System and method for manufacturing a space-based component

Patent metadata

Field	Value
Publication number	US-11874061-B2
Application number	US-202217936199-A
Country	US
Kind code	B2
Filing date	Sep 28, 2022
Priority date	Sep 29, 2016
Publication date	Jan 16, 2024
Grant date	Jan 16, 2024

Abstract

A system and method for manufacturing a space-based component in space. The method includes collecting and capturing space debris directly from and suspended in space, heating the collected space debris using solar radiation in a manner that separately and independently melts different constituent elements and compounds in the space debris, collecting the different constituent elements and compounds as they are being separately melted, storing the elements and compounds in a molten, solid or vapor form, and fabricating the space-based component using the stored elements and compounds.

First claim

What is claimed is:

1. A method for manufacturing a space-based component, said method comprising:
collecting and capturing space debris directly from and suspended in space;
heating the collected space debris using solar radiation in a temperature controlled manner so that the amount of heat provided by the solar radiation selectively, separately and independently melts different constituent elements and compounds in the space debris that have different melting points;
collecting the different constituent elements and compounds as they are being separately melted;
storing the separately melted different constituent elements and compounds in a molten, solid or vapor form; and
fabricating the space-based component using the stored and separately melted different constituent elements and compounds.

2. The method according to claim 1 wherein fabricating the space-based component includes using one or more 3-D printers for printing the space-based component.

3. The method according to claim 2 wherein fabricating the space-based component includes using printers capable of printing parts or portions of parts specialized to particular elements or compounds.

4. The method according to claim 1 wherein the spaced-based component is a panelsat or other three-dimensional layered or pocketed structure or component including antennas facing the Earth on one side of the panelsat, solar arrays on other or opposite sides of the panelsat and a complex layered or pocketed structure.

5. The method according to claim 1 wherein collecting and capturing space debris includes using a three-dimensional crucible having a clam-shell or otherwise openable design that allows the crucible to open and collect the space debris.

6. The method according to claim 5 wherein heating the collected space debris using solar radiation includes using a rotary or linear actuator that rotates or moves the crucible so as to evenly heat the crucible and provide centripetal or varying forces to move and extract melted materials or vaporized and then condensed materials.

7. The method according to claim 1 wherein heating the collected space debris using solar radiation includes using a solar concentrator that receives solar flux from the sun and focuses it to a certain location.

8. The method according to claim 7 wherein the solar concentrator is selected from the group consisting of a parabolic mirror, a Fresnel lens and a light focusing element.

9. The method according to claim 1 wherein heating the collected space debris using solar radiation includes using at least one solar array and at least one resistive heater.

10. The method according to claim 1 wherein the space debris is a retired spacecraft or launch vehicle upper stage or component.

11. A system for manufacturing a space-based component, said system comprising:
means for collecting and capturing space debris directly from and suspended in space;
means for heating the collected space debris using solar radiation in a temperature controlled manner so that the amount of heat provided by the solar radiation selectively, separately and independently melts different constituent elements and compounds in the space debris that have different melting points;
means for collecting the different constituent elements and compounds as they are being separately melted;
means for storing the separately melted different constituent elements and compounds in a molten, solid or vapor form; and
means for fabricating the space-based component using the stored and separately melted different constituent elements and compounds.

12. The system according to claim 11 wherein the means for fabricating the space-based component uses one or more 3-D printers for printing the space-based component.

13. The system according to claim 12 wherein the means for fabricating the space-based component uses printers capable of printing parts or portions of parts specialized to particular elements or compounds.

14. The system according to claim 11 wherein the spaced-based component is a panelsat or other three-dimensional layered or pocketed structure or component including antennas facing the Earth on one side of the panelsat, solar arrays on other or opposite sides of the panelsat and a complex layered or pocketed structure.

15. The system according to claim 11 wherein the means for collecting and capturing space debris uses a three-dimensional crucible having a clam-shell or otherwise openable design that allows the crucible to open and collect the space debris.

16. The system according to claim 15 wherein the means for heating the collected space debris using solar radiation uses a rotary or linear actuator that rotates or moves the crucible so as to evenly heat the crucible and provide centripetal or varying forces to move and extract melted materials or vaporized and then condensed materials.

17. The system according to claim 11 wherein the means for heating the collected space debris using solar radiation uses a solar concentrator that receives solar flux from the sun and focuses it to a certain location.

18. The system according to claim 17 wherein the solar concentrator is selected from the group consisting of a parabolic mirror, a Fresnel lens and a light focusing element.

19. The system according to claim 11 wherein the means for heating the collected space debris using solar radiation uses at least one solar array and at least one resistive heater.

20. The system according to claim 11 wherein the space debris is a retired spacecraft or launch vehicle upper stage or component.

Assignees

• Northrop Grumman Systems Corp

Inventors

• Eller Howard S

Classifications

• B64G1/1081

  for debris removal · CPC title

• F27B14/10 Primary

  Crucibles · CPC title

• B22F3/003

  Apparatus, e.g. furnaces (in general F27B) · CPC title

• B22F5/00

  Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product · CPC title

• B22F12/226

  for rotary motion · CPC title