / or another structure configured to change length and having a biasing force to return the structure to a shortened configuration when stretched.

[0079] Exemplary embodiments may include reflective membranes as individual reflective members. The reflective members may be flexible membrane triangular fabrics. The membranes may be used to reduce the overall size and weight of the solar collector, reflector, or antenna. Exemplary embodiments may also or alternatively use rigid reflective members. The rigid reflective members may be supported by a support structure described herein. The rigid reflective members may or may not be tensioned and / or may or may not use tensioning elements, such as springs, to apply additional tension to the reflective members. The rigid reflective members may form flat and / or curved surface shapes. The surface shape may be maintained regardless of the tension applied to the rigid reflective members, at least because the intended tension is applied by the support structure.

[0080] Despite various technological advances in space-based communications, remote sensing, astronomical observation, and ISR (intelligence, surveillance, and reconnaissance), increasing antenna aperture size remains a critical parameter in achieving improved performance. Current space-based systems are primarily limited by storage volume, not payload mass. What is needed are highly deployable, low-cost, lightweight, and low-storage-volume antenna structures that can enable efficient storage capacity. This capability could potentially allocate two or more full-size antennas per launch vehicle, leading to overall cost reductions. Note that it is storage efficiency, not mass, that generally determines overall launch costs. This is because the need for larger fairings almost always shifts to boosters one or two stages larger, increasing launch costs by tens to hundreds of millions of dollars.

[0081] In an exemplary embodiment, the reflecting surfaces described herein may be configured as antennas. The reflector surface may be gold-coated molybdenum mesh or aluminum-clad polyimide material (Kapton). Beneath the reflector surface may be an inverted dome with the same triangular-hexagonal net structure as the reflector dome. The inverted dome is used to attach vertical ties that are used to tension the reflector surface. The combination of the inverted dome and the reflector dome can form a tension drum. As long as tension is maintained, the tension drum is largely unaffected by what happens to the perimeter truss.

[0082] An exemplary embodiment of the antenna described herein can comprise a very large aperture antenna comprising subtruss elements joined together as shown and described herein. This configuration with a very large aperture diameter can be divided into several smaller subtruss structure elements as shown and described herein. The subtruss structures may be identical to one another for economy and associated simplicity of deployment and operation of the assembly in space. Here, the perimeter of the non-circular subaperture uses an exemplary perimeter truss configuration, i.e., rigid diagonals and foldable / packable longerons made of deformable structures (whether shape memory, joints, pivots, or other foldable structures).

[0083] Exemplary embodiments described herein may include a method for joining two sub-truss elements of a large-diameter antenna structure in space. The two sub-elements may be identical and are joined together at forward and aft mounting plates. The exemplary four mounting points on each plate (although any number of mounting points may be used) may be joining cone structures. As shown and described herein, the cone wedges allow each to slide relative to one another even if there is some initial misalignment, thereby reducing the alignment effort required by the space robot. Once the plates are mated, the robot's claws maintain pressure and activate ultrasonic welding of the plates. The plates may be made of either a carbon-epoxy composite, fiberglass epoxy, or epoxy-glass composite. Ultrasonic welding operations and ground tests on epoxy-carbon or epoxy-glass composites have shown excellent welded bonds. In one method of ultrasonic welding, an adhesive sheet can be placed between the plates to be welded. When an ultrasonic frequency signal is applied, minute high-frequency ultrasonic vibrations on the surfaces melt the adhesive sheet, bonding the two surfaces. The adhesive rapidly hardens after the ultrasonic signal is turned off. For added safety, the clamping force exerted by the robotic jaws may not be removed until fully cured.

[0084] The use of ultrasonic welding is a satisfactory option because it allows for the joining of two surfaces without the need for additional bolts, rivets, welding wire, power systems for electromagnets, or the need to bring the application equipment into orbit. Ultrasonic welding has also been shown to join a wide range of materials, including carbon fiber and glass fiber reinforced plastics / epoxies and dissimilar materials.

[0085] One concern is the strength of the weld. This can be increased by using a mating pin-slot to distribute stress and eliminate the rotational and two of the three translational degrees of freedom. Ultrasonic welding limits the final degree of freedom, perpendicular to the joining surfaces. A second concern is that the pin and slot can inhibit the vibrations required to join the materials. This can be addressed by building into the pin and slot design the tolerances required for the surfaces to vibrate.

