Flattenable foldable boom hinge - Patent Review 6343442

Claims

What is claimed is:

1. A spacecraft boom assembly comprised of an elongate boom having at least one opening formed at a location along the boom wherein the at least one opening defines at least one folding region so as to permit the elongate boom to be folded about the at least one folding region to thereby reduce the length of the elongate boom and wherein the elongate boom is formed of a resilient material so as to store elastic energy when the elongate boom is in the folded configuration to thereby bias the folded elongate boom into an unfolded deployed state.

2. The assembly of claim 1, wherein the elongate boom further defines a plurality of rigid sections such that the at least one folding region is integrally interposed between the plurality of rigid sections.

3. The assembly of claim 2, wherein the at least one opening forms at least one connecting strip that interconnects adjacent rigid sections of the plurality of rigid sections, wherein the at least one connecting strip is biased into a first cross-sectional shape that inhibits bending of the at least one connecting strip along an axis that is perpendicular to the elongated axes of the adjacent rigid sections.

4. The assembly of claim 3, wherein the at least one opening comprises two adjacent openings that form two symmetrically shaped adjacently positioned connecting strips each having a first and second end.

5. The assembly of claim 4, wherein the connecting strips form an inner bow and an outer bow when the elongate boom is placed in the storage configuration so that elastic energy stored in the inner bow and outer bow will subsequently return the elongate boom into the deployed configuration.

6. The assembly of claim 5, wherein the opposing ends of the inner bow contact each other when the elongate boom is placed in the storage configuration so as to enable the stored elastic energy to be more readily converted into mechanical work which results in the deployment of the elongate boom.

7. The assembly of claim 4, wherein the first and second ends of each of the connecting strips are formed with a flared shape so as to extend from the adjacent rigid sections substantially along the entire circumference of the adjacent rigid sections and so as to enable the central region of the connecting strips to be deformed from the first cross-sectional shape so that the adjacent rigid sections can be folded about the folding region.

8. The assembly of claim 5, wherein each rigid section is formed with a length of 100 cm, an inner diameter of 38.0 mm, and an outer diameter of 38.5 mm.

9. The assembly of claim 6, wherein each connecting strip is formed with a length of 5 cm, an inner radius of curvature of 38 mm, an outer radius of curvature of 38.5 mm, and a width of 15 mm.

10. The assembly of claim 1, wherein the elongate boom is formed from glass fiber in an epoxy matrix having a tubular shape.

11. The assembly of claim 1, wherein the elongate boom is formed so as to extend in a linear manner.

12. The assembly of claim 1, wherein the elongate boom is capable of extending into the deployed configuration with a length of 2.095 m and folding into the storage configuration having a width of 60 mm, a length of 105 cm, and a depth of 15 cm.

13. The assembly of claim 1, wherein the elongate boom is formed so as to extend along multiple directions.

14. The assembly of claim 1, wherein the elongate boom further comprises a torsion stiffening assembly.

15. The assembly of claim 14, wherein the torsion stiffening assembly comprises a plurality of torsion stiffening elements that rigidly couple a first end and a second end of the folding region so as to inhibit the distance between the first and second ends of the folding region from increasing.

16. The assembly of claim 1, further comprising a latching mechanism that is adapted to retain the boom assembly in the storage configuration while the latching mechanism is in a latched state, wherein the boom assembly extends from the storage configuration to the deployed configuration when the latching mechanism is placed into an unlatched state.

17. A spacecraft boom assembly having a storage and a deployed configuration, the assembly comprising:

a first and a second mounting member; and

a foldable interconnection connected between the first and the second mounting members wherein the foldable interconnection is formed of an elastic material that is formed integrally with at least the first mounting member and in which the elastic material biases the foldable interconnection into a deployed configuration wherein the first and second mounting members are maintained in a deployed configuration such that the foldable interconnection rigidly maintains the first and second mounting members in a desired orientation with respect to each other such that the length of the boom assembly is a deployed length and wherein the foldable interconnection is adapted to permit release from the deployed configuration so that the first and second mounting members can be positioned in a storage configuration wherein the first and second mounting members can be positioned so as to reduce the length of the boom assembly.

18. The assembly of claim 17, wherein the foldable interconnection comprises at least one connecting strip that is biased into a first cross-sectional shape that inhibits bending of the at least one connecting strip along an axis that is perpendicular to the elongated axes of the first and second mounting members.

19. The assembly of claim 18, wherein the at least one connecting strip comprises two symmetrically shaped adjacently positioned connecting strips each having a first and second end.

