Stacked Satellite Assemblies for Space-Efficient Launch Deployment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The high cost of launching satellites and the need for effective structural designs that minimize weight, production costs, and launch preparation time while maximizing launch vehicle space utilization and ensuring efficient deployment in space.

Innovation Solution

A satellite assembly design featuring a central support structure spanning the housing, connected only at the first and second walls, with a cylindrical core structure configured for connection to a launch vehicle, allowing satellites to be stacked perpendicular to the launch axis and deployed horizontally, utilizing additively manufactured components for strength and customization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple satellites are deployed from a single launch vehicle to offset high launch costs, then the number of satellites per launch increases, but the launch vehicle space utilization and structural load management become more complex

Engineering Contradiction:

Improvenumber of satellites per launchVSAvoidlaunch vehicle space utilization and structural arrangement

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The satellite system is divided into modular units (CubeSats, microsats) that can be independently designed, manufactured, and stacked. Each satellite is a self-contained module with standardized interfaces, allowing multiple units to be combined in a launch vehicle without increasing overall system complexity. The support structure is also segmented into reusable and disposable portions, with each satellite having its own dedicated support structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal support structure design is provided that can accommodate different types and sizes of satellites (CubeSats, microsats, nanosats) through standardized mounting interfaces. The support structure serves multiple functions: structural support during launch, separation mechanism deployment, and post-separation guidance. This multi-functionality reduces the need for specialized components for each satellite type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If satellites are mounted to withstand high bending or torsional loads from selected mounting arrangements, then structural strength increases, but satellite weight and production costs increase

Engineering Contradiction:

Improvestructural strength to withstand launch loadsVSAvoidsatellite weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The support structure is pre-configured with optimized geometry and material distribution before satellite assembly. Finite element analysis and structural optimization are performed on the support structure design prior to manufacturing, ensuring maximum strength-to-weight ratio. The reusable support structure is pre-manufactured with precise tolerances to ensure proper load distribution during launch.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support structure utilizes advanced materials and manufacturing processes (additive manufacturing, composite materials) that enable significant weight reduction while maintaining or improving structural strength. Design parameters such as wall thickness, rib spacing, and material composition are optimized through iterative analysis to achieve the minimum weight configuration that still withstands launch loads.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If specialized mounting structures are engineered for each satellite to withstand launch forces, then reliability increases, but production costs and launch preparation time increase

Engineering Contradiction:

Improvesatellite launch reliabilityVSAvoidproduction cost and preparation time

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Inventive Principle:

Principle #10Preliminary action

4Volume of moving object

If limited launch vehicle space is maximized through optimized satellite arrangements, then space utilization increases, but structural design complexity and launch preparation time increase

Engineering Contradiction:

Improvelaunch vehicle space utilizationVSAvoidstructural design and preparation complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Satellites are arranged in three-dimensional stacked configurations within the launch vehicle, utilizing vertical and radial spaces efficiently. The support structures extend in multiple dimensions (longitudinal, radial, and circumferential directions) to provide optimal space utilization while maintaining structural integrity. This multi-dimensional arrangement maximizes the payload capacity of the launch vehicle.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20250269982A1Stacked satellite assemblies and related methods

Publication Date: 2025.08.28 THE BOEING CO

AI summary

A satellite apparatus is disclosed, including a housing having first and second opposing walls, and a support structure inside the housing spanning the first and second walls. The support structure is structurally connected to the housing only at the first and second walls, and an end portion of the support structure is configured for connection to a launch vehicle by a separation system.