Solar array with FLIP-out panels

Abstract

: A solar array system for spacecraft includes a motorized central column of rigid panels and flexible outer flip-out panels. Each central hinge module is motor-driven and rigidizes when deployed. Flip-out panels may deploy passively or via motorized hinges, and are constrained from deployment until the central column completes deployment. A keep-alive panel is exposed while stowed, providing early power generation. The system enables modular manufacturing, damage tolerance, and efficient packing for launch.

Description

SOLAR ARRAY WITH FLIP-OUT PANELSFIELD OF THE INVENTION

[0001] The invention relates to deployable solar array systems for spacecraft, particularly modular systems featuring hybrid active-passive or fully motorized deployments combining rigid and flexible solar panels.BACKGROUND

[0002] Solar arrays have played an important role in the long term operation of satellites and other systems in space. Deployable solar arrays in particular have been recognized as early as in the 1970s as a means to provide power to spacecraft (see, for example, National Aeronautics and Space Administration, “Spacecraft Solar Cell Arrays,” NASA Space Vehicle Design Criteria (Guidance and Control), NASA SP-8074, May 1971accessed 2024-08-02)). However, currently available systems suffer from a variety of shortcomings, such as heavy weight, complex deployment procedures, and fragility.

[0003] Thus, there is a need for improved solar array systems for space applications.SUMMARY

[0004] The present disclosure provides solar array systems for deployment with a spacecraft, comprising a yoke configured to mount the system to a spacecraft solar array drive assembly (SADA). The system comprises a central column comprising a plurality of central rigid solar panels interconnected via hinge modules (which may be motorized), each configured to rotate under active control from a stowed to a deployed position along a primary deployment direction. Using a stiffer126500.02116central column and lightweight, flexible flip-outs, maximizes power generation area while limiting mass at the extremities of the system, thereby improving inertia and modes.

[0005] In accordance with various aspects of the present disclosure, one or more keep-alive panels may be positioned so that they are externally facing when the solar array system is in a stowed configuration, the keep-alive panel(s) thus providing pre-deployment power generation. In accordance with various aspects of the present disclosure, at least one flip-out panel mounted to at least one rigid solar panel via at least one hinge is provided and configured to deploy in a direction perpendicular to the primary deployment direction. Various control systems (and related software) are configured to sequence the deployment of the flip-out panels including preventing or otherwise constraining the flip-out panels from deploying until the central column is fully deployed.

[0006] In accordance with various aspects of the present disclosure, methods for deployment of solar array systems for spacecraft are provided comprising the steps of positioning a keep-alive panel to be externally facing from the solar array system when the solar array system is in a stowed configuration, deploying a central column comprising a plurality of central rigid solar panels interconnected via motorized hinge modules, each rigid solar panel configured to rotate under active control from a stowed position to a deployed position along a primary deployment direction, and activating at least one hinge to deploy at least one flip-out panel in a direction perpendicular to a primary deployment direction of the central column after the central column is fully deployed.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The accompanying drawings provide a further understanding of226500.02116the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and together with the description serve to explain the principles of the invention.

[0008] FIG. 1 shows the portion of a solar array system in a fully stowed position in accordance with the present disclosure.

[0009] FIG. 2 shows a Z-fold action of the solar array system of FIG. 1 as partially deployed in a primary deployment direction in accordance with the present disclosure.

[0010] FIG. 3 shows primary Z-fold completion, before releasing the flip- out panels in accordance with the present disclosure.

[0011] FIG. 4 shows the solar array system of FIGS. 1 - 3, as partially deployed in a direction perpendicular to the primary deployment direction in accordance with the present disclosure.

[0012] FIG. 5 shows the solar array system of FIGS. 1 - 4, with all panels fully deployed in the flip-out direction in accordance with the present disclosure.

[0013] FIG. 6 shows a close-up view of a portion of the solar array system of FIGS. 1 - 5, as partially deployed in the flip-out direction in accordance with the present disclosure.

