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Membranes for large and precision deployable reflectors

Article · January 2005

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4 authors, including:

Leri Datashvili Torsten Sixt

Large Space Structures GmbH (LSS GmbH) Wacker Chemie AG
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When the diameter of a space antenna reflector exceeds
the launcher shroud dimensions, a large deployable
reflector technology must be applied. For deployable
reflector concepts different approaches are available
ranging between shells, rod-cables and rod-membrane
systems. For the latest ones having dimensionally
stable thin membranes with high in plane stiffness
and/or finite bending stiffness facilitating for the
stowablity is significant. Using such membranes,
highly accurate double curved large reflector surfaces,
so called flexible shell-membranes can be built.
achievement of much higher accuracies compared
to metal meshes or tensed membranes;
• it is possible to integrate the CFRS shell-
membrane to the backside structure directly from
the mould, so mould RMS can be maintained as a
reflector surface manufacturing accuracy;
• it is still flexible enough to stow and deploy in
any desirable way.
All this points are drivers for the CFRS flexible shell-
membrane reflecting surface (Fig. 1) development.

New types of flexible shell-membranes based on fiber

reinforced silicone technology being developed at the
Institute of Lightweight Structures (LLB) are discussed
and an evaluation of thermo-mechanical properties is
given. (a)
The deployable reflector SMART is presented next,
which uses the mentioned shell-membrane. The design (b)
principles and building blocks of SMART as well as
results of thermo-elastic and dynamic analysis using a
fully parametric FE model are addressed. (c)
Fig. 1. Laboratory model of the SMART with CFRS
 ,1752'8&7,21 (a), triax CFRS rolled (b) and folded (c)
At the institute of lightweight structures (LLB TUM)
The deployable LDR SMART (Fig. 2) is presented as
the next step is performed to advance the FDUERQILEUH
an example of the use of the CFRS reflecting shell-
UHLQIRUFHG VLOLFRQH (CFRS) technology for space
membrane. The design principles and building blocks
reflector antenna applications as a flexible shell-
of SMART as well as results of thermo-elastic and
membrane reflecting surface. The results of material
dynamic analysis using a fully parametric FE model
characterization tests are presented in this paper. Tests
are addressed.
were performed in order to identify thermo-mechanical
0DLQ5DGLDO5LEV $X[LOLDU\
and radio frequency (RF) properties of CFRS. A 0HPEUDQH
triaxially woven fabric (TWF) made of T300 carbon 5LEV
fibres is used to reinforce the silicone elastomer.

Why is it important to have such a material like CFRS

for a reflecting surface of large deployable reflectors
(LDR)? Here are some answers listed below:
• double curved dimensionally stable shell-
membrane can be made, which means high 5HIOHFWLQJ
accuracy can be guaranteed; 6XUIDFH
• it does not require to be prestressed in an
Fig. 2. CAD parametric model of the SMART
operational state. This then facilitates for the
 %$6,&3523(57,(62)0$7(5,$/6 tow width is 0.9mm. As it was proved (see section 3.3),
86(',1&)56 this fabric with mentioned geometry successfully can
be used for the RF up to 10GHz.
 6LOLFRQH6IURP:DFNHU&KHPLH*PE+

Silicone S 690 is a recent development of the Wacker-

Chemie GmbH. Most important properties of the
silicone S690 for the use in space reflectors are:
- low outgassing
- resistivity to UV radiation and to ATOX
- wide range of service temperature
- low glass transition temperature (Tg) ~-105°C
- room temperature cure possibility
- optical transparency

Although above Tg the silicone has a very high CTE of

~300e-6/°C it does not significantly influence the Fig. 4. Microscopic photo of the cell of triax CFRS
resulting CTE of the composite because of its
extremely low E-modulus of ~1N/mm². CTE
measurement results for S 690 elastomer are given in  &)567+(5020(&+$1,&$/$1'5)
Fig. 3 &+$5$&7(5,=$7,21
10^-3
55
50
45
Key properties of the selected triax CFRS (in addition
40
35 Tg to those given in section 2.1 for pure silicone) making
30
25
it usable as a reflecting surface are listed bellow:
20 CTE = 290*10-6/°C
15
10
- Flexible above -100°C
Strain

5
0
- Low and q/isotropic CTE
-5
-10
- Sufficient bending stiffness
-15
-20 - Double parabolic curvature
-25
- No prestress needed
CTE = 104*10-6/°C
-30
-35
-40 - No micro-cracks (after several cycles from
-45
-150 -100 -50 0 50 100 150 200 -150°C to RT)
T, °C °C

- Applicable up to 10GHz RF.