[0086] In addition to joining the surfaces using ultrasonic welding, redundancy can be added by providing additional mechanical clamps as shown and described herein. In an exemplary embodiment, the surface with the male mating pin can include a cylindrical block with two spring-loaded plates inside. After the two surfaces are welded in intimate contact, a robot clamps a tether to the cylindrical block and pulls it until the cylindrical block and attached spring-loaded plates move to the outer surface of the mounting plate. As the spring-loaded plates pass through the slots, the plates rotate 90 degrees to their deployed position. A spool within the block may be spring-loaded to maintain the mechanical clamping force. The attachment methods described herein can be used alone or in combination to strengthen the attachment between panels.

[0087] In an exemplary embodiment, to address micrometeorite damage, the perimeter of each substructure may be covered with a thin sheet of Kevlar or Vectran tarp. These tarps may act as Whipple shields against micrometeorite impingement. The tarps may be "removed" to expose rigid diagonals (made of carbon epoxy or fiberglass epoxy). In an exemplary embodiment, each substructure can be folded in the same way for storage and deployment.

[0088] Depending on the diameter size of the antenna, it may have to be divided along a radial line. Instead of one substructure spanning half the diameter, this length may have to be further divided into two or three (or more) substructures. This configuration is shown and described herein with all subtruss elements joined together to form an ultra-large diameter antenna (see, e.g., FIG. 5A). Note that along the diameter, there are three substructures that are repeated on either side of the center of the antenna, i.e., mirrored around the center of the antenna, for a total of six substructures spanning the entire diameter of the antenna. These radial substructures may be joined together as shown and described herein.

[0089] Use of the disassembly methods described herein allows for a reduction in the packaging volume of each substructure, allowing each to fit within currently available rocket booster fairing volumes, or other desired storage volumes. Once these substructures are in orbit, they can be collected and assembled in situ (in space) using any in-space assembly method, including humans and / or space assembly vehicle robots.

[0090] An exemplary embodiment of the system described herein includes a deployable structure comprising a plurality of modular deployable structures, each of the plurality of modular deployable structures being a separate structure from each other of the plurality of modular deployable structures.

[0091] The deployable structure can have a plurality of modular deployable structures each comprising an attachment mechanism configured to attach to an attachment mechanism of another of the plurality of modular deployable structures.

[0092] The deployable structure can have an attachment mechanism having a mating surface configured to correspond to another mating surface of another attachment mechanism of another of the plurality of modular deployable structures, the mating surface and the other mating surface comprising corresponding tapered cylindrical surfaces, the relative sizes of the mating surface and the other mating surface enabling ultrasonic welding of the attachment mechanism to the attachment mechanism of another of the plurality of modular deployable structures. In an exemplary embodiment, the respective sizes and shapes may be such that desired vibrations of the respective surfaces can be achieved to achieve the desired welding by applying ultrasonic vibrations to the surfaces. The respective sizes and shapes of the mating surfaces may be such that the surfaces can be brought together in a desired relative position in a desired and / or predetermined configuration and / or orientation to attach one surface to another.

[0093] The deployable structure may have modular deployable structures each having a perimeter frame, the perimeter frame being foldable and deployable between a stored configuration having a reduced volume and a deployed configuration having an expanded volume relative to the reduced volume, a support structure coupled to the perimeter frame, and a surface supported by the support structure.

[0094] The deployable structure may have a frame for each of the modular deployable structures with at least three sides, two opposing sides of which are tapered to form a narrower end and a wider end between the two opposing sides, and a third side extending between the two opposing sides at the wider end between the two opposing sides, the frame forming a closed loop structure, and the two opposing sides may be directly joined to each other at the narrower ends of the two opposing sides or may be joined via a fourth side.

[0095] The deployable structure may have a modular deployable structure frame each having a plurality of longerons, a plurality of diagonal members, and nodes connecting adjacent longerons and diagonal members, the longerons being flexible to deform in the stowed configuration and expand in the deployed configuration.

[0096] The deployable structure can have a plurality of modular deployable structures comprising a first set of modular deployable structures, each of the first set of modular deployable structures having the same configuration. The first set of modular deployable structures can comprise all of the modular deployable structures or only a subset of the plurality of modular deployable structures.

[0097] The deployable structures have a first of two opposing sides of each of the first set of modular deployable structures, the first side being coupled to a second of two opposing sides of another of the plurality of first sets of modular deployable structures, and the first sets of modular deployable structures are configured to be attached to one another to form a first ring. The first set of modular deployable structures can be coupled side-by-side along each of the two opposing sides of the modular deployable structures.

