US20200127151A1 - Multi-mission modular array - Google Patents
Multi-mission modular array Download PDFInfo
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- US20200127151A1 US20200127151A1 US16/719,860 US201916719860A US2020127151A1 US 20200127151 A1 US20200127151 A1 US 20200127151A1 US 201916719860 A US201916719860 A US 201916719860A US 2020127151 A1 US2020127151 A1 US 2020127151A1
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- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/041—Provisions for preventing damage caused by corpuscular radiation, e.g. for space applications
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- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
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- B64G—COSMONAUTICS; VEHICLES OR EQUIPMENT THEREFOR
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- B64G1/22—Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
- B64G1/222—Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles for deploying structures between a stowed and deployed state
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B64G1/22—Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
- B64G1/42—Arrangements or adaptations of power supply systems
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B64G1/22—Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
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- H01L31/02—Details
- H01L31/02002—Arrangements for conducting electric current to or from the device in operations
- H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
- H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/0248—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies
- H01L31/036—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes
- H01L31/0392—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate
- H01L31/03926—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate comprising a flexible substrate
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- H—ELECTRICITY
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- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
- H01L31/0508—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module the interconnection means having a particular shape
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
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- H—ELECTRICITY
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- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S30/00—Structural details of PV modules other than those related to light conversion
- H02S30/20—Collapsible or foldable PV modules
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the disclosure including accompanying figure(s) (“disclosure”) relates in general to solar arrays, and in particular to, for example, without limitation, lightweight flexible solar arrays such as multi-mission modular arrays.
- the description provided in the background section should not be assumed to be prior art merely because it is mentioned in or associated with the background section.
- the background section may include information that describes one or more aspects of the subject technology.
- Flexible arrays have typically provided improvements in stowed volume and reduced mass compared to conventional “rigid” panel arrays. Properties such as reduced volume and mass are important to spacecraft designers interested in maximizing payload volume and mass of conventional arrays.
- disadvantages in providing the aforementioned properties as improvements to conventional arrays generally take the form of increased mechanical complexity and cost. In particular, flexible array costs are driven by mechanically complex deployer assemblies that create a large structural spar or mast from a compact stowed assembly.
- a system for compact stowage and deployment of a flexible solar array includes a deployer unit and a blanket container for containing the flexible solar array.
- the deployer unit includes a closed-section collapsible mast for deploying and supporting the solar array, a mast stowage reel for supporting the mast in a stowed state, and an actuator coupled to the mast to drive the mast from the stowed state to a deployed state.
- the stowage reel includes a pair of wheels interposed by a plurality of rods coupling the pair of wheels to each other, and the collapsible mast configured to be reeled about the plurality of rods in the stowed state.
- the blanket container is rotationally coupled to a structural frame of the deployer unit.
- a side surface thereof In a stowed state of the blanket container, a side surface thereof is oriented facing the structural frame.
- the side surface In a deployed state of the blanket container, the side surface is oriented perpendicular to a longitudinal axis of the mast.
- a solar array comprising includes a semi-conductive substrate blanket material, a plurality of solar cells mounted to the semi-conductive substrate blanket material to form a solar power supply network, and a series of circuit paths formed on the semi-conductive substrate blanket material.
- the series of circuit paths are formed for electrically connecting the solar cells together within the solar power supply network.
- the flexible semi-conductive substrate blanket material is configured to (1) dissipate current across the power supply network to minimize solar arcing and (2) isolate power circuits within the power supply network.
- FIG. 1 illustrates a system for compact stowage and deployment of a flexible solar array, according to some embodiments of the present disclosure.
- FIG. 2 illustrates the system of FIG. 1 with a deployed blanket container containing the flexible solar array prior to deployment of the array, according to some embodiments of the present disclosure.
- FIG. 3 illustrates a perspective view of a closed-section mast of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 4 illustrates one of the first and second first and second halves of the closed-section mast of FIG. 3 , according to some embodiments of the present disclosure.
- FIG. 5 illustrates a perspective view of a sleeve for supporting the mast of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 6A illustrates a first perspective view of a mast stowage reel of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 6B is a cross-sectional view of the mast stowage reel of the system of FIG. 1 with the mast stowed thereon, according to some embodiments of the present disclosure.
- FIG. 6C illustrates a second perspective view of the mast stowage reel of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 7A illustrates a side view of an actuator of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 7B illustrates a front view of the actuator of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 7C illustrates an enlarged partial view of the actuator engaged with the mast of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 8 illustrates a flexible solar array contained in the blanket container of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 9A is a perspective view illustrating a solar array deployment assembly including a boom and yoke for deploying the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 9B illustrates a first deployment phase of the assembly of FIG. 9A , according to some embodiments of the present disclosure.
- FIG. 9C illustrates a second deployment phase of the assembly of FIG. 9A , according to some embodiments of the present disclosure.
- FIG. 1 illustrates a system for compact stowage and deployment of a flexible solar array, according to some embodiments of the present disclosure.
- FIG. 2 illustrates the system of FIG. 1 with a deployed blanket container containing the flexible solar array prior to deployment of the array, according to some embodiments of the present disclosure.
- a system 100 for compact stowage and deployment of a flexible solar array may include a deployer unit 101 and a blanket container 140 for containing the flexible solar array.
- the deployer unit 101 has a frame 110 having a first section 111 extending along a vertical plane and a second section 112 extending along a horizontal plane.
- the blanket container 140 is pivotably coupled to the second section 112 of the frame 110 through at least one hinge 174 .
- This configuration advantageously allows for the blanket container to be rotatable about an axis X 1 (illustrated in FIG. 9A ) between a stowed position during launch (illustrated in FIG. 9 ), and an upright deployed position prior to deployment of the solar array (illustrated in FIG. 2 ).
- the blanket container 140 in the stowed position, the blanket container 140 may be oriented facing the second section 112 of the frame 110 .
- the blanket container 140 is disposed lying flat against, or directly above the second section 112 of the frame 110 .
- the blanket container 140 is oriented parallel to the vertical plane, and perpendicular to a longitudinal axis of the mast 115 .
- the deployer unit 101 may include a closed-section collapsible mast 115 for deploying and supporting the solar array, a stowage reel 120 for supporting the mast in a stowed state, and an actuator 135 coupled to the mast 115 to drive the mast 115 from the stowed state to a deployed state.
- FIG. 3 illustrates a perspective view of a closed-section mast of the system of FIG. 1 , according to some embodiments of the present disclosure.
- the mast 115 includes a plurality of grommets 117 .
- the grommets 117 are engaged by the protrusions 136 of the rotating interface 135 (illustrated in FIGS. 7A-7C ) to drive and deploy the mast 115 .
- the closed-section mast 115 may be fabricated by bonding first and second mast shells 145 , 147 together. As bonded, the two shells 145 , 147 form a lenticular cross-sectional shape capable of withstanding both torsional and bending loads.
- the first and second mast shells 145 , 147 may be composite shell structures that are cured with a continuous layer of carbon fiber.
- the aforementioned configuration advantageously yields a mast formed with reduced part count, and having the capability to withstand occurrence of lengthwise splices thereon.