[0014] FIG. 7 shows a close-up view of a portion of the solar array system of FIGS. 1 - 6, fully deployed in the flip-out direction in accordance with the present disclosure.

[0015] FIG. 8 shows another solar array system in its fully stowed configuration with an externally facing keep-alive panel in accordance with the present disclosure.

[0016] FIG. 9 shows the solar array system of FIG. 8 with a first bay326500.02116partially deployed in a primary deployment direction in accordance with the present disclosure.

[0017] FIG. 10 shows the solar array system of FIGS. 8 - 9 with its first bay fully deployed in the primary deployment direction in accordance with the present disclosure.

[0018] FIG. 11 shows the solar array system of FIGS. 8 - 10 with its first bay partially deployed in a flip-out direction and a second bay partially deployed in the primary deployment direction in accordance with the present disclosure.

[0019] FIG. 12 shows the solar array system of FIGS. 8 - 11 with its first bay fully deployed in both the primary deployment and flip-out directions and a second bay partially deployed in the primary deployment direction in accordance with the present disclosure.

[0020] FIG. 13 shows the solar array system of FIGS. 8 - 12 with its first bay fully deployed in both the primary deployment and flip-out directions, its second bay fully deployed in the primary deployment direction and partially deployed in the flip-out direction, and a third bay partially deployed in the primary deployment direction in accordance with the present disclosure.

[0021] FIG. 14 shows the solar array system of FIGS. 8 - 13 with its first bay and second bay fully deployed in the primary deployment and flip out directions, its third bay fully deployed in the primary deployment direction and partially deployed in the flip-out direction, and a fourth bay partially deployed in the primary deployment direction in accordance with the present disclosure.

[0022] FIG. 15 shows the solar array system of FIGS. 8 - 14 with its first, second, and third bays fully deployed in the primary deployment and flip-out directions, its fourth bay fully deployed in the primary deployment direction and partially deployed426500.02116in the flip-out direction, and a fifth bay partially deployed in the primary deployment direction in accordance with the present disclosure.

[0023] FIG. 16 shows the solar array system of FIGS. 8 - 15 with its first, second, third, and fourth bays fully deployed in the primary deployment and flip-out directions, and its fifth bay partially deployed in the primary and flip-out directions in accordance with the present disclosure.

[0024] FIG. 17 shows the solar array system of FIGS. 8 - 16 in full deployment in accordance with the present disclosure.

[0025] FIG. 18 shows the solar array system of FIGS. 8 - 17 in full deployment connected to a spacecraft in accordance with the present disclosure.

[0026] FIG. 19 shows the motorized hinge comprising a motor connected to the motorized hinge using a motor coupler in accordance with the present disclosure.

[0027] FIG. 20 shows the motorized hinge in a stowed position in accordance with the present disclosure.

[0028] FIG. 21 shows the motorized hinge in a deployed and locked position in accordance with the present disclosure.DETAILED DESCRIPTION

[0029] Persons skilled in the art will readily appreciate that various aspects of the present invention may be realized by any number of methods and apparatuses configured to perform the intended functions. Stated differently, other methods and apparatuses may be incorporated herein to perform the intended functions. It should also be noted that the accompanying drawing figures referred to herein are not all drawn to scale but may be exaggerated to illustrate various aspects of the present invention, and in that regard, the drawing figures should not be526500.02116construed as limiting. Finally, although the present invention may be described in connection with various principles and beliefs, the present invention should not be bound by theory.

[0030] The above being noted, in accordance with various aspects of the present disclosure and as will be described in more detail below and with reference to the figures included herewith solar array systems for deployment with a spacecraft 10 are provided, comprising a yoke 50 configured to mount the system to a spacecraft solar array drive assembly (SADA). The system may comprise a central column comprising a plurality of central rigid solar panels interconnected via hinge modules (which may be motorized), each configured to rotate under active or passive control from a stowed to a deployed position along a primary deployment direction. In accordance with various aspects of the present disclosure, in the lateral to primary deployment direction (i.e. , flip-out direction), the panels may be connected by simple hinges, while in the parallel to the primary deployment direction, panels may be connected by “V-back” hinges, which provide stiffening in a deployed state.

