Spacecraft Material Transfer Interfaces for Autonomous Refueling

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Solution Overview

Problem

Existing space systems face limitations in launch vehicle volume and mass capacities, leading to spacecraft with limited fuel supplies and shortened lifetimes, especially for spacecraft with long lifecycles. Additionally, existing docking systems are complicated, often incompatible, and lack the capability for autonomous material transfer.

Innovation Solution

The development of a material transfer interface system that includes a service valve portion and a space coupling portion, enabling autonomous or semi-autonomous material transfer between spacecraft. This system facilitates docking and provides a structural interface while allowing for the transfer of materials such as fuel, propellant, and waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If spacecraft are launched with limited fuel capacity due to launch vehicle constraints, then launch vehicle volume and mass capacities are respected, but spacecraft lifetime and operational utility are reduced

Engineering Contradiction:

Improvespacecraft lifetimeVSAvoidfuel capacity

Core Design Contradiction:

Duration of action of moving objectVSQuantity of substance

Solution Approach 1:

The patent implements preliminary action by enabling spacecraft to perform refueling operations in orbit after launch. The material transfer interface system allows fuel to be transferred from a source spacecraft or orbital fuel depot to the target spacecraft, effectively adding fuel capacity beyond what can be launched initially. This resolves the contradiction by separating the fuel acquisition timing from the launch phase.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediary material transfer interface system that enables fuel transfer between spacecraft. This intermediary system includes docking mechanisms, valves, and conduits that facilitate the transfer of propellant from an external source to the spacecraft, allowing extended operational lifetime without increasing launch vehicle capacity constraints.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If existing docking systems are used for material transfer, then docking capability is provided, but system complexity and incompatibility issues arise

Engineering Contradiction:

Improvedocking compatibilityVSAvoiddocking system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a standardized material transfer interface that serves multiple functions: structural docking, material transfer (fuel, propellant, waste), and electrical connections. This multi-functional interface reduces the need for separate specialized systems and improves compatibility across different spacecraft platforms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges previously separate functions into a single integrated material transfer interface system. The docking mechanism, material transfer conduits, valves, and sealing systems are combined into one unified interface, reducing overall system complexity while maintaining adaptability for different spacecraft types.

Inventive Principle:

Principle #5Merging (Combining)

3Extent of automation

If existing docking systems are used for material transfer, then docking capability is provided, but autonomous operation capability is lacking

Engineering Contradiction:

Improveautonomous docking capabilityVSAvoiddocking operation simplicity

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The patent implements self-service through autonomous docking and material transfer capabilities. The system includes sensors, actuators, and control systems that enable spacecraft to automatically align, dock, and transfer materials without human intervention. This resolves the contradiction by making the system autonomous while maintaining operational simplicity through automated procedures.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent incorporates feedback mechanisms with sensors that monitor docking alignment, contact forces, and material transfer rates. This feedback enables autonomous control systems to adjust positioning and operation parameters automatically, achieving both high automation and operational simplicity through closed-loop control.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20250289593A1Material transfer interfaces for space vehicles, and associated systems and methods

Publication Date: 2025.09.18 ORBIT FAB INC

AI summary

Material transfer interfaces for space vehicles, and associated systems and methods, are disclosed. A representative system includes a coupling mechanism including a support structure, a latch-arm base movably connected to the support structure, and a latch arm pivotably connected to the latch-arm base. Another representative system includes a service valve portion, a coupling portion configured to receive the service valve portion, and a coupling mechanism for coupling the service valve portion to the coupling portion. The coupling mechanism can include latch arms positioned to pivot between a position in which the latch arms are pivoted outwardly and a position in which the latch arms are pivoted inwardly to capture the service valve portion. The latch arm can be carried by a latch-arm base that translates relative to a support structure of the coupling portion. Material transfer interfaces can include self-aligning ports having faces that engage each other with cup-and-cone structures.