- conventional tri and quad longeron lattice masts traditionally include multiple pieces which require lengthwise splice-joints in order for the masts to be rolled up and stowed. Further, the lengthwise splice-joints can fail on orbit due to load and thermal cycling.
- the aforementioned configuration provides advantages over conventional composite masts that are traditionally formed of one shell structure (e.g., a tube wrapped mandrel), these masts typically require a slit lengthwise to remove the mast from the mold (after manufacture) and to roll up to stow in orbit.
- the lengthwise slit makes an “open section” mast which has no torsion capability.
- conventional composite masts traditionally include multi-piece masts in fixed length autoclaves requiring lengthwise splice-joints which can fail on orbit due to load and thermal cycling.
- the various aspects of this disclosure present a solution to the aforementioned deficiencies by providing the closed-section mast which uses fewer parts than conventional tri and quad longeron lattice masts.
- the lenticular closed-section structure of the mast is capable of supporting both bending and torsional loads with a single deployer and mast per array, which open (i.e., slit) masts cannot efficiently support without collapsing.
- the mast 115 may be formed of a light-weight material having a low co-efficient of thermal expansion (CTE).
- CTE co-efficient of thermal expansion
- the mast 115 may be formed of, but not limited to, a carbon fiber material. This is in contrast to conventional composite masts formed of metallic elements, and which are generally heavier and have a higher CTE than carbon fiber material. The higher CTE is disadvantageous in that the mast can be adversely affected by extreme heating and cooling based on period of on-and-off exposure to the sun.
- the mast 115 may be formed of an aramid fiber material, a carbon and aramid fiber blend material, or a glass fiber material.
- FIG. 4 illustrates one of the first and second first and second halves 145 , 147 of the closed-section mast of FIG. 3 , according to some embodiments of the present disclosure.
- the mast 115 may be formed using a mold 148 to mold a continuous layer of carbon fiber material in an out-of-autoclave process.
- This method of manufacture is advantageous in that the length of the mast 115 is not limited by the size of the autoclave pressure vessel, as with conventional masts.
- Conventional methods of forming masts generally involve processing and curing the composite mast material in an autoclave pressure vessel.
- the autoclave vessels are generally limited in size to a maximum of 60 feet long. The various embodiments described herein thus are capable of producing lenticular masts lengths which are greater than 60 feet long, due to the out-of-autoclave manufacturing process.
- FIG. 5 illustrates a perspective view of a sleeve for supporting the mast of the system of FIG. 1 , according to some embodiments of the present disclosure.
- the system 100 further includes sleeve 160 for anchoring and strengthening the mast 115 in the deployed state. Due to the collapsible nature of the mast 115 , the sleeve 160 is provided to reinforce the stiffness of the mast 115 in the deployed state. To this effect, the sleeve has a shape which corresponds to the shape of the mast 115 .
- the sleeve 160 is designed with an inner perimeter that is slightly larger than an outer perimeter of the mast 115 so as to allow the mast 115 to be inserted into the sleeve 160 as illustrated in FIG.
- the sleeve 160 is disposed over the outer perimeter of the deployed mast 115 .
- the sleeve 160 includes a linear portion and a plurality of curved portions coupled to, and extending along the length of the linear portion.
- the linear portion is disposed over the flanges 119 of the mast 115 and extends partially along the length of the deployed mast 115 .
- the sleeve 160 extends along the length, and up to the end of the second section 112 of the frame 110 .
- the curved portions extend over the first and second mast shells 145 , 147 and have the same curvature as the first and second mast shells 145 , 147 .
- the sleeve may thus provide enhanced deployed stiffness and strength to the flexible mast by providing peripheral base support at at least eight points along the length of the mast 115 .
- the aforementioned configuration is advantageous in preventing significant buckling and collapse of the mast 115 , thereby strengthening the deployed mast 115 to withstand higher loads.
- the sleeve 160 may be lined with a material configured to reduce friction between the mast and the sleeve. As the mast 115 is deployed into the sleeve 160 , the outer perimeter of the sleeve rubs against the inner perimeter of the sleeve. In order to reduce friction between the mast 115 and the sleeve 160 , the inner perimeter of the sleeve 160 is lined with a material which reduces friction, e.g. Teflon.
- FIG. 6A illustrates a first perspective view of a mast stowage reel of the system of FIG. 1 , according to some embodiments of the present disclosure.
- the mast 115 Prior to deployment, the mast 115 is stowed at least partially on the stowage reel 120 in a collapsed and flattened configuration. Whilst being retracted from the deployed phase to the stowed phase, the mast 115 is passed through pinch rollers 165 (illustrated in FIG. 1 ) to flatten the for storage on the stowage reel 120 .
- the stowage reel 120 is a lightweight body including a pair of wheels 125 interposed by a plurality of rods 130 which couple wheels 125 to each other.
- each of the rods 120 may be hollow tubular rods.
- the tubes 130 may be formed of a lightweight material, for example, but not limited to, carbon fiber or aluminum.
- the stowage reel 120 includes four rods 130 equally spaced from each other circumferentially about a rotational center of the wheels 125 .
- the reel 120 may alternatively include less than four rods 130 , or more than four rods 130 which are equally spaced apart from each circumferentially about a rotational center of the wheels 125 .
- the weight of the wheels 125 of the stowage reel 120 may further be reduced by forming the wheels 125 with a plurality of cut-outs 129 similar to spokes of a bicycle wheel.
- FIG. 6B is a cross-sectional view of the mast stowage reel of the system of FIG. 1 with the mast stowed thereon, according to some embodiments of the present disclosure.
- the mast 115 In the stowed state, at least a portion of the mast 115 is stowed on the reel 120 .
- the mast 115 is reeled around the rods 130 .
- the mast 115 may be retracted from the deployed state to the stowed and stowed as a flattened sheet on the reel 120 using a set of pinch rollers 165 (illustrated in FIGS. 1 and 2 ).
- the pinch rollers 165 are actuated to flatten the collapsible mast 115 to a planar form which is flexible enough to be stowed on the reel 120 .
- the mast 115 expands back to the almost strain-free state.
- the mast 115 In the stowed state, the mast 115 is biased to expanding outwards toward its original non-flattened (deployed) shape, thereby causing “strain pockets” S at various positions on the stowed mast 115 .
- the stowage reel 120 of the present disclosure advantageously allows the stowed mast 115 to expand and bulk out as necessary at the various positions S.
- the open reel structure with supporting rods 130 advantageously allows for localized deformation of the stowed mast in response to the high strain stowed conditions.
- the various embodiments described herein thus provide a deployment system having lighter weight as compared to conventional deployment systems.
- the storage drum for the mast is structured as an open reel so as to allow for localized deformation of the stowed mast in response to high strain stowed conditions.
- the aforementioned configuration provides further advantages over conventional stowage drums for masts which are traditionally closed-section drums which are heavier, impose geometric constraints on the inside of the stowed mast, and can increase local strain and stress thereby causing damage to the stowed structure.
- the system 100 may further include a constraint band 170 (illustrated in FIGS. 1 and 2 ) to prevent the mast 115 stowed on the stowage reel 120 from unreeling prior to deployment.
