Modular Spacecraft Solar Array Structure for Fast Scalable Design

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Solution Overview

Problem

Existing solar array designs for satellites face challenges in balancing the need for a lightweight, stiff, and stable structure that provides sufficient surface area for power generation while minimizing on-orbit attitude control disturbances, and they require lengthy redesigns for varying spacecraft shapes and power requirements, leading to high costs and long lead times.

Innovation Solution

A modular approach using semi-rigid face-sheet structural elements with multiple solar array cells mounted on composite panels, connected by tubes and nodes, allowing for scalable, configurable, and producible wing structures that can be quickly adapted to new photovoltaic technologies and unique array shapes, enabling rapid design iterations and mass production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a large surface area of photovoltaic cells is used to generate sufficient electricity, then the power generation capability is improved, but the weight and volume of the solar array structure increase

Engineering Contradiction:

Improvepower generation capabilityVSAvoidweight of solar array structure

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The solar array is divided into multiple identical modular units, each comprising photovoltaic cells mounted on a lightweight composite panel. These modules can be independently configured and assembled to achieve the required total power generation area while using minimal structural material per unit area.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Lightweight composite panels are used as the substrate for mounting photovoltaic cells, replacing traditional heavier materials. This reduces the structural weight per unit area while maintaining the mechanical strength and stiffness required to support the photovoltaic cells and withstand launch and operational loads.

Inventive Principle:

Principle #40Composite materials

2Strength

If the solar array structure is made stiff and strong to maintain stability and flatness, then the structural integrity is improved, but the weight increases

Engineering Contradiction:

Improvestructural integrityVSAvoidweight of solar array structure

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Composite panels with optimized fiber reinforcement patterns provide high strength-to-weight and stiffness-to-weight ratios. The composite material construction achieves the required structural integrity and dimensional stability while minimizing the weight penalty compared to traditional metallic structures.

Inventive Principle:

Principle #40Composite materials

3Power

If the solar array is designed for a specific spacecraft shape and power requirement, then the performance is optimized, but the redesign time and cost increase for varying requirements

Engineering Contradiction:

Improvepower supply capabilityVSAvoidredesign time

Core Design Contradiction:

PowerVSLoss of time

Solution Approach 1:

The solar array system is segmented into standardized modular units that can be independently configured. By varying the number of modules, their arrangement, and panel dimensions within the modular framework, different power outputs and shapes can be achieved without redesigning the fundamental module architecture, thus reducing development time and cost for different spacecraft applications.

Inventive Principle:

Principle #1Segmentation

4Volume of stationary object

If the solar array structure is minimized for launch volume, then the launch cost is reduced, but the deployed surface area and power generation capability are compromised

Engineering Contradiction:

Improvelaunch volumeVSAvoidpower generation capability

Core Design Contradiction:

Volume of stationary objectVSPower

Solution Approach 1:

The modular architecture allows the solar array to be compactly packaged during launch by stowing individual modules separately, achieving minimal launch volume. Upon deployment, the same modules can be fully extended to achieve the required large surface area for power generation, with the modular connections enabling both compact stowage and full deployment configurations.

Inventive Principle:

Principle #1Segmentation

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 approach enables rapid design and production of solar arrays that meet specific spacecraft requirements, reducing costs and lead times, while accommodating non-rectangular shapes and being adaptable to future photovoltaic technologies.

Implementation Method 1

solar array structures with a large surface area of photovoltaic cells to generate electricity from the sunlight incident on the array structure

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS12454372B2Modular solar array

Publication Date: 2025.10.28 LANTERIS SPACE LLC

AI summary

A solar array structure for a spacecraft is based on a modular approach, allowing for arrays to be designed, and designed to be modified, and manufactured in reduced time and with reduced cost. The embodiments for the solar array are formed of multiple copies of a “bay” of a multiple strings of solar array cells mounted on semi-rigid face-sheet structural elements. The bays are then placed into frame structures made of tubes connected by nodes to provide an easily scalable, configurable, and producible solar array wing structure. This allows for rapid turnaround of program specific designs and proposal iterations that is quickly adaptable to new/future PhotoVoltaic (PV) technologies and that can create uniquely shaped (i.e., not rectangular) arrays, allowing for mass production with simple mass producible building blocks.