Deployable Panel Array With Tension Cables for Compact Space Stowage

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Solution Overview

Problem

Existing panel arrays deployed in space, such as satellites, face challenges in efficiently expanding and deploying two-dimensional arrays due to size and weight constraints, which limits their surface area and functionality.

Innovation Solution

A deployable panel array system that includes a plurality of panels arranged in columns and rows, with interlocking features and tension cables to expand and secure the array, allowing for a larger surface area to be deployed efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of moving object

If panel arrays are made larger to increase surface area for power generation and signal transmission, then functionality is improved, but size and weight constraints make deployment difficult

Engineering Contradiction:
Improvesurface areaVSAvoiddeployment complexity
Core Design Contradiction:
Area of moving objectVSDevice complexity

Solution Approach 1:

The panel array is divided into multiple individual panels that can be folded together in an accordion configuration. Each panel is a separate unit that can be independently managed, allowing the entire array to be collapsed into a compact form for launch while deploying to a large surface area in orbit. The tension cables are also segmented, with individual cables running through multiple panels to maintain tension across the entire array.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The panel array employs a nested folding structure where panels are stacked within each other in a compact configuration for storage and transportation. When deployed, the panels unfold in sequence similar to a nested doll expanding, achieving a large two-dimensional surface area from a small initial volume. This nesting approach maximizes the surface area-to-volume ratio during storage.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Volume of moving object

If panel arrays are folded compactly for storage and transportation, then space requirements are reduced, but deployment mechanisms become more complex

Engineering Contradiction:
Improvestorage volumeVSAvoiddeployment mechanism complexity
Core Design Contradiction:
Volume of moving objectVSDevice complexity

Solution Approach 1:

The panel array transitions from a static compact folded state to a dynamic deployed state through controlled tension application. The system uses movable spools that can wind and unwind tension cables, allowing the array to be dynamically adjusted between compact storage and full deployment. This dynamic mechanism simplifies the deployment process compared to complex mechanical unfolding structures.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent replaces complex mechanical unfolding mechanisms with a tension-based system using cables and spools. Instead of using intricate linkages, hinges, and locking mechanisms to control panel deployment, the system uses tensile forces applied through cables wrapped around spools. This substitution of mechanical systems with tension-based actuation simplifies the deployment mechanism while achieving the same functional result.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Stability of the object's composition

If tension cables are used to secure panels during deployment, then panel stability is improved, but system weight increases

Engineering Contradiction:
Improvepanel stabilityVSAvoidsystem weight
Core Design Contradiction:
Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The tension cables function as flexible tensile elements that provide structural stability to the rigid panels. By using thin, high-strength cable elements rather than bulky structural supports, the system achieves panel stability with minimal added weight. The cables act as tensioned membranes that maintain panel positioning and prevent deformation during deployment and operation.

Inventive Principle:
Principle #30Flexible shells and thin films

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 system effectively increases the surface area of panel arrays, enhancing their power generation and signal transmission capabilities while reducing the space required for storage and transportation.

Implementation Method 1

The first cable may be configured to apply tension between the plurality of panels in the first row and cause the interlocking features to engage

Methodology Applied
Scientific EffectTension: Tension

Data Source

PatentUS12296986B2Deployable panel array and related assemblies and methods
Publication Date: 2025.05.13 NORTHROP GRUMMAN SYSTEMS CORP
  • US12296986B2 patent drawing
  • US12296986B2 patent drawing
  • US12296986B2 patent drawing

AI summary

A panel array and associated deployment system may include a first cable extending along a first row of panels and coupled to each panel of the first row of panels. The array and system may further include a second cable extending along a second row of panels and coupled to each panel of the second row of panels. The array and system may also include a first column of panels comprising a panel from the first row of panels and a panel from the second row of panels. The system may further include a spool positioned adjacent the first column of panels. The spool may be coupled to at least one of the first cable and the second cable and configured to apply tension to the first cable and/or the second cable.