[0031] In accordance with various aspects of the present disclosure, one or more keep-alive panels may be positioned so that they are externally facing when the solar array system is in a stowed configuration, the keep-alive panel(s) thus providing pre-deployment power generation. Stated another way, the keep-alive panel can provide solar power generation even when the solar array system is in the stowed position. The keep-alive panel may have flip-outs stowed behind its power-generating face, or alternatively, no flip-outs.

[0032] In accordance with various aspects of the present disclosure, at least one flip-out panel mounted to at least one rigid solar panel via at least one hinge is provided and configured to deploy in a direction perpendicular to the primary626500.02116deployment direction. Various control systems configured to sequence the deployment of the flip-out panels prevent or otherwise constraining the flip-out panels from deploying until the central column is fully deployed. In accordance with various aspects the solar array system may comprise a 3x2 array of panels, though other combinations may also be employed and fall within the scope of the present disclosure.

[0033] In accordance with various aspects of the present disclosure, solar array systems contemplated herein may include a panel frame structure or backing frame configured for supporting the solar panels. For example, the frame may support a solar panel or blanket. The frame may hold a flexible blanket in tension. In accordance with some aspects, the panel frame structure may include the plurality of panel frames connected with V-back hinge structures configured in a direction parallel to a primary deployment direction. Perpendicular to the primary deployment direction, the plurality of panel frames may be connected with a plurality of conventional hinges, now known or as yet unknown.

[0034] In accordance with the present disclosure, the panels may comprise various flexible photovoltaic laminates including, for example, silicon heterojunction with a flexible backing, bifacial photovoltaic laminates held in tension by a frame structure, and the like. Other non-limiting materials and configurations include 11 l-V photovoltaic cells and cover glass, silicon-based solar cells, 11 l-V solar cells, radiation-protection film, transition metal dichalcogenides (TMD) cells, or other thin, flexible photovoltaic cells, though other now known or as yet unknown panel materials may be used and fall within the scope of the present disclosure.

[0035] In accordance with various aspects of the present disclosure, methods for deployment of solar array systems for spacecraft are provided, comprising726500.02116the steps of positioning a keep-alive panel to be externally facing from the solar array system when the solar array system is in a stowed configuration, deploying a central column comprising a plurality of central rigid solar panels interconnected via motorized hinge modules, each rigid solar panel configured to rotate under active control from a stowed position to a deployed position along a primary deployment direction, and activating at least one hinge to deploy at least one flip-out panel in a direction perpendicular to a primary deployment direction of the central column after the central column is fully deployed.

[0036] Expanding on the foregoing and as will be described in more detail below with reference to the accompanying Figures, the present disclosure contemplates deployable solar array systems for spacecraft that improves on prior art by integrating motor-driven hinges for primary deployment and flexible outer flip-out panels. In this regard, the system uses the central column of rigid solar panels, each interconnected via actively controlled motorized hinge modules enabling precise control over the dynamics of Z-fold deployment and lock-out (e.g., active momentum management). After full extension (e.g., provided via sensor feedback), flexible flip- out panels mounted on compliant lateral hinges or motor-driven hinges deploy outward to increase the power-generating surface area. Each panel is modular; with all central panels alike and all flip-out panels alike, enabling efficient manufacturing processes and simplifying replacement (e.g., “hot-swapping” during assembly if a panel is damaged). The central panels can be mounted on a stiff substrate or composite material. The flexible panels can be flexible blankets held in tension with a central boom or distal booms, or in a frame that surrounds the panel. The flexible panels and keep-alive panels can utilize bifacial photovoltaic blankets.

