Abstract

An elastically deployable panel structure for space solar array applications includes a support structure having a first stowed configuration and a second deployed configuration. The stowed configuration has elastic strain energy that powers deployment of the support structure. The elastically deployable panel structure does not include a boom. Longitudinal edges of the support structure may be curved downward to form an open cylinder when in the deployed configuration. The support structure is configured to be operable as a mounting surface for solar cell arrays.

IPC Classes  ?

• B64G 1/44 - Arrangements or adaptations of power supply systems using radiation, e.g. deployable solar arrays
• B64G 1/22 - Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
• H02S 30/20 - Collapsible or foldable PV modules

Abstract

A modular, lightweight, high-survivable, photovoltaic flexible blanket assembly for a space solar array is disclosed. The modular blanket is an accordion foldable or rollable flexible photovoltaic solar panel blanket assembly comprising a plurality of common photovoltaic modules spaced in an orthogonal pattern. Each module is mechanically attached with multiple low profile fasteners on their backside to an open weave mesh tensioned backplane structure. The backplane forms a tensioned dimensionally stable planar surface in the deployed configuration onto which the modules are suspended. Each module is common and comprised of a rectangular substrate that includes solar cell assemblies, circuitry, exposed electrical contacts for integration of blanket-level harnessing, and frontside and rearside shielding and coatings as required for the mission application. The blanket assembly may be dispersed with an open pattern of compliant and formable material on the backside to provide insulation against the vigorous vibration of the launch environment.

IPC Classes  ?

• H01L 31/044 - PV modules or arrays of single PV cells including bypass diodes
• H02S 30/20 - Collapsible or foldable PV modules
• H01L 31/041 - Provisions for preventing damage caused by corpuscular radiation, e.g. for space applications

Abstract

An elastic roll out boom includes a thin wall, tubular, elongate structure having a plurality of interlocking elements disposed in spaced-apart relation along the surface thereof. The elastic roll out boom is configured to be flattened and rolled tightly to form a roll in a stowed configuration. The plurality of interlocking elements are positioned such that a first interlocking element engages a second interlocking element when the elastic roll out boom is in the stowed configuration. This prevents shear displacement between layers of the roll out boom.

IPC Classes  ?

• B64G 1/44 - Arrangements or adaptations of power supply systems using radiation, e.g. deployable solar arrays
• B64G 1/22 - Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles

Abstract

A deployable root stiffness mechanism and method increases the bending and torsional stiffness and strength of a tubular slit boom while allowing the slit boom to be flattened and rolled to a compact stowage volume. The slit booms may be flattened and rolled into a compact cylindrical stowage volume and once released, elastically and immediately deploy from the rolled stowed configuration to the final structural tube shape. An embodiment of the disclosed apparatus comprises a base member which is engaging contact with a bottom surface of the tubular slit boom and a reaction member which translates along the base member as the tubular slit boom transitions between the storage configuration to the deployed configuration and between the deployed configuration to the storage configuration. The reaction member provides an opposing reactive force to a load conveyed through the thin-wall construction of the boom. The method provides a means for increasing the bending and torsional stiffness and strength of a tubular slit boom by reacting external loads through the boom walls into a structure which generally conforms to the shape of the boom as it is deployed.

IPC Classes  ?

• B64G 1/22 - Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
• B64G 1/10 - Artificial satellitesSystems of such satellitesInterplanetary vehicles

Abstract

An automated system provides automated manufacturing of photovoltaic standard power modules for utilization in a space solar array, in both rolled blanket and z-folded configurations. The automated system provides robotically controlled systems for CIC-ing, glassing, stringing, laydown and acceptance testing of interconnected photovoltaic devices. A method of manufacturing the photovoltaic standard power modules includes the steps of robotic positioning of diodes, interconnects and busbars onto a SPM stringing tray followed by the robotic positioning of bare cells into position adjacent to the diodes, interconnects and busbars to form strings. The SPM stringing tray is thereafter robotically positioned adjacent to an integral welder for welding of the front side of the string. Cover glass is thereafter robotically placed over the cells. The string is flipped and the backside of the string is robotically positioned for welding.

IPC Classes  ?