Fig. 3. Thermal strain measurement graph of Silicone
It can be seen from Fig. 3 that two different ranges are
to be differed: below Tg with CTE ~104*10-6/°C and
above Tg with CTE ~290*10-6/°C. In addition to the
change in CTE below Tg, the E-modulus of the
silicone increases approximately by order of three.
 7ULD[LDOO\ZRYHQFDUERQILEUHIDEULF
The weave and geometry of the carbon fibre fabric
used as a reflecting material determines the reflector’s
RF properties. So it is important to select a fabric with
a proper cell size and tow width corresponding to the
RF frequency. Mass per unit area is an important
parameter also since many square meters must be
covered by the reflecting surface of LDR.
Selected TWF (also sometimes called ‘triax’) is woven
using 1K carbon T300 fibre yarns (fabric style nr.
SK802 from Sakase-Adtech Ltd., Japan) in the
directions of 0°/±60°. A photo of the unit cell of the
triax in silicone matrix can be found in Fig. 4.
The areal density of the fabric is 74g/m². Thickness
(dry) is 0.13mm. Cell size is slightly above 2mm and
The results of the following measurements carried out
for CFRS material characterization are discussed in this
section:
• CTE measurement
• Measurements of engineering constants
• RF tests
The most important task in the CFRS material thermo-
mechanical characterization is the measurement of
CTE and confirmation of the idea that silicone having
very low E-modulus has insignificant influence on
thermal deformations of the CFRS. In addition quasi-
isotropic thermal behaviour is important to prove.
In plane engineering constants are of second order
importance, since no mechanical stresses are to be
introduced during attachment to the already prestressed
backside structure. Besides, compatible CTE-s of the
reflecting surface and the backside structure can ensure
similar thermal orbital deformations of both and thus
insignificantly low level of static in plane stresses.
RF tests are also very important for validation of the
electrical concept of the reflecting surface using the
selected material composition.
 7KHUPRHODVWLFEHKDYLRXURIWULD[&)56 defined above 100 up to 200°C. CTE in this
range is low with some negative and some
Performing CTE measurements on non standard very positive values. The average CTE is in the
flexible materials and their specimens is connected to range of 0.25*10-6/°C.
certain difficulties. This calls for innovative solutions
• Combining the last two ranges, one could talk
to enable the measurement process at all. Creating the
about the effective CTE of CFRS in the most
special form of the specimens for the flexible single
important temperature range from -110°C to
layer laminates, cutting of the specimens, ensuring the
+200°C as equal to -0.4*10-6/°C (practically
parallelism of the edges, – these are some problems
fibers’ CTE).
solved during the tests discussed bellow.
Specimen 1.1, 45° Specimen 1.2, 45°
Specimen 2.1, 45° Specimen 2.2, 45° - entfällt

A Dilatometer (WSK TMA 500 with a temperature Specimen 3.1, 90°

Specimen 4.1, 0°
Specimen 5.1, 0°
Specimen 3.2, 90°
Specimen 4.2, 0°
Specimen 5.2, 0°
range from –196 °C to +500 °C) was used for CTE 10^-6
150
measurements.
100
aHƒ&
The aim of these measurements was to fully 50
aHƒ&
characterize the CFRS material thermal expansion 0
coefficient (CTE) in different combinations of fabrics
and fibre orientation. Namely two kind of fabrics were -50

used for the silicone reinforcement: 0/90° and triax -100

plane weave fabrics of T300 fibres. In addition T300 aHƒ&

-150

12K fibre roving was used for a unidirectional FRS aHƒ&
-200
specimen. Non-standard single layer tube specimens
(Fig. 5) were also used for triax CFRS CTE -250 Full range - effective
aHƒ&
measurements (method developed at LLB). -300
ƒ& ƒ&
-350

CFRS single layer rolled tube -140 -120 -100 -80 -60 -40 -20 0 20 40 60 80 100 120 140 160 180 200
°C

