Modular Spacecraft Radiator Assembly With Unitary Extruded Modules
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Solution Overview
Problem
Conventional spacecraft radiators face challenges in withstanding extreme thermal cycling, micrometeoroid and orbital debris impacts, and structural integrity due to the joining of independently formed flow tubes and heat-rejection sheets, leading to performance issues under mission conditions.
Innovation Solution
The development of radiator systems comprising pre-formed thermal-transfer modules joined using solid-state welding processes, specifically extrusion-formed as single unitary pieces with integrated fluid channels and facesheets, and friction-stir welding to create durable, scalable heat rejection assemblies with enhanced impact protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional radiators use independently formed flow tubes and heat-rejection sheets joined together, then manufacturing flexibility is improved, but structural integrity and reliability deteriorate under extreme thermal cycling and MMOD impacts
Solution Approach 1:
The patent merges the flow tubes and heat-rejection sheets into a single unitary structure formed by extrusion. This eliminates the joints between separately formed components, thereby maintaining manufacturing flexibility while dramatically improving structural integrity and reliability under thermal cycling and MMOD impact conditions.
Solution Approach 2:
The radiator is segmented into modular units that can be independently formed and then joined. Each module maintains the benefits of extrusion-formed unitary construction, while the modular architecture allows for flexible assembly configurations without compromising the structural integrity of individual modules.
2Strength
If radiator components are formed as a single unitary piece by extrusion, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The complex radiator system is divided into standardized modular units that can be manufactured using routine extrusion processes. Each module is relatively simple in design, but the system achieves complexity through modular assembly, thereby maintaining structural integrity without excessively increasing manufacturing complexity.
3Adaptability or versatility
If radiators are designed as modular assemblies, then scalability and adaptability are improved, but the number of joints and potential failure points increases
Solution Approach 1:
The radiator system is divided into modular units that can be assembled in various configurations to achieve different heat rejection capacities and geometries. This segmentation enables scalability and adaptability while maintaining reliable connections through standardized joining methods.
Solution Approach 2:
Critical structural components within each module are pre-formed as integral parts of the extrusion process, eliminating internal joints within modules. This preliminary integration reduces the number of potential failure points while preserving the benefits of modular assembly for overall system scalability.
4Ease of operation
If conventional joining methods are used for radiator components, then ease of assembly is improved, but resistance to thermal cycling and MMOD impacts deteriorates
Solution Approach 1:
Within each modular unit, the flow tubes and heat-rejection sheets are merged into a single extruded structure, eliminating vulnerable joints at critical locations. This merging maintains ease of assembly through modular construction while dramatically improving resistance to thermal cycling and MMOD impacts by removing joint interfaces.
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 solution provides durable, lightweight radiator assemblies that effectively manage heat transfer and withstand environmental stresses, enhancing operational reliability and scalability while reducing critical failure points and damage from micrometeoroids and debris.
Implementation Method 1
at least one solid-state-welding facilitator structured and arranged to facilitate fixedly joining such at least one modular engager to at least one other such modular engager by at least one solid-state welding process
Implementation Method 2
forming at least one radiator assembly by fixedly joining such selected combination of such thermal-transfer modules and such at least one modular spacers using one or more substantially continuous welds, wherein such substantially continuous weld is formed by at least one friction-stir-weld process
Implementation Method 3
a thermal-interaction facesheet comprising a sheet-surface area structured and arranged to thermally interact with the at least one surrounding environment
Data Source
AI summary
A system of spacecraft radiators comprising pre-formed thermal-transfer modules joined together by at least one solid-state welding process. Critical failure points are eliminated by forming the thermal-transfer modules as a single unitary piece, preferably by an extrusion process. The thermal-transfer modules allow the formation of larger radiator assemblies, which may comprise a wide range of sizes and physical geometries.