20. The assembly of claim 19, wherein the connecting strips form an inner bow and an outer bow when the boom assembly is placed in the storage configuration so that elastic energy stored in the inner bow and outer bow will subsequently return the boom assembly into the deployed configuration.

21. The assembly of claim 20, wherein the opposing ends of the inner bow contact each other when the boom assembly is placed in the storage configuration so as to enable the stored elastic energy to be more readily converted into mechanical work which results in the deployment of the boom assembly.

22. The assembly of claim 19, wherein the first and second ends of each of the connecting strips are formed with a flared shape so as to extend from the first and second mounting members substantially along the entire circumference of the first and second mounting members and so as to enable the central region of the connecting strips to be deformed from the first cross-sectional shape so that the first and second mounting members can be folded about the foldable interconnection.

23. An elongate structural support member for a spacecraft comprising:

a first rigid member having a first and a second end;

a second rigid member having a first and a second end;

a foldable connecting member integrally attached to the first ends of the first and second rigid members so as to interconnect the first and second rigid members, wherein the foldable connecting member is bendable so as to allow the first and second rigid members to be positioned substantially adjacent each other substantially along the lengths of the first and second rigid members in a storage configuration and wherein the foldable connecting member is biased towards a deployed configuration wherein the first rigid member is rotated about the connecting member with respect to the second rigid member so that the first and second rigid members extend outward from the foldable connecting member.

24. The structural support member of claim 23, wherein the foldable connecting member is formed of a resilient material that is biased into a first cross sectional shape such that when the first and second rigid members are in the deployed configuration, the foldable connecting member has the first cross sectional shape which retains the first and second rigid members in the deployed configuration.

25. The structural support member of claim 24, wherein the foldable connecting member is released from the first cross sectional shape by exertion of force against a surface of the foldable connecting member to thereby allow the foldable connecting member to be folded to permit the first and second rigid members to be positioned in the storage configuration.

26. The structural support member of claim 25, wherein the first and second rigid members are formed of a resilient material that is biased into a second cross sectional shape such that when the first and second rigid members are in the deployed configuration, the first and second rigid members have the second cross sectional shape which provides the first and second rigid members with improved rigidity.

27. The structural support member of claim 26, wherein the first and second rigid members are released from the second cross sectional shape while the structural support member is placed in the storage configuration so as to reduce the size of the structural support member.

28. The structural support member of claim 27, wherein the connecting member comprises a first connecting strip having a first and second end and a second connecting strip having a first and second end, wherein the first end of the first and second connecting strips extend into the first end of the first rigid member, and wherein the second end of the first and second connecting strips extend into the first end of the second rigid member.

29. The structural support member of claim 28, wherein the first and second ends of each connecting strip is formed with a flared shape so as to more easily enable the connecting member to be released from the first cross-sectional shape so as to more easily enable the connecting member to be folded and so as to prevent stress fractures from forming along the first and second rigid members.

30. The structural support member of claim 29, wherein the first and second rigid members are formed of a thin walled tubular shaped material so that the second cross-sectional shape of the first and second rigid members is annular.

31. The structural support member of claim 30, wherein each of the connecting strips are formed with a concave inner surface and a convex outer surface, wherein the inner and outer surfaces are shaped so as respectively align in a substantial manner with the inner and outer surfaces of the first and second rigid members.

32. The structural support member of claim 31, wherein the first and second rigid members and the foldable connecting member are integrally formed from glass fiber in an epoxy matrix.

33. The structural support member of claim 32, further comprising a torsion stiffening assembly that provides additional torsional strength so as to inhibit a torsional stress from deforming the structural support member while in the deployed configuration.

34. The structural support member of claim 33, wherein the torsion stiffening assembly comprises a plurality of stiffening members that attach across the foldable connecting member in a diagonal manner so as to respectively couple the first and second ends of the first connecting member with the second and first ends of the second connecting member.

35. The structural support member of claim 34, wherein the first and second rigid members are each formed with a length of 100 cm, an inner diameter of 38 mm, an outer diameter of 38.5 mm.

36. The structural support member of claim 35, wherein the first and second connecting strips are formed with a length of 5 cm, an inner diameter of 38 mm, an outer diameter of 38.5 mm, and a width of 15 mm.

37. The structural support member of claim 23, wherein the first and second rigid members coaxially extend from each other in the deployed configuration.

38. The structural support member of claim 23, wherein the first and second rigid members perpendicularly extend from each other in the deployed configuration.

