Extruded Spacecraft Radiators With Solid-State Welded Modules
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Solution Overview
Problem
Conventional spacecraft radiators face challenges in withstanding extreme thermal cycling, micrometeoroid and orbital debris impacts, and structural reliability due to the joining of independently formed flow tubes and heat-rejection sheets.
Innovation Solution
The development of radiator systems using extrusion-formed thermal-transfer modules joined by solid-state welding processes, such as friction-stir welding, to create a single unitary piece that enhances structural integrity and scalability while providing a continuous heat rejection surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional radiators use independently formed flow tubes and heat-rejection sheets joined together, then manufacturing flexibility is improved, but structural reliability deteriorates due to bonding failures under thermal cycling
Solution Approach 1:
The patent combines previously separate components (flow tubes and heat-rejection sheets) into a single monolithic structure formed by extrusion. This eliminates the bonded joints that failed under thermal cycling while maintaining the functional separation of fluid transport and heat rejection surfaces. The single-piece construction directly resolves the reliability issue by removing the weak bonding interface.
Solution Approach 2:
The patent segments the radiator into modular extruded sections that can be independently manufactured and then assembled. Each module is formed as a single piece through extrusion, but multiple modules can be joined to create larger radiator systems. This segmentation approach maintains manufacturing flexibility while ensuring each module's internal structure is inherently reliable.
2Strength
If radiators are designed as single unitary pieces through extrusion, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the radiator system into multiple extruded modules that are manufactured separately and then assembled. Each module is a single-piece extrusion with high structural integrity, but the overall system is built by joining these standardized modules together using simple mechanical connectors. This segmentation reduces the complexity of manufacturing each individual component while maintaining the structural benefits of monolithic construction.
3Ease of operation
If conventional bonding methods are used to join radiator components, then assembly ease is improved, but resistance to thermal cycling deteriorates
Solution Approach 1:
The patent eliminates bonding entirely by forming the flow tubes and heat-rejection surfaces as a single monolithic extruded piece. The components are inherently joined through the extrusion process itself, creating a bonded-free structure that naturally withstands thermal cycling without the failures associated with conventional adhesive or weld joints.
Solution Approach 2:
The patent replaces the chemical bonding system (adhesives, epoxies) with a mechanical formation process (extrusion). The single-piece construction achieves component joining through the extrusion process rather than through separate bonding operations, eliminating the thermal cycling sensitivity of bonded joints while maintaining assembly simplicity through modular design.
4Temperature
If radiator surface area is increased for better heat rejection, then thermal performance is improved, but vulnerability to micrometeoroid impacts increases
Solution Approach 1:
The patent utilizes thin-walled extruded structures that provide large surface area for heat rejection while maintaining structural adequacy through the extrusion process. The continuous extruded walls provide uniform thickness and inherent structural integrity that resists micrometeoroid impacts better than conventional assembled structures, even at large surface areas.
Solution Approach 2:
The patent combines the structural support function with the heat rejection surface in a single monolithic extruded structure. The flow tube walls themselves serve as both the structural element and the heat rejection surface, eliminating separate thin surfaces that would be vulnerable to impact. This integrated structure provides large surface area while maintaining impact resistance through its unified construction.
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 provides durable, lightweight radiators with improved thermal performance and impact resistance, capable of handling dynamic space environments and varying heat rejection demands.
Implementation Method 1
at least one solid-state-welding facilitator structured and arranged to facilitate fixedly joining such at least one modular engager to at least one other such modular engager by at least one solid-state welding process
Implementation Method 2
wherein such thermal-transfer module comprises a single extruded piece
Implementation Method 3
In the vacuum environment of space, the primary heat rejection mechanism is radiation
Data Source
AI summary
A system of spacecraft radiators comprising pre-formed thermal-transfer modules joined together by at least one solid-state welding process. Critical failure points are eliminated by forming the thermal-transfer modules as a single unitary piece, preferably by an extrusion process. The thermal-transfer modules allow the formation of larger radiator assemblies, which may comprise a wide range of sizes and physical geometries.