- the constraint band 170 may be tensioned uniformly by a constant force spring system (not shown).
- the constraint band is released and retracted into a compartment in the frame 110 .
- the aforementioned configuration is advantageous over conventional mast stowage systems in that a constant force spring system tensions the band uniformly even though the mast diameter is reduced as it deploys.
- the aforementioned configuration also accounts for any uneven “lobing” effect of the open reel drum.
- FIG. 6C illustrates a second perspective view of the mast stowage reel of the system of FIG. 1 , according to some embodiments of the present disclosure.
- the mast stowage reel may further include a latch 155 configured to maintain the mast stowage reel 120 in a locked position to prevent rotation during launch.
- the latch 155 includes a first end 156 having a pin 158 protruding therefrom, and a second end 157 .
- each of the wheels 125 may include a notch surface 127 including a plurality of notches 131 .
- the downward force on the latch 155 maintains the pin 158 in engagement with the one of the notches 131 , thereby locking the reel and preventing rotation thereof during launch.
- the force is removed from the latch 155 and the pin 158 disengages from the notch 131 .
- the reel 120 is then free to rotate as the mast 115 is deployed.
- drum latch is configured to be passively actuated as a result of the blanket container being deployed.
- the drum latch of the various embodiments described herein does not require a separate pin-puller or other actuator that could cause reliability issues, as is the case with traditional storage drums.
- FIG. 7A illustrates a side view of an actuator of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 7B illustrates a front view of the actuator 135 of the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 7C illustrates an enlarged partial view of the actuator 135 engaged with the mast 115 of the system of FIG. 1 , according to some embodiments of the present disclosure.
- the actuator 135 is configured to drive deployment of the mast 115 from the stowed state to a deployed state.
- the actuator 135 includes a motor 133 and a rotating interface 134 .
- the rotating interface 133 include a plurality of protrusions 136 which are configured to engage the grommets 117 of the mast 115 to drive deployment and retraction of the mast 115 as desired.
- the actuator 135 is advantageously reversible on orbit to facilitate both retraction and deployment of the mast.
- the deployer unit may further include a controller communicatively coupled to the actuator 135 for deployment and retraction of the mast 115 and the mast 115 upon a control command of the controller.
- FIG. 8 illustrates a flexible solar array 800 contained in the blanket container 140 of the system of FIG. 1 , according to some embodiments of the present disclosure.
- the flexible solar array 800 includes a flexible semi-conductive substrate blanket material 802 on which a plurality of solar cells, e.g., 806 a - 806 i are mounted or fabricated.
- the plurality of solar cells 806 a - 806 i are mounted to the flexible semi-conductive substrate blanket material 802 to form a solar power supply network of the flexible solar array 800 .
- the flexible solar array 800 may include a plurality of panels 804 a - 804 f .
- Each panel 804 a - 804 f may include a set of solar cells 806 a - 806 i . As depicted, each panel 804 a - 804 f includes nine solar cells 806 a - 806 i . However, the aforementioned configuration is not limited thereto, and the panels 804 a - 804 f may include more or less solar cells as desired.
- the flexible semi-conductive substrate blanket material 802 is made of charge dissipative material (e.g., charge dissipative Kapton, black Kapton or a charge dissipative polyimide).
- charge dissipative Kapton may be formed by adding indium tin oxide (ITO) to the conventionally used yellow or gold Kapton to increase the conductivity of the yellow or gold Kapton so that the resultant Kapton material is charge dissipative.
- ITO indium tin oxide
- the flexible substrate blanket of the various embodiments described herein includes improvements over the state of the art to minimize solar array charging and dissipation via arcing discharges.
- the flexible substrate blanket 802 may include a semi-conductive, charge dissipative black poly (4,4′-oxydiphenylene-pyromellitimide) “Kapton” material that reduces or eliminates on-orbit arcing by bleeding charge to the power circuit so as to prevent high voltage potentials from occurring.
- the semi-conductive, charge dissipative flexible blanket substrate material is additionally capable of isolating the power circuits sufficiently to avoid short circuits.
- the aforementioned configuration is advantageous relative to conventional non-conductive yellow or gold Kapton material which is susceptible to electrostatic discharge (arcing).
- the black Kapton achieves a balance between being conductive and non-conductive such that desirable power, current or voltage to be transmitted through the flexible solar array 800 (cells and panels) is not lost through dissipation.
- the black Kapton is conductive enough to dissipate the arc or undesirable energy spike throughout the black Kapton substrate such that the voltage seen by cells 806 a - i of the solar array 802 is maintained as a very small voltage potential. For example, the excess charge resulting from the arc or undesirable energy spike is dissipated throughout the power circuits of the flexible solar array 800 .
- the flexible semi-conductive substrate blanket material 802 is a foldable flexible substrate.
- foldable flexible substrate blanket material 802 includes a plurality of panels 804 a - 804 f which may be folded together in a stowed configuration, and unfolded or extended in a deployed configuration.
- the flexible solar array 800 may further include a plurality of hinge pins 812 interposed between adjacent panels to hingedly couple the adjacent panels 804 b - 804 f .
- the hinge pins 812 are made of a material configured to enhance stiffness of the blanket material 802 in the location where adjacent panels are joined together.
- the hinge pins 812 may be formed of a carbon fiber material which may improve blanket stiffness of the deployed flexible semi-conductive substrate blanket material 802 .
- the aforementioned configuration is advantageous over conventional hinging mechanisms which traditionally employ a thin fiberglass material which provides minimal stiffness to the blanket material when deployed.
- the hinge pins of the various embodiments described herein improve stiffness of the deployed blanket material and facilitate easier blanket panel integration during assembly.
- circuit paths 810 a and 810 b of the flexible solar array may traverse the flexible semi-conductive substrate blanket material 802 .
- the circuit paths 810 a and 810 b electrically connect the solar cells 806 a - 806 i together within the solar power supply network.
- the flexible semi-conductive substrate blanket material 802 is configured to (1) dissipate current across the power supply network to minimize solar arcing and (2) isolate power circuits (not shown) within the power supply network.
- the power circuits provide electrical capacity to operate a load, e.g., on a spacecraft.
- the power supply comes from the flexible solar array 800 .
- the flexible semi-conductive substrate blanket material 802 isolates the power circuits from undesirable energy spikes (e.g., arcing). Otherwise, the power circuits are subject to the undesirable energy spikes.
- the circuit paths 810 a and 810 b , and the corresponding solar cells may be part of or coupled to the power circuits.
- the solar cells 806 a - 806 i in each of the panels 804 a - 804 f may be coupled to each other in accordance with a series or parallel configuration to form a string of cells in the respective set of solar cells.
- a series connected set of solar cells or panels forms a string of solar cells.
- the sets of solar cells 804 a , 804 c and 804 e may be connected in series to form a first string.
- the sets of solar cells 804 b , 804 d and 804 f may be connected in series to form a second string.
- the combination of series and parallel connections may lead to several problems in solar arrays.
- One potential problem is that the solar array 800 or a subset of the solar cells in the solar array 800 may be subjected to undesirable energy spikes (e.g., arcing).