• B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
• H01L 31/18 - Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• B23K 9/00 - Arc welding or cutting
• H01L 31/041 - Provisions for preventing damage caused by corpuscular radiation, e.g. for space applications
• B23K 101/36 - Electric or electronic devices

Abstract

An automated system provides automated manufacturing of photovoltaic standard power modules for utilization in a space solar array, in both rolled blanket and z-folded configurations. The automated system provides robotically controlled systems for CIC-ing, glassing, stringing, laydown and acceptance testing of interconnected photovoltaic devices. A method of manufacturing the photovoltaic standard power modules includes the steps of robotic positioning of diodes, interconnects and busbars onto a SPM stringing tray followed by the robotic positioning of bare cells into position adjacent to the diodes, interconnects and busbars to form strings. The SPM stringing tray is thereafter robotically positioned adjacent to an integral welder for welding of the front side of the string. Cover glass is thereafter robotically placed over the cells. The string is flipped and the backside of the string is robotically positioned for welding.

IPC Classes  ?

• B23K 37/00 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
• H01L 31/18 - Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• H01L 31/041 - Provisions for preventing damage caused by corpuscular radiation, e.g. for space applications

Abstract

An elastically deployable three-dimensional panel structure for a solar array that can be collapsed to a flattened state and subsequently rolled, bended, or folded to achieve a compact stowage volume. The panel structure has top facing planar surface region on which one or more photovoltaic modules are attached, and other non-planar regions, located at the structure edges, that increase the deployed stiffness and strength of the structure. The deployable structure may include one or more panel structure modules mechanically interconnected in series and one or more photovoltaic modules electrically interconnected and mechanically adhered to the panel structure surface or tensioned within an openings within in the panel structure. Structural deployment is motivated by the elastic strain energy of the one or more panel structures from their stowed state. Deployment control is provided to ensure a known and repeatable deployment path through interlocking strips attached to one or more panel structures.

IPC Classes  ?

• B64G 1/44 - Arrangements or adaptations of power supply systems using radiation, e.g. deployable solar arrays
• B64G 1/42 - Arrangements or adaptations of power supply systems

Abstract

A large area, deployable flexible blanket photovoltaic solar array architecture for high power applications is disclosed. The structure is a modularized and scalable solar array system that provides high power level scalability. The structure is comprised of repeating, similar modular deployable roll-out solar array wings mounted in an opposing manner and along the length of a rigid, strong and efficiently packaged deployable backbone structure. The deployable roll-out solar array building block modular “winglet” elements can be comprised of either a rolled or z-folded flexible photovoltaic blanket configuration, and their structural deployment is motivated by the elastic strain energy of longitudinal roll-out booms. The backbone structure is comprised of a stiff deployable beam structure articulated that is deployed perpendicular with respect to the spacecraft sidewall and latched out. Deployment of the “winglets” can be conducted once the articulated backbone structure has been deployed, is latched, and forms a rigid beam.

IPC Classes  ?

• B64G 1/22 - Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
• B64G 1/44 - Arrangements or adaptations of power supply systems using radiation, e.g. deployable solar arrays

Abstract

A long, elastically deployable tubular boom structure consisting of two or more thin-walled booms with a continuous longitudinal slit-opening along its entire length on the backside and a composite reinforced or metallic construction. The slit-opening, thin-walled tubular section accompanied by the boom elastic properties and unique fastening method between the boom segments allows the segmented boom to be flattened and then rolled up into an extremely compact cylindrical stowage volume. The boom elastically and immediately deploys from a rolled stowed configuration under its own strain energy without use of a motor or other complicated actuators/mechanisms. The segmented construction of multiple tube elements allows for unlimited boom lengths and enables unlimited structure scaling. In addition, the segmented slit-boom construction minimizes the overall boom cost and allows for tailoring of the boom stiffness along its length and facilitates repair of the boom if a material flaw is identified or localized damage occurs.

IPC Classes  ?