[0098] The deployable structure can have a plurality of modular deployable structures comprising a second set of modular deployable structures, each of the second set of modular deployable structures having a second same configuration. The second same configuration of the second set of modular deployable structures can be different from the same configuration of the first set of deployable structures. The second set of modular deployable structures can be configured to couple together to form a second ring, the second ring being sized and shaped relative to the first ring size and shape to be concentric with and radially disposed outward of the first ring.

[0099] The deployable structure can have a plurality of modular deployable structures configured to attach and position each of the surfaces of the plurality of modular deployable structures to one another to form an antenna surface of the deployable structure.

[0100] The deployable structure can have a plurality of modular deployable structures each forming a closed-loop frame expandable between a stowed configuration and a deployed configuration, the stowed configuration having a smaller volume than the deployed configuration, a support structure coupled to the frame, and a surface supported by the support structure, the surface comprising a portion of an antenna surface, a portion of a reflective surface, or a portion of a collector surface, the antenna surface, the reflective surface, or the collector surface being formed by individual surfaces of the plurality of modular deployable structures coupled to each other in the deployed configuration.

[0101] Exemplary embodiments described herein include a method of deploying a deployable structure, comprising launching a plurality of modular deployable structures to a deployed position, coupling the plurality of modular deployable structures to one another to form a deployable structure, and deploying the deployable structures from a folded configuration to a deployed configuration.

[0102] A method for deploying a deployable structure can include launching a plurality of modular deployable structures, including storing each of the plurality of modular deployable structures in a separate payload of one or more spacecraft for moving the plurality of modular deployable structures from Earth to a deployment location in space.

[0103] The method of deploying the deployable structure may also or alternatively include using a robot to position each of the plurality of modular deployable structures relative to one another and attaching the plurality of modular deployable structures to one another.

[0104] It should be emphasized that many variations and modifications can be made to the embodiments described herein, and that the elements thereof should be understood to be among other acceptable examples. All such modifications and variations are intended to be included within the scope of this disclosure herein and protected by the following claims. Furthermore, any of the steps described herein can be performed simultaneously or in a different order than that described herein. Furthermore, it will be apparent that the features and attributes of specific embodiments disclosed herein can be combined in various ways to form further embodiments, all of which are within the scope of this disclosure.

[0105] Certain terms may be used in the following description for reference purposes only and are not intended to be limiting. For example, terms such as "top" and "bottom" refer to directions in the referenced drawings. Terms such as "front," "rear," "left," "right," "behind," and "side" describe the orientation and / or location of a component or portion of an element within a consistent but arbitrary frame of reference, which becomes clear by reference to the text and associated drawings that describe the component or element being described. Additionally, terms such as "first," "second," and "third" may be used to describe separate components. Such terms may include the words specifically mentioned above, derivatives thereof, and words of similar meaning.

[0106] As used herein, conditional language, particularly "can," "could," "might," "may," "e.g.," and the like, is generally intended to convey that a particular embodiment includes a particular feature, element, and / or condition, unless specifically stated otherwise or understood otherwise within the context in which it is used. However, such language also includes embodiments in which that feature, element, or condition is absent. Thus, such conditional language is generally not intended to imply that a feature, element, and / or condition is somehow required by one or more embodiments, or that one or more embodiments necessarily exclude undescribed components by another embodiment.

[0107] Additionally, the following terms may be used herein: The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, a reference to an item includes a reference to one or more items. The term "one" refers to one, two, or more and generally applies to the selection of part or all of a quantity. The term "plurality" refers to two or more items.

[0108] As used herein, the terms "about," "substantially," or "approximately" with respect to any numerical value, range, shape, distance, relative relationship, etc., indicate appropriate dimensional tolerances that allow a portion or collection of components to function for its intended purpose as described herein. Numerical ranges may also be given herein. Unless otherwise indicated, each range is intended to include the endpoints and any number within the given range. Thus, a range of 2 to 4 includes 2, 3, 4, and any subdivision between 2 and 4, such as 2.1, 2.01, and 2.001. Ranges also encompass any combination of ranges, such as 2 to 4 including 2 to 3 and 3 to 4.

[0109] As used in this specification and claims, the terms "comprises" and "comprises," and variations thereof, mean that the specified features, steps, or integers are included. These terms are not to be interpreted as excluding the presence of other features, steps, or components.

[0110] The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, and presented in their specific form or as means for performing a disclosed function, or as methods or processes for achieving a disclosed result, can, where appropriate, be utilized separately or in any combination of such features to realize the invention in diverse forms thereof.