[0037] With reference now to FIGS. 1 - 5, an exemplary solar array 100826500.02116system in various stages of deployment is shown to illustrate a deployment sequence. For example, FIG. 1 shows the portion of the solar array system 100 in a fully stowed position. FIG. 2 shows a Z-fold action of the solar array system 100 of FIG. 1 as partially deployed in a primary deployment direction. FIG. 3 shows primary Z-fold completion, before releasing the flip-out panels 110 now fully deployed in the primary deployment direction.

[0038] FIG. 4 shows the portion of the solar array system of FIGS. 1 - 3, as partially deployed in a direction perpendicular to the primary deployment direction (e.g., “flip-out” direction) and FIG. 5 shows the solar array system of FIGS. 1 - 4, with all panels fully deployed in the flip-out direction.

[0039] With particular reference now to FIGS. 6 and 7, FIG. 6 shows a close-up view of a portion of the solar array system 100 of FIGS. 1 - 5, as partially deployed in the flip-out direction and FIG. 7 shows a close-up view of a portion of the solar array system 100 of FIGS. 1 - 6, fully deployed in the flip-out direction. During steps one and two, the flip-out panels 110 are passively sequenced to remain stowed via a connection 115 between each set of flip-out panels 110, as shown in FIGS. 6 and 7. Due to this link crossing over the apex of the Z-fold, the flips-outs are prevented from deployment until the Z-fold reaches its fully deployed state.

[0040] With reference now to FIGS. 8 -17, another exemplary solar array system 200 in various stages of deployment is shown to illustrate another deployment sequence. More specifically, FIG. 8 shows the solar array system 200 in its fully stowed configuration, with an externally facing keep-alive panel 220. FIG. 9 shows the solar array system 200 of FIG. 8 with its first bay 201 partially deployed in a primary deployment direction. FIG. 10 shows the solar array system 200 of FIGS. 8 - 9 with its first bay 201 fully deployed in the primary deployment direction. FIG. 11 shows the926500.02116solar array system 200 of FIGS. 8 - 10 with its first bay partially deployed in a flip-out direction and its second bay 202 partially deployed in the primary deployment direction. FIG. 12 shows the solar array system 200 of FIGS. 8 - 11 with its first bay 201 fully deployed in both the primary deployment and flip-out directions and its second bay 202 partially deployed in the primary deployment direction. FIG. 13 shows the solar array system 200 of FIGS. 8 - 12 with its first bay 201 fully deployed in both the primary deployment and flip-out directions, its second bay 202 fully deployed in the primary deployment direction and partially deployed in the flip-out direction, and its third bay 203 partially deployed in the primary deployment direction. FIG. 14 shows the solar array system 200 of FIGS. 8 - 13 with its first bay 201 and second bay 202 fully deployed in the primary deployment and flip out directions, its third bay 203 fully deployed in the primary deployment direction and partially deployed in the flip-out direction, and its fourth bay 204 partially deployed in the primary deployment direction. FIG. 15 shows the solar array system 200 of FIGS. 8 - 14 with its first, second, and third bays 201 , 202, 203 fully deployed in the primary deployment and flip-out directions, its fourth bay 204 fully deployed in the primary deployment direction and partially deployed in the flip-out direction, and its fifth bay 205 partially deployed in the primary deployment direction. FIG. 16 shows the solar array system 200 of FIGS. 8 - 15 with its first, second, third, and fourth bays 201 , 202, 203, 204 fully deployed in the primary deployment and flip-out directions, and its fifth bay 205 partially deployed in the primary and flip-out directions. Finally, FIG. 17 shows the solar array system 200 of FIGS. 8 - 16 in full deployment and FIG. 18 shows the solar array system 200 in full deployment connected to a spacecraft 10 (as illustrated, a satellite).

