Modular Stray-Light Shielding for Optical Metering Structures

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Solution Overview

Problem

Stray light originating from bright objects near the field of view of optical sensors, particularly in telescope systems, poses a significant noise source that limits mission operations and on-orbit observation efficiency, often discovered late in the design process, necessitating significant redesign.

Innovation Solution

A modular system using a semi-rigid shield with a highly absorptive surface finish, thermally decoupled from the strut via multi-layer insulation (MLI), secured with fasteners, to mitigate stray light in optical metering structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a metering structure is used to support sensor elements, then structural support and positioning are provided, but stray light from bright objects near the field of view reflects off the structure and creates noise

Engineering Contradiction:

Improvestray light noiseVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

An MLI blanket is introduced as an intermediary layer between the metering structure and the optical field. The blanket includes a light-blocking layer that intercepts stray light before it can reflect off the metering structure and enter the optical path, while the thermal insulation layers provide thermal management. This mediator solves the stray light problem without requiring fundamental redesign of the metering structure itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution segments the stray light mitigation function into a separate, modular MLI blanket component rather than integrating it directly into the metering structure. The blanket can be independently designed, manufactured, and installed, allowing the metering structure to maintain its structural function while the blanket provides optical and thermal management functions.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the MLI system is secured to the strut using multiple fasteners at spaced apart locations, then the shield is firmly attached, but the structure becomes more complex

Engineering Contradiction:

Improveattachment reliabilityVSAvoidfastening complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The MLI blanket is designed to serve multiple functions simultaneously: it provides thermal insulation, blocks stray light, and serves as a substrate for mounting the rigid shield. The fasteners serve dual purposes by securing both the MLI blanket to the strut and the rigid shield to the MLI blanket. This multi-functionality reduces the need for separate components and simplifies the overall structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If the shield length is made substantially coextensive with the strut length, then stray light coverage is maximized, but the shield becomes more difficult to install and accommodate thermal expansion

Engineering Contradiction:

Improvestray light coverageVSAvoidthermal expansion accommodation

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The MLI blanket serves as a flexible intermediary between the rigid shield and the metering structure. The blanket's flexibility allows it to accommodate differential thermal expansion between the shield and the strut while maintaining secure attachment. The fasteners are positioned to allow for thermal movement without compromising the attachment or creating excessive stress.

Inventive Principle:

Principle #30Flexible shells and thin films

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 effectively reduces stray light reflection while maintaining thermal stability and structural integrity, allowing easy integration into existing designs to address stray light issues without major modifications.

Implementation Method 1

The MLI system is secured to the strut using a plurality of first fasteners... thermally decoupled from the strut via multi-layer insulation (MLI)

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Implementation Method 2

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Data Source

PatentUS12436027B2Modular stray light mitigation

Publication Date: 2025.10.07 EAGLE TECHNOLOGY LLC

AI summary

Stray light in a metering structure is controlled by surrounding with a rigid shield an elongated length of a strut and supporting on the rigid shield a surface finish which is highly absorptive of light. The strut is thermally decoupled from the rigid shield using a plurality of insulating web layers comprising a multi-layer insulation (MLI) system disposed between the strut and the rigid shield. The MLI in such scenarios (1) thermally isolates the strut from the shield (2) serves as a support structure to support the rigid shield on the strut, and (3) absorbs thermally induced mechanical stresses as between the rigid shield and the strut.