[0111] Although the embodiments of the present invention have been fully described with reference to the accompanying drawings, it should be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications should be understood to be included within the scope of the embodiments of the present invention, as defined by the appended claims. In particular, exemplary components are described herein. Any combination of these components can be used in any combination. For example, any component, feature, procedure, or part can be integrated, separated, subdivided, removed, duplicated, added, or used in any combination and remain within the scope of the present disclosure. The embodiments are merely illustrative and present exemplary combinations of features, but are not limited thereto.

Claims

1. A deployable structure comprising:

1. A deployable structure comprising a plurality of modular deployable structures, each of the plurality of modular deployable structures being a separate structure from each other of the plurality of modular deployable structures.

2. The deployable structure of claim 1 , wherein each of the plurality of modular deployable structures comprises an attachment mechanism configured to attach to an attachment mechanism of another of the plurality of modular deployable structures.

3. 3. The deployable structure of claim 2, wherein the attachment mechanism comprises a mating surface configured to correspond to another mating surface of another attachment mechanism of another of the plurality of modular deployable structures, the mating surface and the other mating surface comprising corresponding tapered cylindrical surfaces, and the relative sizes of the mating surface and the other mating surface permit ultrasonic welding of the attachment mechanism to the attachment mechanism of another of the plurality of modular deployable structures.

4. 10. The deployable structure of claim 1, wherein each of the modular deployable structures comprises a perimeter frame, the perimeter frame being foldable and expandable between a storage configuration having a reduced volume and a deployed configuration having an expanded volume relative to the reduced volume, a support structure coupled to the perimeter frame, and a surface supported by the support structure.

5. 5. The deployable structure of claim 4, wherein each frame of the modular deployable structure comprises at least three sides, two opposing sides of the at least three sides tapering to form a narrower end and a wider end between the two opposing sides, and a third side extending between the two opposing sides with the wider end between the two opposing sides, the frames forming a closed loop structure.

6. 6. The deployable structure of claim 5, wherein each frame of the modular deployable structure comprises a plurality of longerons, a plurality of diagonal members, and nodes connecting adjacent longerons and diagonal members, the longerons being flexible to deform in the stowed configuration and expand in the deployed configuration.

7. 7. The deployable structure of claim 6, wherein the plurality of modular deployable structures comprises a first set of modular deployable structures, each of the first set of modular deployable structures having the same configuration.

8. 8. The deployable structure of claim 7, wherein a first of two opposing sides of each of the first set of modular deployable structures is coupled to a second of two opposing sides of another of the plurality of first sets of modular deployable structures, and the first sets of modular deployable structures are configured to be attached to one another to form a first ring.

9. 9. The deployable structure of claim 8, wherein the plurality of modular deployable structures comprises a second set of modular deployable structures, each of the second set of modular deployable structures having a second same configuration.

10. 10. The deployable structure of claim 9, wherein the second set of modular deployable structures are configured to couple together to form a second ring, the second ring being sized and shaped relative to the first ring size and shape such that it is concentric with and positioned radially outward of the first ring.

11. 11. The deployable structure of claim 10, wherein the plurality of modular deployable structures are configured to attach and position each of the surfaces of the plurality of modular deployable structures to one another to form an antenna surface of the deployable structure.

12. 10. The deployable structure of claim 1, wherein each of the plurality of modular deployable structures comprises a closed-loop frame expandable between a stowed configuration and a deployed configuration, the stowed configuration having a smaller volume than the deployed configuration, a support structure coupled to the frame, and a surface supported by the support structure, the surface comprising a portion of an antenna surface, a portion of a reflective surface, or a portion of a collector surface, the antenna surface, the reflective surface, or the collector surface being formed by individual surfaces of the plurality of modular deployable structures coupled to each other in the deployed configuration.

13. 1. A method of deploying a deployable structure, comprising: launching a plurality of modular deployable structures into a deployed position; coupling a plurality of modular deployable structures together to form a deployable structure; deploying the deployable structure from a folded configuration to an deployed configuration; A method for expanding a expandable structure, including:

14. A method for deploying a deployable structure, wherein launching a plurality of modular deployable structures includes storing each of the plurality of modular deployable structures in a separate payload of one or more spacecraft for moving the plurality of modular deployable structures from Earth to a deployment position in space.

15. 1. A method of deploying a deployable structure, comprising: A method of deploying a deployable structure, further comprising using a robot to position each of the plurality of modular deployable structures relative to one another and attaching the plurality of modular deployable structures to one another.

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