Expandable Spacecraft Layer Hinge Design
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Solution Overview
Problem
Inflatable and expandable space structures face challenges in efficiently packing outer layer materials without causing damage due to excess bulk and sharp bends, which can compromise their protective functions and launch vehicle fitment.
Innovation Solution
A core element with strategically positioned hinges allows panels to move in two perpendicular directions, minimizing bulk and damage during packing and unpacking, using low-bend-radius hinges and adaptable materials for thermal or debris protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the material is folded over itself repeatedly to pack it, then the material can be packed for launch, but excess bulk is created and the material may be damaged by sharp bends
Solution Approach 1:
The outer layer material is divided into multiple panels (first panel, second panel, third panel, fourth panel) that can be independently folded and positioned. This segmentation allows each panel to be managed separately during packing, reducing the sharp bends and bulk compared to folding a single continuous material layer.
Solution Approach 2:
The panels are arranged in a nested configuration where the first panel is positioned over the second panel, and the third panel is positioned over the fourth panel. This nesting allows the panels to compact efficiently while maintaining their structural integrity and minimizing damage from folding.
2Volume of moving object
If the material is folded to reduce launch volume, then the spacecraft can fit in the launch vehicle, but the bend radius becomes too small causing material damage
Solution Approach 1:
Dividing the material into multiple panels allows each panel to be folded with adequate bend radius, preventing sharp bends that would damage the material while still achieving compact packing for launch volume requirements.
Solution Approach 2:
The panels are arranged to move in two generally perpendicular directions during packing, utilizing multiple dimensions to achieve compact configuration without requiring sharp bends in any single direction, thereby protecting the material from damage.
3Volume of moving object
If the panels are tightly packed to minimize launch volume, then the spacecraft fits better, but the material is subjected to potential damage from excessive compression and bending
Solution Approach 1:
The segmented panel structure allows for controlled packing where each panel maintains its strength and protective capability while achieving tight overall packing. The segmentation prevents excessive compression and bending stresses that would compromise material strength.
Solution Approach 2:
Different regions of the outer layer are designed with different properties - the panels are positioned to provide thermal protection and micrometeoroid protection in specific areas while maintaining overall structural integrity during packing and deployment.
Data Source
AI summary
A core element for use with an inflatable or expandable spacecraft is claimed. The core element has a plurality of panels connected by hinges so that the core element can be packed into a smaller volume for loading into a launch vehicle. Upon deployment in space, the core element can be unpacked and can enclose a larger volume than that in the packed state. Multiple core elements can be used to cover a spacecraft to a desired degree.