39. A boom assembly for a spacecraft comprising:

a first boom sub-assembly having a first and a second rigid section with a folding section interposed therebetween and integrally formed with the first and second rigid sections wherein the folding section enables the first and second rigid sections to be folded about the folding section to thereby reduce the length of the first boom sub-assembly in a storage configuration and wherein the folding section is biased so as to urge the first boom sub-assembly into a deployed configuration; and

a second boom sub-assembly having a first rigid section and a folding section wherein the second boom sub-assembly is mounted to the second rigid section of the first boom sub-assembly wherein the folding section of the second boom sub-assembly enables the first rigid section of the second boom sub-assembly to be folded with respect to the second rigid section of the first boom sub-assembly to reduce the length of the second boom sub-assembly with respect to the first boom sub-assembly.

40. The assembly of claim 39, wherein the first and second rigid members in the first boom sub-assembly extend in a first direction when the first boom sub-assembly is in the deployed configuration.

41. The assembly of claim 40, wherein the first rigid member of the second boom sub-assembly extends in a second direction, other than the first direction when the second boom sub-assembly is in the deployed configuration.

42. The assembly of claim 41, wherein the boom assembly is formed from glass fiber in an epoxy matrix having a tubular shape.

43. A structural support member for a spacecraft boom assembly, the support member comprising:

a plurality of rigid sections that include a first, a second, and a third rigid section; and

a plurality of foldable sections that interconnect the plurality of rigid sections and which are integrally formed with the plurality of rigid sections, wherein the plurality of foldable sections include a first foldable section that interconnects the first and second rigid sections and a second foldable section that interconnects the second and third rigid sections, wherein each of the foldable sections is formed of a resilient material having a shape that is biased into a rigid unfolded state such that the foldable sections rigidly interconnect the rigid sections so as to maintain the structural support member in a rigid deployed configuration, wherein each of the foldable sections is configurable into a strained folded state so as to enable the plurality of rigid members to be positioned substantially adjacent each other substantially along the lengths of the plurality of rigid members so as to place the structural support member in a storage configuration having a reduced size such that the first and second rigid sections are able to fold and unfold with respect to each other along a first plane and such that the second and third rigid sections are able to fold and unfold with respect to each other along a second plane, wherein the first and second planes intersect each other.

44. The assembly of claim 43, wherein the structural support member further comprises a torsion stiffening assembly.

45. The assembly of claim 44, wherein the torsion stiffening assembly comprises a plurality of torsion stiffening elements that rigidly couple a first end and a second end of each foldable section.

46. The assembly of claim 43, further comprising a latching mechanism that is adapted to retain the structural support member in the storage configuration while the latching mechanism is in a latched state, wherein the structural support member is allowed to extend from the storage configuration to the deployed configuration when the latching mechanism is placed into an unlatched state.

47. An elongate structural support member for a spacecraft comprising:

a first rigid section having a first and a second end and a first bending stiffness about an axis normal to the first rigid section;

a second rigid section having a first and a second end and a second bending stiffness about an axis normal to the second rigid section;

a foldable section connecting the first end of the first rigid section to the first end of the second rigid section, wherein the foldable section has a bending stiffness about an axis normal to the foldable section that is less than the first bending stiffness and the second bending stiffness, the foldable section being bendable so as to allow the first and second rigid sections to be positioned substantially adjacent each other in a first configuration wherein the foldable section stores elastic potential energy, and wherein the stored elastic potential energy biases the foldable section toward a second configuration wherein the first rigid section is rotated about the foldable section with respect to the second rigid section so that the first and second rigid sections extend outward from the foldable section.

48. The elongate structural support member of claim 47 wherein the foldable section comprises a pair of connecting strips.

49. The elongate structural support member of claim 48 wherein each of the pair of connecting strips is biased into a shape having a concave inner surface and a convex outer surface so as to resist bending about an axis normal to the foldable section of the elongate member.

50. A spacecraft boom assembly comprising an elongate boom and a means for facilitating the folding of the boom at a folding section, said folding of the boom permitting the length of the boom to be reduced in the folded configuration, and said folding also storing elastic energy in the folding section of the boom, the stored elastic energy biasing the folding section to an unfolded configuration.

51. The spacecraft boom assembly of claim 50 wherein the means for facilitating folding comprises a region of the boom constructed with reduced flexural stiffness.