Fig. 6. Thermal strains vs. temperature for CFRS and

CTEs in different temperature zones

Average results of standard and rolled tube specimens

Dilatometer chamber
Fig. 5. Rolled tube specimen for CTE measurement
Triax CFRS specimens CTE measurement results (Fig.
6) show the following:
• CTE of the CFRS is variable in the range of
the temperatures from -150 to +200°C.
• Three characteristic ranges are defined:
- below -110°C (~Tg of silicone)
- from -110 to 100°C
- from 100 to 200°C
• In the first range measurements show stable
results (in the order of 10*10-6/K). Since all
specimens are relatively stiff in that
temperature range, the silicone influence on
the resulting CTE is significant. Specimens
with higher silicone volume show a higher
CTE.
• Next range is characterized with nearly no
influence of silicone. The resulting CTE is
always negative (in the order of -0.7*10-6/°C)
• At approximately 100°C the
deformation/temperature curve changes its
direction slightly, therefore the next range is
fit completely to the CTE of a single triax CFRS layer
specimen manufactured under slight pressure, which
had better controlled geometry and mass properties.
Quasi-isotropic thermo-elastic behaviour of the triax
CFRS was proved.
 0HDVXUHPHQWRIWKHHQJLQHHULQJFRQVWDQWV
According to the common idea a quasi isotropic
mechanical behaviour of the triax/silicone composite
laminate was expected. Very first measurements
showed counter results for Triax CFRS: E-modulus in
the fibre direction (0° direction) is much higher than
orthogonal to the fibre direction (90° direction) and
equal to ~7.7GPa and ~1.7GPa respectively. Tests were
repeated (also including the hysteresis) and similar
results were measured. These results are summarized in
Fig. 7, which shows the relations in between E(90°)
and E(0°) of laminate and matrix and fibre E-modulus,
which could be a good indication of laminate in-plane
anisotropic properties.
In addition, the existence of the fibres in between the
0° and 90° directions (namely +60° and -60° fibres)
indicates that triax CFRS (generally triax composite
laminas) must be treated as multidirectional symmetric
constructions [1] when considering in plane stiffness of The triax CFRS reflecting surface shows excellent
the lamina. polarization behavior which means, that all
requirements concerning depolarization, amplitude and
Extensometer_1
7ULD[PDWUL[SURSHUWLHV
Cross head
phase variations for orthogonal polarizations are
movement
Extensometer_2 completely fulfilled with some additional margins
1,2 facilitating the use of material up to 10GHz confirmed
,VRWURSLF
1 by antenna analysis [2].
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0,000001 0,00001 0,0001 0,001 0,01 0,1 1 The following design goals make the development of
(P(I the large deployable reflector challenging:
Fig. 7. Mechanical behaviour of triax fabric with
silicone matrix
 5)WHVWVRQWULD[&)56UHIOHFWLQJVXUIDFH
VSHFLPHQV
To perform RF tests on triax CFRS reflecting surface
specimens the following three types of measurement
facilities were selected:
ƒ Free space measurements of fairly large
samples in a Compensated Compact Test
Range, CCR
ƒ Waveguide measurements of small samples
ƒ Free space measurements of samples put close
to the aperture of a Standard Gain Horn, SGH
antenna
Tests were performed at the Munich University of
Applied Sciences in the Laboratory for Satellite
Communications. Details of the tests can be found in
[2].
The measurement results obtained with the three test
setups are summarized in Table 1 and compared to the
performance requirements given in the same table.
Table 1. Comparison of measurement results with the
requirements in the frequency range of 5.5 to 8 GHz
6XEMHFW5)5HTXLUHPHQW
Reflection loss <0.1 dB
Depolarization <-40dB
Amplitude variation for 2 orth.
Polarizations < 0.02 dB
Phase variation for 2 orthogonal
polarizations < 2o
Transmission coefficient < -20 dB
It can be stated that nearly all requirements are fulfilled
for triax CFRS samples for frequencies up to 8 GHz.
• L to Ku band frequencies
• Reflector aperture >3m up to very large diameters
• Circular, 2D-elliptical, 3D-elliptical apertures
• Symmetric, offset configurations
• Shape accuracy 0.5mm RMS
• Aerial density 0.5kg/m2, especially for larger
diameters.
• High design flexibility, for the range of
requirements.
• Shaping capability
• Easy integration of enabling technologies
(different reflecting surfaces, deployment and
shape control etc.)
• Lowest deployment temperature ”-100°C
To achieve the above listed goals a reflector concept
was established and is discussed in the following.
 &RQFHSWRIWKH60$57
The approach to the SMART concept development is
split in two:
• to develop the multi-purpose large deployable
structure of the reflector;
• to create easily foldable-deployable high
accurate double curved flexible shell-membrane
reflecting surface with no pillow effect (already
discussed in this paper).
SMART uses the concept of tensed membranes for
7ULD[&)56
both stiffness and accuracy provision. For that radially
0.05 … 0.13 positioned pantographs deploy and tension all
membranes.
<-47 …- 42
The SMART’s structure consists of six main radial ribs
(Fig. 2), attached to the central unit. In between the
< 0.02 radial ribs the system of auxiliary membrane ribs
supports the reflecting surface. The auxiliary ribs are
connected to pantographs using spring adapters.
< 0.5o
The main radial rib consists of two components:
- 33 … - 21 - radially deployable double or single pantograph,
- profiled membranes, attached to the central unit
and to the end of the pantograph.
Carbon fibre reinforced silicone (CFRS) is used to for different kind of multi-criteria optimization
manufacture the flexible shell-membrane. Attached to problems.
the membrane ribs along the profiles it serves as a
Total 62 input parameters were used for the stiffness
reflecting surface of SMART (Fig. 1, Fig. 2). It is not
optimization. The result of the prestress analysis after
pretensioned in an operational state, so, the pillow
the stiffness optimization is shown in Fig. 9 in the same
effect can not appear.
scale as in Fig. 8.
CFRS flexible shell-membrane manufacturing process
ensures high manufacturing accuracy, which is
maintained during the reflector assembly so that
backside rib contour prestress deviations do not
contribute to the surface accuracy.
Shell-membrane bending stiffness is defined so that it
takes loads in a certain cell of the backside structure
and does not interfere any kind of stowing and
deployment.