- the flexible solar array 800 includes a series of blocking diodes (e.g., blocking diodes 814 a - 814 f ) disposed on the flexible semi-conductive substrate blanket material 802 within the electrically conductive circuit paths 810 a and 810 b .
- the blocking diodes 814 a - 814 f prevent damage to the flexible solar array 800 in the presence of the arc or undesirable energy spike.
- the blocking diodes 814 a - 814 f prevent the solar power supply network (including solar cells 806 a - 806 i and/or the corresponding plurality of panels 804 a - 804 f not affected by the arc or undesirable energy spike) from back feeding (power, current or voltage) into the one string of cells that has a trigger arc or undesirable energy spike.
- the diodes may be positioned on the panels 804 a - 804 f or between the modules panels 804 a - 804 f . The aforementioned configuration is advantageous over conventional solar arrays which traditionally utilize bypass diodes positioned in a separate discreet box below the blanket material.
- FIG. 9A is a perspective view illustrating a solar array deployer assembly including a boom and yoke for deploying the system of FIG. 1 , according to some embodiments of the present disclosure.
- FIG. 9B illustrates a first deployment phase of the assembly of FIG. 9A , according to some embodiments of the present disclosure.
- FIG. 9C illustrates a second deployment phase of the assembly of FIG. 9A , according to some embodiments of the present disclosure.
- a method of deploying the stowed solar array (MMA) includes a first phase and a second phase.
- the first phase begins with the solar array system (multi-mission modular array (MMA)) in the stowed state, as it would be folded against the side of a spacecraft not shown).
- the solar array is held to the spacecraft by several Launch Restraint Assemblies (LRAs) 163 (illustrated in FIG. 9A ).
- LRAs Launch Restraint Assemblies
- the blanket container 140 In the stowed position, the blanket container 140 is disposed lying flat on the second section 112 of the frame 110 in a compact configuration.
- the LRAs are released. Hinges are located on the boom 195 and yoke 190 to deploy the LRAs 163 and the solar array system 100 away from the spacecraft.
- the blanket container 140 is then rotated about the hinge 174 to translate the blanket container 140 to an orientation perpendicular to the second section 112 of the frame 110 .
- the boom 195 and the yoke 190 are fully deployed.
- the first phase places the mast 115 and blanket container 140 away from the side of the spacecraft, which enables the spacecraft payload panel (to which the solar array was originally restrained) to thermally radiate and cool the payload electronics devices.
- the first phase also positions the blanket container 140 so that the second phase, the active deployment of the solar panels of the flexible semi-conductive substrate blanket material, may begin.
- the second phase begins with deployment of the flexible solar array 800 from the blanket container 140 .
- the mast is then deployed using the actuators (illustrated in FIG. 9A ) and in turn deploys the panels of the solar array in a Z-unfolding manner.
- the mast continues to deploy the flexible blanket material 802 of the solar array 800 until unfolding of the Z-shaped solar array is completed.
- the second phase is complete when the mast has tensioned the deployed blanket structurally by pulling it between the mast tip and a lower tension bar of the solar array system (not shown).
- a clock signal may refer to one or more clock signals
- a control signal may refer to one or more control signals
- an input signal may refer to one or more input signals
- an output signal may refer to one or more output signals
- a signal may refer to differential voltage signals.
- the term some refers to one or more.
- Pronouns in the masculine include the feminine and neuter gender (e.g., her and its) and vice versa. Headings and subheadings, if any, are used for convenience only and do not limit the invention.
- phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology.
- a disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations.
- a disclosure relating to such phrase(s) may provide one or more examples.
- a phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.
- a term coupled or the like may refer to being directly coupled. In another aspect, a term coupled or the like may refer to being indirectly coupled.
- top, bottom, front, rear, side, horizontal, vertical, and the like refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Thus, such a term may extend upwardly, downwardly, diagonally, or horizontally in a gravitational frame of reference.
- a phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item).
- the phrase “at least one of” does not require selection of at least one item; rather, the phrase allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items.
- the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.
- the terms “substantially” and “approximately” may provide an industry-accepted tolerance for their corresponding terms and/or relativity between items. Such an industry-accepted tolerance may range from less than one percent to 20 percent.
Abstract
Description
- The present application is a divisional of the U.S. patent application Ser. No. 15/959,151 filed on Apr. 20, 2018 in the United States Patent and Trademark Office, which claims priority under 35 U.S.C. § 119 to Provisional Application No. 62/488,683 filed on Apr. 21, 2017, in the United States Patent and Trademark Office.
- Not applicable.
- The disclosure including accompanying figure(s) (“disclosure”) relates in general to solar arrays, and in particular to, for example, without limitation, lightweight flexible solar arrays such as multi-mission modular arrays.
- The description provided in the background section, including without limitation, any problems, features, solutions or information, should not be assumed to be prior art merely because it is mentioned in or associated with the background section. The background section may include information that describes one or more aspects of the subject technology.
- Space solar arrays have been in use for over 50 years, dating back to the Vanguard satellite launched in 1958. Lightweight “flexible” substrate space solar arrays have been in use for over 30 years, dating to the Solar Array Flight Experiment (SAFE), flown on the Space Shuttle in 1985. The largest and most powerful solar arrays in use are of similar flexible substrate type, on the International Space Station (ISS). These arrays have been in use for over 10 years.
- Flexible arrays have typically provided improvements in stowed volume and reduced mass compared to conventional “rigid” panel arrays. Properties such as reduced volume and mass are important to spacecraft designers interested in maximizing payload volume and mass of conventional arrays. However, disadvantages in providing the aforementioned properties as improvements to conventional arrays generally take the form of increased mechanical complexity and cost. In particular, flexible array costs are driven by mechanically complex deployer assemblies that create a large structural spar or mast from a compact stowed assembly.
- Numerous deployment methods have been used in conventional flexible substrate arrays, including open-section lenticular struts, nesting open section lenticular struts, and tri and quad-longeron lattice masts. However, these methods have presented drawbacks in terms of reduced stiffness, higher weight, and great complexity. In addition, the advent of higher power and higher voltage solar arrays has exposed reliability issues associated with solar particle charging leading to arcing discharges on the arrays.
- In one or more implementations, a system for compact stowage and deployment of a flexible solar array is provided that includes a deployer unit and a blanket container for containing the flexible solar array. The deployer unit includes a closed-section collapsible mast for deploying and supporting the solar array, a mast stowage reel for supporting the mast in a stowed state, and an actuator coupled to the mast to drive the mast from the stowed state to a deployed state. The stowage reel includes a pair of wheels interposed by a plurality of rods coupling the pair of wheels to each other, and the collapsible mast configured to be reeled about the plurality of rods in the stowed state. The blanket container is rotationally coupled to a structural frame of the deployer unit. In a stowed state of the blanket container, a side surface thereof is oriented facing the structural frame. In a deployed state of the blanket container, the side surface is oriented perpendicular to a longitudinal axis of the mast.
