Compact Plasma Thruster PCB Integration for CubeSat
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Solution Overview
Problem
Current electric-propulsion thrusters for spacecraft, particularly micro-satellites like CubeSats, face challenges in achieving compact size while maintaining high power output, as they occupy significant space and weight within the spacecraft platform.
Innovation Solution
The integration of a compact power converter and electro-thermal plasma-ion thruster architecture on a printed circuit board (PCB) secured along the spacecraft's sidewall, which serves as both structural support and minimizes space usage, utilizing air core inductors and a class Φ2 switched mode dc-RF power inverter for efficient power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional electric-propulsion thrusters are used, then sufficient thrust power is provided, but the thruster occupies significant space and weight within the spacecraft platform
Solution Approach 1:
The patent merges the power converter and thruster into a single integrated assembly where the power converter is mounted directly on the thruster housing. This integration eliminates the need for separate power converter mounting space, reducing the overall footprint while maintaining sufficient thrust power output.
Solution Approach 2:
The patent transitions from a planar arrangement of components to a three-dimensional integrated structure. The power converter is positioned in the vertical dimension above the thruster, utilizing the Z-axis space rather than expanding the X-Y footprint, thereby reducing the thruster's planar footprint while preserving power delivery capability.
2Volume of moving object
If the thruster size is reduced for micro-satellites, then space and weight are minimized, but the power output capability is compromised
Solution Approach 1:
The patent employs a class Φ2 switched mode power inverter that operates at high switching frequencies, allowing the use of smaller inductors and capacitors that would traditionally require more space. This parameter change in the power conversion approach enables compact sizing while maintaining adequate power output for micro-satellite applications.
Solution Approach 2:
The patent uses air core inductors with optimized geometries positioned strategically within the compact assembly. By locally optimizing the inductor design and placement, the system achieves efficient power delivery in a reduced volume, balancing power output capability with miniaturization requirements.
3Volume of moving object
If a compact power converter architecture is implemented, then the thruster footprint is reduced, but the complexity of integrating multiple components is increased
Solution Approach 1:
The PCB serves multiple functions simultaneously: it acts as the structural sidewall of the spacecraft, provides mechanical mounting for the thruster, and integrates the power converter circuitry. This multi-functionality reduces the number of separate components needed, simplifying the overall system despite the integrated design.
Solution Approach 2:
The PCB is designed to perform its own structural support function while housing the electronic components. The rigidity of the PCB itself provides the structural framework, eliminating the need for separate support structures and reducing integration complexity through self-service design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables a compact and efficient propulsion system that reduces the thruster's footprint, allowing for increased propellant and payload capacity within the spacecraft, while maintaining high thrust power and efficiency, even in low power budget environments.
Implementation Method 1
electro-thermal plasma-ion thruster for electric spacecraft propulsion
Implementation Method 2
electro-thermal plasma-ion thruster
Implementation Method 3
class Φ2 switched mode dc-RF power inverter
Implementation Method 4
air core inductors
Data Source
AI summary
According to certain aspects, an electric-propulsion thruster is used as part of a base or platform which also includes a power converter, having a plurality of inductors and other electrical components, and a printed circuit board (PCB). The PCB includes a layer at which the other electrical components and printed circuit inductor traces, for the plurality of inductors, are secured. The electric-propulsion thruster includes a housing (e.g., as part of the base or platform) providing a cavity and having at least one structurally-rigid side wall along the cavity, where the PCB is integrated with the electric-propulsion thruster for a compact arrangement which can be used to propel the apparatus. Such a compact design might be used as an important part of thruster spacecraft architecture such as micro-satellites (e.g., CubeSats).