Composite Foldable Reflector Structure for Wrinkle-Free Deployment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing foldable reflectors for space-based applications face challenges in compact storage and deployment, often resulting in wrinkled surfaces due to material properties not being accounted for in design, and require complex hinge systems that are not efficient for lightweight composite materials.
Innovation Solution
A doubly curved reflector design using composite materials with gores that include fold roll hinges or living hinges, stress relieving slits, and a perimeter structure like a C-shaped spring, which allows for compact storage and deployment without wrinkles, utilizing finite element analysis to optimize fold lines based on material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional foldable reflector designs are used, then compact storage is achieved, but wrinkled surfaces occur due to material properties not being accounted for in design
Solution Approach 1:
The patent modifies the geometric parameters of fold lines by calculating optimal curvature radii based on material properties (thickness, elastic modulus, Poisson's ratio). This parameter optimization ensures that the fold lines accommodate material deformation characteristics, preventing wrinkle formation while maintaining compact folding capability.
Solution Approach 2:
The patent performs preliminary finite element analysis and iterative calculations during the design phase to determine optimal fold line geometries before manufacturing. This preliminary action accounts for material properties in advance, allowing the reflector to fold without wrinkles by pre-configuring the fold line curvatures to match material behavior.
2Ease of operation
If complex hinge systems are used, then foldable functionality is achieved, but device complexity increases and lightweight composite materials are not efficiently utilized
Solution Approach 1:
The patent extracts and eliminates complex hinge mechanisms from the design, replacing them with simplified fold lines directly integrated into the composite material structure. This extraction removes unnecessary mechanical complexity while retaining the essential folding functionality through carefully designed geometric fold lines.
Solution Approach 2:
The patent merges the hinge function into the fold line geometry itself, integrating the folding mechanism directly into the composite material structure rather than using separate hinge components. This merging simplifies the overall system by combining structural and functional elements into a unified design.
3Volume of moving object
If fold lines are optimized for compact folding, then storage volume is reduced, but material strain increases causing wrinkles
Solution Approach 1:
The patent optimizes fold line parameters (curvature radius, angle, position) to balance compact folding requirements with material strain limitations. By calculating optimal parameters based on material properties, the design achieves tight folding while keeping stresses within acceptable limits to prevent wrinkle formation.
Solution Approach 2:
The patent incorporates stress-relieving features such as slots and notches at critical locations along fold lines. These partial modifications locally reduce material continuity to relieve excessive strain concentrations, allowing more aggressive folding geometries without causing wrinkles in the overall structure.
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
The solution enables a lightweight, compact, and wrinkle-free foldable reflector that can efficiently deploy into a doubly curved surface, suitable for space applications, with improved packaging and reduced material strain, suitable for solar concentrators and other space-based uses.
Implementation Method 1
the perimeter structure spring biases the doubly curved reflector surface towards the deployed doubly curved reflector structure locked open state
Data Source
AI summary
A doubly curved reflector for compact storage in a folded state includes a plurality of gores, each gore having on either long side a gore side curve. At least one hinge is mechanically coupled between each adjacent gore, the at least one hinge including a fold roll hinge or a living hinge. In a stowed doubly curved reflector state each gore folds about the at least one hinge when folded closed such that a face surface of each gore folds against an adjacent face surface of another gore into a substantially cylindrical structure. In a deployed doubly curved reflector state, each hinge. A doubly curved reflector for compact storage in a folded state and a locked open state, a method of manufacture, and a method for designing a substantially wrinkle free doubly curved foldable reflector having gores of a composite material are also described.