- In one or more implementations, a solar array comprising is provided that includes a semi-conductive substrate blanket material, a plurality of solar cells mounted to the semi-conductive substrate blanket material to form a solar power supply network, and a series of circuit paths formed on the semi-conductive substrate blanket material. The series of circuit paths are formed for electrically connecting the solar cells together within the solar power supply network. The flexible semi-conductive substrate blanket material is configured to (1) dissipate current across the power supply network to minimize solar arcing and (2) isolate power circuits within the power supply network.
- The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.
-
FIG. 1 illustrates a system for compact stowage and deployment of a flexible solar array, according to some embodiments of the present disclosure. -
FIG. 2 illustrates the system ofFIG. 1 with a deployed blanket container containing the flexible solar array prior to deployment of the array, according to some embodiments of the present disclosure. -
FIG. 3 illustrates a perspective view of a closed-section mast of the system ofFIG. 1 , according to some embodiments of the present disclosure. -
FIG. 4 illustrates one of the first and second first and second halves of the closed-section mast ofFIG. 3 , according to some embodiments of the present disclosure. -
FIG. 5 illustrates a perspective view of a sleeve for supporting the mast of the system ofFIG. 1 , according to some embodiments of the present disclosure. -
FIG. 6A illustrates a first perspective view of a mast stowage reel of the system ofFIG. 1 , according to some embodiments of the present disclosure. -
FIG. 6B is a cross-sectional view of the mast stowage reel of the system ofFIG. 1 with the mast stowed thereon, according to some embodiments of the present disclosure. -
FIG. 6C illustrates a second perspective view of the mast stowage reel of the system ofFIG. 1 , according to some embodiments of the present disclosure. -
FIG. 7A illustrates a side view of an actuator of the system ofFIG. 1 , according to some embodiments of the present disclosure. -
FIG. 7B illustrates a front view of the actuator of the system ofFIG. 1 , according to some embodiments of the present disclosure. -
FIG. 7C illustrates an enlarged partial view of the actuator engaged with the mast of the system ofFIG. 1 , according to some embodiments of the present disclosure. -
FIG. 8 illustrates a flexible solar array contained in the blanket container of the system ofFIG. 1 , according to some embodiments of the present disclosure. -
FIG. 9A is a perspective view illustrating a solar array deployment assembly including a boom and yoke for deploying the system ofFIG. 1 , according to some embodiments of the present disclosure. -
FIG. 9B illustrates a first deployment phase of the assembly ofFIG. 9A , according to some embodiments of the present disclosure. -
FIG. 9C illustrates a second deployment phase of the assembly ofFIG. 9A , according to some embodiments of the present disclosure. - It is understood that various configurations of the subject technology will become readily apparent to those skilled in the art from the disclosure, wherein various configurations of the subject technology are shown and described by way of illustration. As will be realized, the subject technology is capable of other and different configurations and its several details are capable of modification in various other respects, all without departing from the scope of the subject technology. Accordingly, the summary, drawings and detailed description are to be regarded as illustrative in nature and not as restrictive
- The detailed description set forth below is intended as a description of various configurations of the subject technology and is not intended to represent the only configurations in which the subject technology may be practiced. The appended drawings are incorporated herein and constitute a part of the detailed description. The detailed description includes specific details for the purpose of providing a thorough understanding of the subject technology. However, it will be apparent to those skilled in the art that the subject technology may be practiced without these specific details. In some instances, well-known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the subject technology. Like components are labeled with identical element numbers for ease of understanding.
-
FIG. 1 illustrates a system for compact stowage and deployment of a flexible solar array, according to some embodiments of the present disclosure.FIG. 2 illustrates the system ofFIG. 1 with a deployed blanket container containing the flexible solar array prior to deployment of the array, according to some embodiments of the present disclosure. According to various aspects of the present disclosure, as illustrated inFIGS. 1 and 2 , asystem 100 for compact stowage and deployment of a flexible solar array may include adeployer unit 101 and ablanket container 140 for containing the flexible solar array. As depicted, thedeployer unit 101 has aframe 110 having afirst section 111 extending along a vertical plane and asecond section 112 extending along a horizontal plane. - A. Hinged Blanket Container
- In the depicted embodiments, the
blanket container 140 is pivotably coupled to thesecond section 112 of theframe 110 through at least onehinge 174. This configuration advantageously allows for the blanket container to be rotatable about an axis X1 (illustrated inFIG. 9A ) between a stowed position during launch (illustrated inFIG. 9 ), and an upright deployed position prior to deployment of the solar array (illustrated inFIG. 2 ). As illustrated inFIG. 1 , in the stowed position, theblanket container 140 may be oriented facing thesecond section 112 of theframe 110. In the depicted example, theblanket container 140 is disposed lying flat against, or directly above thesecond section 112 of theframe 110. This configuration is advantageous as the overall size (height) of thesystem 100 is minimized during launching, prior to deployment. As illustrated inFIG. 2 , in the upright deployed position, prior to deployment of the solar array, theblanket container 140 is oriented parallel to the vertical plane, and perpendicular to a longitudinal axis of themast 115. - In contrast, currently existing solar array containment and stowage systems are typically designed with the blanket container and the deployer fixed at right angles relative to each other, with the blanket container in the upright position. Since the orientation of the blanket container relative to the deployer is fixed, it remains this way during launching and deployment. Thus, currently existing systems take up more stowed volume and lack the ability for compact stowage of the blanket container in comparison with the systems and methods of the various embodiments described herein.
- B. Deployer Unit
- 1. Closed-Section Lenticular Mast
- As illustrated in
FIGS. 1 and 2 , thedeployer unit 101 may include a closed-sectioncollapsible mast 115 for deploying and supporting the solar array, astowage reel 120 for supporting the mast in a stowed state, and anactuator 135 coupled to themast 115 to drive themast 115 from the stowed state to a deployed state. -
FIG. 3 illustrates a perspective view of a closed-section mast of the system ofFIG. 1 , according to some embodiments of the present disclosure. As depicted, themast 115 includes a plurality ofgrommets 117. In operation, thegrommets 117 are engaged by theprotrusions 136 of the rotating interface 135 (illustrated inFIGS. 7A-7C ) to drive and deploy themast 115. In some embodiments, the closed-section mast 115 may be fabricated by bonding first andsecond mast shells shells second mast shells - The aforementioned configuration provides advantages over conventional composite masts that are traditionally formed of one shell structure (e.g., a tube wrapped mandrel), these masts typically require a slit lengthwise to remove the mast from the mold (after manufacture) and to roll up to stow in orbit. The lengthwise slit makes an “open section” mast which has no torsion capability. Further, conventional composite masts traditionally include multi-piece masts in fixed length autoclaves requiring lengthwise splice-joints which can fail on orbit due to load and thermal cycling. The various aspects of this disclosure present a solution to the aforementioned deficiencies by providing the closed-section mast which uses fewer parts than conventional tri and quad longeron lattice masts. In addition, the lenticular closed-section structure of the mast is capable of supporting both bending and torsional loads with a single deployer and mast per array, which open (i.e., slit) masts cannot efficiently support without collapsing.