52. A hinge element for a structural support for a spacecraft comprising a foldable member connecting a first section of the structural support to a second section of the structural support, wherein the foldable member is bendable so as to allow the first and second sections of the structural support to be positioned substantially adjacent each other in a first configuration of the hinge element and wherein the foldable member provides a bias towards a second configuration wherein the first section of the support is rotated about the foldable section with respect to the second section of the support so that the first and second sections of the

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to rocket-launched spacecraft and, in particular, relates to boom assemblies that deploy extendable components of the spacecraft.

2. Description of the Related Art

Rocket-launched spacecraft, which include orbiting satellites and deep space probes, perform increasingly complex tasks. In particular, telecommunication satellites enable vast amounts of information, including voice and data, to be sent and received around the globe. In other examples, satellites equipped with earth imaging devices enable weather forecasters to more accurately study and predict global weather patterns. Furthermore, since satellites are positioned outside of the earth's atmosphere, they provide an ideal platform for observing and studying the universe. Additionally, deep space probes equipped with increasingly advanced scientific instrumentation that are launched into a non-earthbound trajectory enable scientists to obtain heretofore unobtainable data about the solar system.

The rocket-launched spacecraft is launched into a preferred trajectory by rocket-propelled means that includes positioning the spacecraft into a relatively small capsule of a rocket-propelled vehicle. Thus, the typical spacecraft is required to be configurable between a storage configuration that enables the spacecraft to be positioned within the capsule of the rocket-propelled vehicle and a deployed configuration that enables the spacecraft to function in a desired manner while in outer space.

Thus, subsequent to the launching of the spacecraft, the spacecraft is typically configured for use by deploying an assembly of extendable components. For example, the assembly of extendable components may comprise an extended solar panel array that is used to convert collected solar radiation into electrical energy. In another example, the assembly of extendable components may comprise an extendable antenna assembly that is used to transmit and receive electromagnetic signals to and from a plurality of earth-based installations.

To deploy each assembly of extendable components, the typical spacecraft often utilizes a boom assembly. In particular, the assembly of extendable components is usually mounted to the extendable boom assembly which is adapted to fold-up in the storage configuration and fold-out in the deployed configuration. Furthermore, the boom assembly also serves as a support structure for supporting the assembly of extendable components while the boom assembly is in the deployed configuration. Moreover, although the spacecraft is often in a weightless environment, forces applied by rocket thrusters of the spacecraft that are sometimes used to correct the trajectory of the spacecraft may create considerable stress throughout the boom assembly. Therefore the boom assembly is required to be rigid and have sufficient structural integrity while in the deployed configuration.

As increasingly advanced types of spacecraft are being developed, it has become apparent that known types of boom assemblies provide insufficient capabilities. In particular, deep space probes currently being designed require boom assemblies that are capable of extending to unprecedentedly large sizes. Furthermore, the required boom assembly must be lightweight so as to reduce the amount of fuel that is needed to launch the spacecraft into the required trajectory, be reducible to a small size so as to enable the large boom assembly to fit into the small capsule, and have a high degree of strength when fully deployed. Moreover, since cost is a major consideration in the design of spacecraft, it is preferable for the boom assembly to have a simple design so as to reduce the manufacturing costs of the boom assembly.

Hence, there is a continuing need for extendable boom assemblies for spacecraft that are lightweight and are readily foldable into a compacted storage configuration for launch of the spacecraft. The boom assembly should also be readily deployable into an extended configuration upon the spacecraft reaching a desired trajectory and have sufficient strength to maintain spacecraft components in a desired deployed configuration.

SUMMARY OF THE INVENTION

The aforementioned needs are satisfied by the spacecraft boom assembly of the present invention comprised of an elongate boom having at least one opening formed at a location along the boom. In particular, the at least one opening defines at least one folding region so as to permit the elongate boom to be folded about the at least one folding region to thereby reduce the length of the elongate boom. Furthermore, the elongate boom is formed of a resilient material so as to store elastic energy when the elongate boom is in the folded configuration to thereby bias the folded elongate boom into an unfolded deployed state.

In another aspect of the invention, the aforementioned needs are satisfied by the spacecraft boom assembly of the present invention having a storage and a deployed configuration. In particular, the assembly comprises a first and a second mounting member and a foldable interconnection connected between the first and the second mounting members. Furthermore, the foldable interconnection is formed of an elastic material that is biased into a deployed configuration wherein the first and second mounting members are maintained in a deployed configuration such that the foldable interconnection rigidly maintains the first and second mounting members in a desired orientation with respect to each other such that the length of the boom assembly is a deployed length. Moreover, the foldable interconnection is adapted to permit release from the deployed configuration so that the first and second mounting members can be positioned in a storage configuration wherein the first and second mounting members are positioned so as to reduce the length of the boom assembly.