• E04C 3/00 - Structural elongated elements designed for load-supporting
• B64G 1/22 - Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles

Abstract

A directionally-controlled roll-out elastically deployable solar array structure is disclosed. The structure includes one or more longitudinal elastic roll out booms that may be closed section or open section to allow for efficient rolled packaging onto a lateral mandrel. A flexible photovoltaic blanket is attached to a tip structure and to a lateral base support structure, but remains uncoupled from the longitudinal booms. The solar array system may be stowed simultaneously into a rolled package comprised of the roll out booms and the flexible planar blanket together, or onto independent rolls. Alternatively, the system may be stowed by rolling the booms, and accordion Z-folding the hinged flexible photovoltaic blanket into a flat stack. Structural deployment is motivated by the elastic strain energy of the roll out booms, and several methods of deployment direction control are provided to ensure a known, controlled, and unidirectional deployment path of the elastically unrolling booms.

IPC Classes  ?

• B64G 1/44 - Arrangements or adaptations of power supply systems using radiation, e.g. deployable solar arrays
• H02S 30/20 - Collapsible or foldable PV modules
• B64G 1/22 - Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
• E04H 12/18 - TowersMasts or polesChimney stacksWater-towersMethods of erecting such structures movable or with movable sections, e.g. rotatable or telescopic
• H01L 31/045 - collapsible or foldable

Abstract

A directionally-controlled roll-out elastically deployable solar array structure is disclosed. The structure includes one or more longitudinal elastic roll out booms that may be closed section or open section to allow for efficient rolled packaging onto a lateral mandrel. A flexible photovoltaic blanket is attached to a tip structure and to a lateral base support structure, but remains uncoupled from the longitudinal booms. The solar array system may be stowed simultaneously into a rolled package comprised of the roll out booms and the flexible planar blanket together, or onto independent rolls. Alternatively, the system may be stowed by rolling the booms, and accordion Z-folding the hinged flexible photovoltaic blanket into a flat stack. Structural deployment is motivated by the elastic strain energy of the roll out booms, and several methods of deployment direction control are provided to ensure a known, controlled, and unidirectional deployment path of the elastically unrolling booms.

IPC Classes  ?

• B64G 1/22 - Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
• H02S 30/20 - Collapsible or foldable PV modules
• B64G 1/44 - Arrangements or adaptations of power supply systems using radiation, e.g. deployable solar arrays
• E04H 12/18 - TowersMasts or polesChimney stacksWater-towersMethods of erecting such structures movable or with movable sections, e.g. rotatable or telescopic
• H01L 31/042 - PV modules or arrays of single PV cells
• H01L 31/045 - collapsible or foldable

Abstract

A directionally-controlled roll-out elastically deployable solar array structure is disclosed. The structure includes one or more longitudinal elastic roll out booms that may be closed section or open section to allow for efficient rolled packaging onto a lateral mandrel. A flexible photovoltaic blanket is attached to a tip structure and to a lateral base support structure, but remains uncoupled from the longitudinal booms. The solar array system may be stowed simultaneously into a rolled package comprised of the roll out booms and the flexible planar blanket together, or onto independent rolls. Alternatively, the system may be stowed by rolling the booms, and accordion Z-folding the hinged flexible photovoltaic blanket into a flat stack. Structural deployment is motivated by the elastic strain energy of the roll out booms, and several methods of deployment direction control are provided to ensure a known, controlled, and unidirectional deployment path of the elastically unrolling booms.

IPC Classes  ?

• E04H 12/18 - TowersMasts or polesChimney stacksWater-towersMethods of erecting such structures movable or with movable sections, e.g. rotatable or telescopic
• H01L 31/045 - collapsible or foldable

Abstract

A rollable and accordion foldable refractive lens concentrator flexible solar array blanket structure assembly for a spacecraft/satellite application consisting of at least one or more rows of electrically interconnected solar cells and at least one or more rows of deployable elongated refractive lenses elevated and aligned from the top surface of the solar cells. The entire blanket assembly, inclusive of lenses and solar cell substrates, kinematically deploys by unrolling or unfolding the assembly for its stowed package configuration, and the final tensioning of the blanket assembly produces an aligned assembly where the solar cell substrate subassembly and the lens subassembly are coplanar. Deployment of the integrated blanket assembly (with refractive lenses) is directly coupled through the unrolling or the accordion unfolding deployment kinematics of the concentrator blanket assembly.

IPC Classes  ?

• B64G 1/44 - Arrangements or adaptations of power supply systems using radiation, e.g. deployable solar arrays