[0041] Those skilled in the art will appreciate that the sequence described in connection FIGS. 8-17, could be extended to any number of additional1026500.02116bays (6th, 7th, nth...) along the primary axis, depending on the application. The same could be applied to the sequence of FIGS. 1-7 described above. Moreover, the deployment of any flip-out sections may occur on a bay-by-bay basis, groups of adjacent or intermittent bays, or all at once at the end of primary central deployment, and any of these configurations fall within the scope of the present disclosure.

[0042] While two deployment sequences are described above, it should be appreciated that these are merely exemplary and numerous other sequences may be used and likewise fall within the scope of the present disclosure.

[0043] In accordance with various aspects of the present disclosure, and as briefly mentioned above, the hinges may comprise various motors, position encoders, and locking mechanisms configured to actively control the deployment dynamics and then rigidize the central column when fully deployed. For example, with reference to FIGS. 19 - 21 , a motorized hinge 300 in accordance with the present disclosure is illustrated. With reference to FIG. 19, the motorized hinge 300 comprises a motor 310 connected to the motorized hinge 300 using a motor coupler 320 which is in turn connected to a spherical bearing 330. The motorized hinge 300 further comprises first and second panel interfaces 340 for mounting the hinge 300 to the panels by any known or as yet unknown means (such as bolts and nuts, rivets, adhesives, and the like). When activated, the motor 310 rotates the hinge 300 to open (deploy) or close (stow) the panels. A locking mechanism 350 may be provided to lock the motorized hinge 300 in place upon deployment. FIG. 20 shows the motorized hinge 300 in a stowed position and FIG. 21 shows the motorized hinge 300 in a deployed and locked position.

[0044] Thus, solar array systems and methods in accordance with the present disclosure provide a variety of benefits including, and not limited to, the1126500.02116following:Improved deployment dynamics via active control enabling significantly larger solar arrays for a given spacecraft class than previously possible.• Equivalent mass and stiffness to state-of-the-art arrays while being more cost-effective, with improved manufacturability and improved serviceability• More compact when stowed for launch.• Scalable from 500W to 10kW and above per wing.• Smaller panel sheets are easier to handle and test.• More damage tolerant during ground integration, test, and transportation. Can “hot swap” row if damaged during integration.• Damage on-orbit is limited to loss of one bay. System does not lose an entire array-worth of cells if there is damage.• External-facing “keep-alive panel” allows for power generation prior to deployment.

[0045] Finally, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. For example, numerous materials, shapes, sizes and configurations can be substituted in place of those described herein. Thus, the present disclosure covers the modifications and variations provided they come within the scope of the appended claims and their equivalents1226500.02116

Claims

WHAT IS CLAIMED:I claim:

1. A solar array system for deployment with a spacecraft, comprising: a central column comprising a plurality of central rigid solar panels interconnected via motorized hinge modules, each rigid solar panel configured to rotate under active control from a stowed position to a deployed position along a primary deployment direction; a keep-alive panel positioned to be externally facing when the solar array system is in a stowed configuration; at least one flip-out panel mounted to at least one rigid solar panel via at least one hinge and configured to deploy the at least one flip-out panel in a direction perpendicular to the primary deployment direction; and a control system configured to control and sequence the deployment of the flip- out panels such that the flip-out panels are constrained from deploying until the central column is fully deployed and such that the deployment dynamics imparted to the spacecraft are selectable and actively controlled.

2. The solar array system for deployment with a spacecraft of claim 1 , further comprising a yoke configured to mount the solar array system to a spacecraft solar array drive assembly (SADA).

3. The solar array system for deployment with a spacecraft of claim 1 , wherein the keep-alive panel provides pre-deployment power generation.

4. The solar array system for deployment with a spacecraft of claim 1 , wherein the at least one flip-out panel is rigid or flexible.1326500.021165. The solar array system for deployment with a spacecraft of claim 1 , wherein the at least one hinge is one of a compliant lateral hinge or a motorized hinge.