- In some embodiments, the
mast 115 may be formed of a light-weight material having a low co-efficient of thermal expansion (CTE). For example, themast 115 may be formed of, but not limited to, a carbon fiber material. This is in contrast to conventional composite masts formed of metallic elements, and which are generally heavier and have a higher CTE than carbon fiber material. The higher CTE is disadvantageous in that the mast can be adversely affected by extreme heating and cooling based on period of on-and-off exposure to the sun. In other embodiments, themast 115 may be formed of an aramid fiber material, a carbon and aramid fiber blend material, or a glass fiber material. -
FIG. 4 illustrates one of the first and second first andsecond halves FIG. 3 , according to some embodiments of the present disclosure. In accordance with some embodiments, themast 115 may be formed using a mold 148 to mold a continuous layer of carbon fiber material in an out-of-autoclave process. This method of manufacture is advantageous in that the length of themast 115 is not limited by the size of the autoclave pressure vessel, as with conventional masts. Conventional methods of forming masts generally involve processing and curing the composite mast material in an autoclave pressure vessel. However, the autoclave vessels are generally limited in size to a maximum of 60 feet long. The various embodiments described herein thus are capable of producing lenticular masts lengths which are greater than 60 feet long, due to the out-of-autoclave manufacturing process. -
FIG. 5 illustrates a perspective view of a sleeve for supporting the mast of the system ofFIG. 1 , according to some embodiments of the present disclosure. In some embodiments, thesystem 100 further includessleeve 160 for anchoring and strengthening themast 115 in the deployed state. Due to the collapsible nature of themast 115, thesleeve 160 is provided to reinforce the stiffness of themast 115 in the deployed state. To this effect, the sleeve has a shape which corresponds to the shape of themast 115. For example, thesleeve 160 is designed with an inner perimeter that is slightly larger than an outer perimeter of themast 115 so as to allow themast 115 to be inserted into thesleeve 160 as illustrated inFIG. 5 . As depicted, thesleeve 160 is disposed over the outer perimeter of the deployedmast 115. In particular, thesleeve 160 includes a linear portion and a plurality of curved portions coupled to, and extending along the length of the linear portion. In the deployed state, the linear portion is disposed over theflanges 119 of themast 115 and extends partially along the length of the deployedmast 115. In particular, thesleeve 160 extends along the length, and up to the end of thesecond section 112 of theframe 110. The curved portions extend over the first andsecond mast shells second mast shells mast 115. The aforementioned configuration is advantageous in preventing significant buckling and collapse of themast 115, thereby strengthening the deployedmast 115 to withstand higher loads. - In some embodiments, the
sleeve 160 may be lined with a material configured to reduce friction between the mast and the sleeve. As themast 115 is deployed into thesleeve 160, the outer perimeter of the sleeve rubs against the inner perimeter of the sleeve. In order to reduce friction between themast 115 and thesleeve 160, the inner perimeter of thesleeve 160 is lined with a material which reduces friction, e.g. Teflon. - 2. Mast Stowage Reel
-
FIG. 6A illustrates a first perspective view of a mast stowage reel of the system ofFIG. 1 , according to some embodiments of the present disclosure. Prior to deployment, themast 115 is stowed at least partially on thestowage reel 120 in a collapsed and flattened configuration. Whilst being retracted from the deployed phase to the stowed phase, themast 115 is passed through pinch rollers 165 (illustrated inFIG. 1 ) to flatten the for storage on thestowage reel 120. In the depicted embodiments, thestowage reel 120 is a lightweight body including a pair ofwheels 125 interposed by a plurality ofrods 130 whichcouple wheels 125 to each other. To further reduce the weight of thestowage reel 120, each of therods 120 may be hollow tubular rods. Additionally, thetubes 130 may be formed of a lightweight material, for example, but not limited to, carbon fiber or aluminum. In the depicted embodiments, thestowage reel 120 includes fourrods 130 equally spaced from each other circumferentially about a rotational center of thewheels 125. However, the various embodiments described herein are not limited to this configuration. Thereel 120 may alternatively include less than fourrods 130, or more than fourrods 130 which are equally spaced apart from each circumferentially about a rotational center of thewheels 125. As depicted, the weight of thewheels 125 of thestowage reel 120 may further be reduced by forming thewheels 125 with a plurality of cut-outs 129 similar to spokes of a bicycle wheel. -
FIG. 6B is a cross-sectional view of the mast stowage reel of the system ofFIG. 1 with the mast stowed thereon, according to some embodiments of the present disclosure. In the stowed state, at least a portion of themast 115 is stowed on thereel 120. In particular, as illustrated inFIG. 6B , themast 115 is reeled around therods 130. In operation, themast 115 may be retracted from the deployed state to the stowed and stowed as a flattened sheet on thereel 120 using a set of pinch rollers 165 (illustrated inFIGS. 1 and 2 ). Thepinch rollers 165 are actuated to flatten thecollapsible mast 115 to a planar form which is flexible enough to be stowed on thereel 120. During deployment, themast 115 expands back to the almost strain-free state. - In the stowed state, the
mast 115 is biased to expanding outwards toward its original non-flattened (deployed) shape, thereby causing “strain pockets” S at various positions on the stowedmast 115. As illustrated inFIG. 6B , since themast 115 is stowed about therods 130, thestowage reel 120 of the present disclosure advantageously allows the stowedmast 115 to expand and bulk out as necessary at the various positions S. Thus, the open reel structure with supportingrods 130 advantageously allows for localized deformation of the stowed mast in response to the high strain stowed conditions. The various embodiments described herein thus provide a deployment system having lighter weight as compared to conventional deployment systems. To achieve this, the storage drum for the mast is structured as an open reel so as to allow for localized deformation of the stowed mast in response to high strain stowed conditions. The aforementioned configuration provides further advantages over conventional stowage drums for masts which are traditionally closed-section drums which are heavier, impose geometric constraints on the inside of the stowed mast, and can increase local strain and stress thereby causing damage to the stowed structure. - In some embodiments, the
system 100 may further include a constraint band 170 (illustrated inFIGS. 1 and 2 ) to prevent themast 115 stowed on thestowage reel 120 from unreeling prior to deployment. In the stowed state of the mast, theconstraint band 170 may be tensioned uniformly by a constant force spring system (not shown). When the mast is ready to be deployed, the constraint band is released and retracted into a compartment in theframe 110. The aforementioned configuration is advantageous over conventional mast stowage systems in that a constant force spring system tensions the band uniformly even though the mast diameter is reduced as it deploys. The aforementioned configuration also accounts for any uneven “lobing” effect of the open reel drum. -
FIG. 6C illustrates a second perspective view of the mast stowage reel of the system ofFIG. 1 , according to some embodiments of the present disclosure. As illustrated inFIG. 6C , the mast stowage reel may further include alatch 155 configured to maintain themast stowage reel 120 in a locked position to prevent rotation during launch. Thelatch 155 includes afirst end 156 having apin 158 protruding therefrom, and asecond end 157. Additionally, each of thewheels 125 may include anotch surface 127 including a plurality ofnotches 131. During launch, at least a portion of thecontainer 140 rests on thelatch 155, thereby applying a downward force on thelatch 155. The downward force on thelatch 155 maintains thepin 158 in engagement with the one of thenotches 131, thereby locking the reel and preventing rotation thereof during launch. When theblanket container 140 is rotated to the upright position in preparation for deployment, as illustrated inFIG. 2 , the force is removed from thelatch 155 and thepin 158 disengages from thenotch 131. Thereel 120 is then free to rotate as themast 115 is deployed. - The aforementioned configuration provides advantages over conventional stowage methods employing traditional storage drums in that the drum latch is configured to be passively actuated as a result of the blanket container being deployed. Thus, the drum latch of the various embodiments described herein does not require a separate pin-puller or other actuator that could cause reliability issues, as is the case with traditional storage drums.