In another aspect of the invention, the aforementioned needs are satisfied by the elongate structural support member for a spacecraft comprising a first rigid member having a first and a second end, a second rigid member having a first and a second end, and a foldable connecting member integrally attached to the first ends of the first and second rigid members so as to interconnect the first and second rigid members. In particular, the foldable connecting member is bendable so as to allow the first and second rigid members to be positioned substantially adjacent each other substantially along the lengths of the first and second rigid members in a storage configuration. Moreover, the foldable connecting member is biased towards a deployed configuration wherein the first rigid member is rotated about the connecting member with respect to the second rigid member so that the first and second rigid members extend outward from the foldable connecting member.

In another aspect of the invention, the aforementioned needs are satisfied by the boom assembly for a spacecraft comprising a first boom sub-assembly having a first and a second rigid section with a folding section interposed therebetween. In particular, the folding section enables the first and second rigid sections to be folded about the folding section to thereby reduce the length of the first boom sub-assembly in a storage configuration. Furthermore, the folding section is biased so as to urge the first boom sub-assembly into a deployed configuration. The boom assembly further comprises a second boom sub-assembly having a first rigid section and a folding section wherein the second boom sub-assembly is mounted to the second rigid section of the first boom sub-assembly. Moreover, the folding section of the second boom sub-assembly enables the first rigid section of the second boom sub-assembly to be folded with respect to the second rigid section of the first boom sub-assembly to reduce the length of the second boom sub-assembly with respect to the first boom sub-assembly.

In another aspect of the invention, the aforementioned needs are satisfied by the structural support member for a spacecraft boom assembly, the support member comprising a plurality of rigid sections that include a first, a second, and a third rigid section and a plurality of foldable sections that interconnect the plurality of rigid sections. In particular, the plurality of foldable sections include a first foldable section that interconnects the first and second rigid sections and a second foldable section that interconnects the second and third rigid sections. Furthermore, each of the foldable sections is formed of a resilient material having a shape that is biased into a rigid unfolded state such that the foldable sections rigidly interconnect the rigid sections so as to maintain the structural support member in a rigid deployed configuration. Moreover, each of the foldable sections is configurable into a strained folded state so as to enable the plurality of rigid members to be positioned substantially adjacent each other substantially along the lengths of the plurality of rigid members so as to place the structural support member in a storage configuration having a reduced size. Additionally, the first and second rigid sections are able to fold and unfold with respect to each other along a first plane and the second and third rigid sections are able to fold and unfold with respect to each other along a second plane such that the first and second planes intersect each other.

The spacecraft boom assembly of the present invention is formed from an improved structural element that is both bendable and compressible so as to enable the boom assembly to be easily folded into a storage configuration so that the boom assembly can be stowed within the relatively small payload space of a launching vehicle. Furthermore, since the foldable sections of the structural element are formed of a resilient material, the elastic energy stored within each of the folded foldable sections provides each of the foldable sections with a bias that urges the boom assembly to self-extend from the storage configuration to the deployed configuration. Moreover, the structural element, when in the deployed configuration, provide sufficient rigidity so that the boom assembly is capable of supporting extending components of the spacecraft. Additionally, the extendable structural element is relatively inexpensive to manufacture, is lightweight, and is capable of extending into relatively large sizes. These and other objects and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an perspective view of a typical spacecraft in a launched state;

FIG. 2A is a side view of an alternative spacecraft having a boom assembly of the present invention which illustrates the boom assembly in the storage configuration;

FIG. 2B is a side view of the spacecraft of FIG. 2A which illustrates the boom assembly extending between the storage configuration and a deployed configuration;

FIG. 2C is a side view of the spacecraft of FIG. 2A which illustrates the boom assembly in the deployed configuration;

FIG. 3A is a perspective view of a structural support member of the boom assembly of the spacecraft of FIG. 2A which illustrates the structural support member in the deployed configuration;

FIG. 3B is a magnified perspective view of the structural support member FIG. 3A which illustrates a foldable section of the structural support member in greater detail;

FIG. 3C is an alternative perspective view of FIG. 3B;

FIG. 3D is a cross-sectional view of the foldable section of FIG. 3B in the deployed configuration;

FIG. 3E is a cross-sectional view of the foldable section of FIG. 3B in a flattened state which illustrates how the foldable section is adapted into the storage configuration;

FIG. 3F is a perspective view of the foldable section of FIG. 3B in a partially folded state;

FIG. 3G is a perspective view of the foldable section of FIG. 3B in the storage configuration;