Integrated Thermal Radiator Structure for Space Heat Rejection

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Solution Overview

Problem

Existing space-based thermal control systems suffer from inefficiencies in heat transfer due to multiple interfaces and planar radiating components that hinder the conductor bar's contribution to radiant heat rejection.

Innovation Solution

A radiating system with an integrated conductor bar and enhanced radiating surface, featuring macroscopic and microscopic surface features, is formed using additive manufacturing to maximize surface area and efficiency, with materials like copper and titanium used for specific properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If multiple interfaces are used in the conductive link and radiator components, then the structural flexibility and ease of assembly are improved, but the heat transfer efficiency deteriorates

Engineering Contradiction:

Improveease of assemblyVSAvoidheat transfer efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent merges the conductor bar and radiating surface into a single integrated component. The conductor bar is formed with an integrated radiating surface that extends from its exterior, eliminating the need for separate radiator components and their associated thermal interfaces. This integration directly reduces interfacial thermal resistance while maintaining manufacturing feasibility through additive manufacturing processes.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If a planar radiating component surface is used, then the manufacturing simplicity is improved, but the radiating capacity and heat rejection efficiency deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidradiating capacity

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent transitions from a two-dimensional planar radiating surface to a three-dimensional complex geometry. The radiating surface includes protrusions, recesses, and an integrated conductor bar structure that extends into the third dimension. This dimensional complexity increases the effective radiating surface area and enhances heat rejection capacity while utilizing additive manufacturing to achieve the complex geometry without significant manufacturing difficulty.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent incorporates curved and non-planar surfaces in the radiating component. The integrated radiating surface features curved geometries and three-dimensional forms that increase the effective surface area for thermal radiation. This curvature approach enhances radiating capacity while the additive manufacturing process enables complex curved geometries that would be difficult to achieve with traditional manufacturing methods.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Loss of energy

If the conductor bar is integrated with the radiating surface, then the heat transfer efficiency is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical assembly processes with additive manufacturing. Instead of manufacturing separate conductor bar and radiating surface components and assembling them together, the integrated structure is created in a single additive manufacturing process. This substitution of manufacturing approach achieves the benefits of integration (eliminated thermal interfaces) while avoiding the complexity of multi-step assembly operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides a high-efficiency thermal connection and increased radiating capacity, minimizing interfaces and enhancing heat rejection performance.

Implementation Method 1

waste heat must be rejected through radiant heat transfer

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 2

a conductive link between the source and the radiator is required

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12459676B1Thermal radiator for heat rejection

Publication Date: 2025.11.04 BAE SYST SPACE & MISSION SYST INC

AI summary

Radiator structures and methods are provided. The radiator includes conductor bar and radiating surface portions that are integral to one another. An interior surface of the conductor bar and an interior surface of the radiating surface form a continuous internal surface, and an exterior surface of the conductor bar and an exterior surface of the radiating surface form a continuous external surface. The overall form of the radiating surface can be similar to that of a flared bell, such that an interior surface of the conductor bar is exposed at a base of the flared radiating surface. Surface features can be formed on one for both of the exterior and interior surfaces of the radiator. The radiating surface can also include voids. Aspects of surface features and voids can vary with distance from a thermal interface with a heat source. The radiator structures can be formed using additive manufacturing processes.