Deployable Thin Shell Reflector Spiral Gore Packaging
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Solution Overview
Problem
Current reflector antennas face challenges in compact packaging for launch and maintaining structural integrity during deployment, as they are often larger than launch fairings and lack effective methods to link gores together once deployed.
Innovation Solution
A deployable thin shell reflector with spiral gores that elastically wrap around a central hub, using a flexible pantograph-like mechanism to connect gores and store elastic strain energy for deployment, allowing for compact packaging and autonomous expansion to a larger configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If reflector antennas are made large for operational use, then antenna performance is improved, but packaging difficulty increases
Solution Approach 1:
The reflector antenna is divided into multiple gores (segments) that can be independently folded and packaged. Each gore is a curved panel that maintains the overall parabolic shape when assembled, allowing the large aperture to be segmented into compact units for launch packaging.
Solution Approach 2:
The gores are designed to nest within each other in a compact configuration during packaging, similar to nested dolls. The folded gores fit inside the launch fairing volume, with each segment containing the previous ones, achieving maximum space utilization.
2Volume of moving object
If gores are made flexible for folding, then packaging efficiency is improved, but structural integrity during deployment deteriorates
Solution Approach 1:
The gore structure employs local quality by using stiffening ribs or reinforcement at critical locations (edges and curvature regions) while maintaining flexibility in the main panel areas. This allows the gores to be flexible enough for folding yet strong enough to maintain structural integrity during deployment and operation.
3Reliability
If gores are connected rigidly for structural stability, then deployment reliability is improved, but packaging flexibility deteriorates
Solution Approach 1:
The connection between gores uses dynamic joints or hinges that allow the structure to transition between folded and deployed states. These connections provide flexibility during packaging but automatically provide structural stability when deployed, adapting their mechanical properties based on the configuration state.
4Ease of manufacture
If traditional folding methods are used, then manufacturing simplicity is maintained, but packaging volume increases
Solution Approach 1:
The patent transitions from traditional radial folding to a spiral folding pattern that utilizes three-dimensional space more efficiently. The gores are arranged in a spiral configuration that allows them to pack into a smaller cylindrical volume, reducing the packaged dimensions while maintaining manufacturing feasibility.
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 achieves greater compaction and rigidity at lower costs than previous designs, enabling efficient packaging and reliable deployment of reflector antennas within CubeSat dimensions, utilizing materials like carbon fiber/epoxy and resilient metals.
Implementation Method 1
using a flexible pantograph-like mechanism to connect gores and store elastic strain energy for deployment
Data Source
AI summary
A reflector useful for communications, radar and sensing application in space and on earth includes thin shell gores emanating from a geometric center of the reflector at its hub. Gores are provided in a spiraled pattern and are in elastic connection to said hub and wrapped around their point of convergence at the hub when the reflector is stowed. The gores emanate from the geometric center of the reflector hub at their elastic connection to the hub when they are deployed and operational as a reflector with a point of convergence to promote operation as a reflector. Thin shell gores can have an inner perimeter and outer perimeter, can be provided in a spiraled pattern, and can be interlocked at their outer perimeter, or in-between their inner and outer perimeter, while also remaining in elastic connection at their inner perimeter to said hub.