Monolithic Self-Locking Hinges for Low-Stow Solar Arrays
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Solution Overview
Problem
Current deployable solar arrays for spaceflight and satellite applications face challenges in scalability, reliability, and cost-effectiveness, with existing hinges requiring multiple components and complex deployment mechanisms, leading to high stow volumes and potential structural issues during deployment.
Innovation Solution
The development of a Morphing Self-Stiffening Array (MOSSA) utilizing high strain composite (HSC) hinges with a smooth tangential spline transition section, which are monolithic, self-opening, and self-locking, allowing for efficient deployment and stowage with reduced parts and weight, and incorporating Thinned Celled Panels (TCPs) for enhanced power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional multi-component hinges are used for deployable solar arrays, then structural support during deployment is maintained, but device complexity and stow volume increase
Solution Approach 1:
The patent combines multiple hinge components (pivot element, support element, and locking mechanism) into a single monolithic hinge structure. This integration eliminates the need for separate parts while maintaining all necessary functions for reliable deployment and stowage of solar array panels.
Solution Approach 2:
The monolithic hinge structure performs multiple functions simultaneously: it provides pivot movement for panel deployment, structural support during the deployment process, and self-locking capability for both deployed and stowed positions. This multi-functionality reduces overall system complexity while enhancing reliability.
2Volume of stationary object
If traditional deployable structures are used, then structural integrity during deployment is maintained, but stow volume increases
Solution Approach 1:
The hinge structure transitions from a rigid configuration during stowage to a flexible, controlled-deployment configuration during array deployment. The monolithic design allows the hinge to adapt its structural characteristics dynamically, providing support when needed and minimizing volume when stowed.
Solution Approach 2:
The solar array is divided into multiple panels connected by individual monolithic hinges, allowing each panel to be independently deployed and stowed. This segmentation enables compact folding during stowage while maintaining structural integrity through the rigid monolithic hinge connections during deployment.
3Ease of manufacture
If multiple components are used in hinge assembly, then structural support is provided, but manufacturing complexity and cost increase
Solution Approach 1:
Multiple hinge components are merged into a single monolithic structure that can be manufactured as one piece using additive manufacturing or other single-step processes. This eliminates the need for assembly of multiple parts while maintaining the structural support functions that would otherwise require separate components.
4Power
If conventional solar arrays are used, then power generation is achieved, but specific power and power density metrics are not exceeded
Solution Approach 1:
The patent changes key structural parameters by using monolithic hinges with optimized geometries and materials, enabling the array to achieve higher specific power (200 W/kg) and power density (129 kW/m3) by reducing structural mass while maintaining or enhancing deployment reliability.
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 MOSSA achieves reliable, scalable, and cost-effective deployment with exceptionally low stow volumes, maintaining structural integrity and power performance, exceeding current state-of-the-art solar array metrics with specific power of 200 W/kg and power density of 129 kW/m3, while being easy to manufacture and assemble.
Implementation Method 1
The center segment has a flexibility greater than a corresponding flexibility of each transition segment. The center segment may be configured to bend during movement of the hinge member between the closed condition and the open condition.
Implementation Method 2
The hinge member may be configured to lock upon transitioning to the open condition.
Data Source
AI summary
A self-deployable array of panels includes a plurality of panels, each panel having a first compressed panel thickness state and a second expanded panel thickness state, and including a spring bias element biased to the second expanded panel thickness state. A plurality of locking hinges hingedly couple each of the panels to an adjoining panel. Each locking hinge is biased to an open position. A release of stored potential energy of both of the spring bias element biased to the second expanded panel thickness state, and the locking hinges biased to the open position causes the self-deployable array of panels to self-deploy from a folded stowed state. A single part offset locking hinge is also described.