- 3. Actuator System
-
FIG. 7A illustrates a side view of an actuator of the system ofFIG. 1 , according to some embodiments of the present disclosure.FIG. 7B illustrates a front view of theactuator 135 of the system ofFIG. 1 , according to some embodiments of the present disclosure.FIG. 7C illustrates an enlarged partial view of theactuator 135 engaged with themast 115 of the system ofFIG. 1 , according to some embodiments of the present disclosure. Theactuator 135 is configured to drive deployment of themast 115 from the stowed state to a deployed state. As depicted, theactuator 135 includes amotor 133 and a rotating interface 134. Therotating interface 133 include a plurality ofprotrusions 136 which are configured to engage thegrommets 117 of themast 115 to drive deployment and retraction of themast 115 as desired. Theactuator 135 is advantageously reversible on orbit to facilitate both retraction and deployment of the mast. The deployer unit may further include a controller communicatively coupled to theactuator 135 for deployment and retraction of themast 115 and themast 115 upon a control command of the controller. - A. Flexible Semi-Conductive Substrate Blanket Material
-
FIG. 8 illustrates a flexiblesolar array 800 contained in theblanket container 140 of the system ofFIG. 1 , according to some embodiments of the present disclosure. As depicted, the flexiblesolar array 800 includes a flexible semi-conductivesubstrate blanket material 802 on which a plurality of solar cells, e.g., 806 a-806 i are mounted or fabricated. The plurality of solar cells 806 a-806 i are mounted to the flexible semi-conductivesubstrate blanket material 802 to form a solar power supply network of the flexiblesolar array 800. For example, the flexiblesolar array 800 may include a plurality of panels 804 a-804 f. Each panel 804 a-804 f may include a set of solar cells 806 a-806 i. As depicted, each panel 804 a-804 f includes nine solar cells 806 a-806 i. However, the aforementioned configuration is not limited thereto, and the panels 804 a-804 f may include more or less solar cells as desired. - In contrast to conventional substrate blankets which are traditionally formed of a non-conductive yellow/gold Kapton material, the flexible semi-conductive
substrate blanket material 802 is made of charge dissipative material (e.g., charge dissipative Kapton, black Kapton or a charge dissipative polyimide). In some embodiments, charge dissipative Kapton may be formed by adding indium tin oxide (ITO) to the conventionally used yellow or gold Kapton to increase the conductivity of the yellow or gold Kapton so that the resultant Kapton material is charge dissipative. - The flexible substrate blanket of the various embodiments described herein includes improvements over the state of the art to minimize solar array charging and dissipation via arcing discharges. To achieve this, the
flexible substrate blanket 802 may include a semi-conductive, charge dissipative black poly (4,4′-oxydiphenylene-pyromellitimide) “Kapton” material that reduces or eliminates on-orbit arcing by bleeding charge to the power circuit so as to prevent high voltage potentials from occurring. The semi-conductive, charge dissipative flexible blanket substrate material is additionally capable of isolating the power circuits sufficiently to avoid short circuits. The aforementioned configuration is advantageous relative to conventional non-conductive yellow or gold Kapton material which is susceptible to electrostatic discharge (arcing). - In some embodiments, the black Kapton achieves a balance between being conductive and non-conductive such that desirable power, current or voltage to be transmitted through the flexible solar array 800 (cells and panels) is not lost through dissipation. The black Kapton is conductive enough to dissipate the arc or undesirable energy spike throughout the black Kapton substrate such that the voltage seen by cells 806 a-i of the
solar array 802 is maintained as a very small voltage potential. For example, the excess charge resulting from the arc or undesirable energy spike is dissipated throughout the power circuits of the flexiblesolar array 800. - In the depicted embodiments, the flexible semi-conductive
substrate blanket material 802 is a foldable flexible substrate. For example, foldable flexiblesubstrate blanket material 802 includes a plurality of panels 804 a-804 f which may be folded together in a stowed configuration, and unfolded or extended in a deployed configuration. The flexiblesolar array 800 may further include a plurality of hinge pins 812 interposed between adjacent panels to hingedly couple the adjacent panels 804 b-804 f. In some embodiments, the hinge pins 812 are made of a material configured to enhance stiffness of theblanket material 802 in the location where adjacent panels are joined together. For example, the hinge pins 812 may be formed of a carbon fiber material which may improve blanket stiffness of the deployed flexible semi-conductivesubstrate blanket material 802. The aforementioned configuration is advantageous over conventional hinging mechanisms which traditionally employ a thin fiberglass material which provides minimal stiffness to the blanket material when deployed. In contrast, the hinge pins of the various embodiments described herein improve stiffness of the deployed blanket material and facilitate easier blanket panel integration during assembly. - In accordance with various embodiments,
circuit paths substrate blanket material 802. For example, thecircuit paths substrate blanket material 802 is configured to (1) dissipate current across the power supply network to minimize solar arcing and (2) isolate power circuits (not shown) within the power supply network. The power circuits provide electrical capacity to operate a load, e.g., on a spacecraft. The power supply comes from the flexiblesolar array 800. In some embodiments, the flexible semi-conductivesubstrate blanket material 802 isolates the power circuits from undesirable energy spikes (e.g., arcing). Otherwise, the power circuits are subject to the undesirable energy spikes. Thecircuit paths - For example, the solar cells 806 a-806 i in each of the panels 804 a-804 f may be coupled to each other in accordance with a series or parallel configuration to form a string of cells in the respective set of solar cells. Similarly, a series connected set of solar cells or panels forms a string of solar cells. For example, the sets of
solar cells solar cells solar array 800 or a subset of the solar cells in thesolar array 800 may be subjected to undesirable energy spikes (e.g., arcing). - B. On-Panel Blocking Diodes
- In accordance with various embodiments, the flexible
solar array 800 includes a series of blocking diodes (e.g., blocking diodes 814 a-814 f) disposed on the flexible semi-conductivesubstrate blanket material 802 within the electricallyconductive circuit paths solar array 800 in the presence of the arc or undesirable energy spike. The blocking diodes 814 a-814 f prevent the solar power supply network (including solar cells 806 a-806 i and/or the corresponding plurality of panels 804 a-804 f not affected by the arc or undesirable energy spike) from back feeding (power, current or voltage) into the one string of cells that has a trigger arc or undesirable energy spike. The diodes may be positioned on the panels 804 a-804 f or between the modules panels 804 a-804 f. The aforementioned configuration is advantageous over conventional solar arrays which traditionally utilize bypass diodes positioned in a separate discreet box below the blanket material. Placing the diodes on the flexible solar array panel provides the advantage of improving thermal dissipation by avoiding the concentrated heat of a diode box, and decreasing complexity by allowing the solar array designer to combine strings into circuits while on the array without having to individually wire each string to the base, which might otherwise require a few hundred conductors, rather than a few dozen. In contrast, conventional flexible arrays traditionally place such diodes, if any, at the base of the solar array in a discreet box. -