6. The solar array system for deployment with a spacecraft of claim 1 , wherein each motorized hinge module comprises a motor, a position encoder, and a locking mechanism configured to rigidize the central column when fully deployed.

7. The solar array system for deployment with a spacecraft of claim 1 , wherein the flip-out panels comprise flexible photovoltaic laminates and are passively deployed via compliant lateral hinges or actively deployed via motorized hinges.

8. The solar array system for deployment with a spacecraft of claim 7, wherein the flexible photovoltaic laminates are silicon heterojunction with a flexible backing.

9. The solar array system for deployment with a spacecraft of claim 1 , wherein the flip-out panels comprise bifacial photovoltaic laminates held in tension by a frame structure.

10. The solar array system for deployment with a spacecraft of claim 1 , wherein each of the central rigid solar panels and flip-out panels are modular and interchangeable.

11. The solar array system for deployment with a spacecraft of claim 1 , wherein the control system comprises software configured to prevent activation of flip- out panel deployment until all central rigid solar panels report full extension provided via sensor feedback.1426500.0211612. A solar array system for deployment with a spacecraft, comprising: a yoke configured to mount the solar array system to a spacecraft solar array drive assembly (SADA); a central column comprising a plurality of central rigid solar panels interconnected via motorized hinge modules, each configured to rotate under active control from a stowed to a deployed position along a primary deployment direction; a keep-alive panel positioned to be externally facing when the solar array system is in a stowed configuration, the keep-alive panel providing pre-deployment power generation; at least one flip-out panel mounted to at least one rigid solar panel via at least one hinge and configured to deploy the at least one flip-out panel in a direction perpendicular to the primary deployment direction; and a control system configured to sequence the deployment of the flip-out panels such that the flip-out panels are constrained from deploying until the central column is fully deployed.

13. The solar array system for deployment with a spacecraft of claim 12, wherein the at least one flip-out panel is rigid or flexible.

14. The solar array system for deployment with a spacecraft of claim 12, wherein the at least one hinge is one of a compliant lateral hinge or a motorized hinge.

15. The solar array system for deployment with a spacecraft of claim 12, wherein each motorized hinge module comprises a motor, a position encoder, and a locking mechanism configured to rigidize the central column when fully deployed.

16. The solar array system for deployment with a spacecraft of claim 12, wherein the flip-out panels comprise flexible photovoltaic laminates and are passively deployed via compliant lateral hinges or actively deployed via motorized hinges.1526500.0211617. The solar array system for deployment with a spacecraft of claim 16, wherein the flexible photovoltaic laminates are silicon heterojunction with a flexible backing.

18. The solar array system for deployment with a spacecraft of claim 12, wherein the flip-out panels comprise bifacial photovoltaic laminates held in tension by a frame structure.

19. The solar array system for deployment with a spacecraft of claim 12, wherein each of the central rigid solar panels and flip-out panels are modular and interchangeable.

20. The solar array system for deployment with a spacecraft of claim 12, wherein the control system comprises software configured to prevent activation of flip- out panel deployment until all central rigid solar panels report full extension provided via sensor feedback.

21. A method for deployment of solar array system for spacecraft, comprising the steps of: deploying a central column comprising a plurality of central rigid solar panels interconnected via motorized hinge modules, each rigid solar panel configured to rotate under active control from a stowed position to a deployed position along a primary deployment direction; and activating at least one hinge to deploy at least one flip-out panel in a direction perpendicular to a primary deployment direction of the central column after the central column is fully deployed.

22. The method for deployment of solar array system for spacecraft of claim1626500.0211621 , further comprising providing a yoke configured for mounting the solar array system to a spacecraft solar array drive assembly (SADA).

23. The method for deployment of solar array system for spacecraft of claim 21 , further comprising providing a keep-alive panel that is externally facing from the solar array system when the solar array system is in a stowed configuration..

24. The method for deployment of solar array system for spacecraft of claim 23, wherein the keep-alive panel provides pre-deployment power generation.1726500.02116

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