FIG. 9A is a perspective view illustrating a solar array deployer assembly including a boom and yoke for deploying the system ofFIG. 1 , according to some embodiments of the present disclosure.FIG. 9B illustrates a first deployment phase of the assembly ofFIG. 9A , according to some embodiments of the present disclosure.FIG. 9C illustrates a second deployment phase of the assembly ofFIG. 9A , according to some embodiments of the present disclosure. In accordance with various embodiments, as illustrated inFIGS. 9A-9C , a method of deploying the stowed solar array (MMA) includes a first phase and a second phase. - The first phase begins with the solar array system (multi-mission modular array (MMA)) in the stowed state, as it would be folded against the side of a spacecraft not shown). In some embodiments, the solar array is held to the spacecraft by several Launch Restraint Assemblies (LRAs) 163 (illustrated in
FIG. 9A ). In the stowed position, theblanket container 140 is disposed lying flat on thesecond section 112 of theframe 110 in a compact configuration. In accordance with some aspects, the LRAs are released. Hinges are located on theboom 195 andyoke 190 to deploy the LRAs 163 and thesolar array system 100 away from the spacecraft. Theblanket container 140 is then rotated about thehinge 174 to translate theblanket container 140 to an orientation perpendicular to thesecond section 112 of theframe 110. At the end of the first phase, theboom 195 and theyoke 190 are fully deployed. The first phase places themast 115 andblanket container 140 away from the side of the spacecraft, which enables the spacecraft payload panel (to which the solar array was originally restrained) to thermally radiate and cool the payload electronics devices. The first phase also positions theblanket container 140 so that the second phase, the active deployment of the solar panels of the flexible semi-conductive substrate blanket material, may begin. - The second phase begins with deployment of the flexible
solar array 800 from theblanket container 140. As illustrated, the mast is then deployed using the actuators (illustrated inFIG. 9A ) and in turn deploys the panels of the solar array in a Z-unfolding manner. The mast continues to deploy theflexible blanket material 802 of thesolar array 800 until unfolding of the Z-shaped solar array is completed. The second phase is complete when the mast has tensioned the deployed blanket structurally by pulling it between the mast tip and a lower tension bar of the solar array system (not shown). - A reference to an element in the singular is not intended to mean one and only one unless specifically so stated, but rather one or more. For example, a clock signal may refer to one or more clock signals, a control signal may refer to one or more control signals, an input signal may refer to one or more input signals, an output signal may refer to one or more output signals, and a signal may refer to differential voltage signals.
- Unless specifically stated otherwise, the term some refers to one or more. Pronouns in the masculine (e.g., his) include the feminine and neuter gender (e.g., her and its) and vice versa. Headings and subheadings, if any, are used for convenience only and do not limit the invention.
- The word exemplary is used herein to mean serving as an example or illustration. Any aspect or design described herein as exemplary is not necessarily to be construed as preferred or advantageous over other aspects or designs. In one aspect, various alternative configurations and operations described herein may be considered to be at least equivalent.
- Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.
- In one aspect, unless otherwise stated, all measurements, values, ratings, positions, magnitudes, sizes, and other specifications that are set forth in this specification, including in the figures, are approximate, not exact. In one aspect, they are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain. In one aspect, some of the dimensions are for clarity of presentation and are not to scale.
- In one aspect, a term coupled or the like may refer to being directly coupled. In another aspect, a term coupled or the like may refer to being indirectly coupled.
- Terms such as top, bottom, front, rear, side, horizontal, vertical, and the like refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Thus, such a term may extend upwardly, downwardly, diagonally, or horizontally in a gravitational frame of reference.
- A phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase “at least one of” does not require selection of at least one item; rather, the phrase allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.
- In one or more aspects, the terms “substantially” and “approximately” may provide an industry-accepted tolerance for their corresponding terms and/or relativity between items. Such an industry-accepted tolerance may range from less than one percent to 20 percent.
- Various items may be arranged differently (e.g., arranged in a different order, or partitioned in a different way) all without departing from the scope of the subject technology. In one aspect of the disclosure, the elements illustrated in the accompanying figures may be performed by one or more modules or sub-modules.
- It is understood that the specific order or hierarchy of steps, operations or processes disclosed is an illustration of exemplary approaches. Based upon design preferences, it is understood that the specific order or hierarchy of steps, operations or processes may be rearranged. Some of the steps, operations or processes may be performed simultaneously. Some or all of the steps, operations, or processes may be performed automatically, without the intervention of a user. The accompanying figures may present elements of various steps, operations or processes in a sample order, and are not meant to be limited to the specific order or hierarchy presented.
- The disclosure is provided to enable any person skilled in the art to practice the various aspects described herein. The disclosure provides various examples of the subject technology, and the subject technology is not limited to these examples. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other aspects.
- All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in claims. No element is to be construed under the provisions of 35 U.S.C. § 112, sixth paragraph, unless the element is expressly recited using a phrase means for or, in the case of a method claim, the element is recited using the phrase step for. Furthermore, to the extent that the term include, have, or the like is used, such term is intended to be inclusive in a manner similar to the term comprise as comprise is interpreted when employed as a transitional word in a claim.
- The Title, Background, and Abstract of the disclosure are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the disclosure. In addition, in the Detailed Description, it can be seen that the description provides illustrative examples and the various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the disclosed subject matter requires more features than are expressly recited in claims of any application claiming priority hereto.
Claims (9)
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US16/719,860 US20200127151A1 (en) | 2017-04-21 | 2019-12-18 | Multi-mission modular array |
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US201762488683P | 2017-04-21 | 2017-04-21 | |
US15/959,151 US10546967B2 (en) | 2017-04-21 | 2018-04-20 | Multi-mission modular array |
US16/719,860 US20200127151A1 (en) | 2017-04-21 | 2019-12-18 | Multi-mission modular array |
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CN111907733A (en) * | 2020-06-28 | 2020-11-10 | 上海宇航系统工程研究所 | Flexible solar wing hinge structure |
CN112874821B (en) * | 2021-01-26 | 2022-07-12 | 深圳航天东方红卫星有限公司 | Solar sailboard driving mechanism for spacecraft and thermal design method thereof |
US20220267029A1 (en) * | 2021-02-23 | 2022-08-25 | Opterus Research and Development, Inc. | Boom deployer |
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- 2018-04-20 US US15/959,151 patent/US10546967B2/en active Active
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US10546967B2 (en) | 2020-01-28 |
EP3619116A4 (en) | 2021-04-28 |
WO2018195512A1 (en) | 2018-10-25 |
EP3619116A1 (en) | 2020-03-11 |
US20180309008A1 (en) | 2018-10-25 |
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