 7KHUPR0HFKDQLFDO6WUXFWXUDO$QDO\VHVRI
60$57
Using a fully parametric FE model prestress, modal,
buckling, stiffness optimization and thermo-elastic
structural analyses where performed for a 6m offset
reflector configuration. Results are discussed in the
following.
 3UHVWUHVVDQDO\VLVDQGVWLIIQHVVRSWLPL]DWLRQ
RIWKHUHIOHFWRU
Since SMART reflector in offset (also in symmetric)
configuration is not symmetric, prestressing of the
reflector when having symmetric distribution of the
stiffnesses causes some torsion of the membrane ribs
(Fig. 8). Therefore, to eliminate the torsion of the ribs
and to reduce the prestressed structure’s surface RMS,
a stiffness optimization was performed.
Fig. 9. Top view of optimized prestress deformations
Rib contour RMS reduction from 0.74mm to 0.21mm
was achieved, while the reflector mass has increased
only by 500g.
All the followed analyses were performed using an
optimized FE model.
 0RGDODQGEXFNOLQJDQDO\VLVUHVXOWV
Many different configurations of the pantograph and
main rib membranes were analyzed on buckling. The
baseline design (double pantograph) shows the first
mode as a buckling out of the pantograph plane at
factor 3 (Fig. 10). The in plane buckling mode appears
at the 34th mode with a factor of 19. So the use of a
single pantograph is still an issue

Fig. 8. Top view of prestress deformations

The optimization was done using the GAME-
optimization toolbox, which was developed at LLB.
The GAME optimization toolbox provides an easy to
use interface for using genetic optimization algorithms
Fig. 10. First buckling mode at factor 3
A modal analysis has been carried out for the centrally
fixed structure. Only a few of many eigen-modes with
eigen frequency below 10 Hz have an effective mass
above 1%
 The lowest occurring important eigenmode with
effective mass of 96% is rotation about the reflector Z-
axis. The eigenfrequency of this mode is 2.15Hz and is
the global eigenmode of the reflector. A plot of this
mode is shown in Fig. 11.
element sizes and irregular meshes into consideration
are included in this RMS calculation.
In Table 2 only results for worst case loads are given.
The last four columns give focal point deviations
compared to the original location of the focus. It can be
seen in the table that under all thermal loads the
deviation of the focal point is in the range of +/-1.2mm
while surface best fit RMS is equal to 0.424mm.

Table 2. Results of worst case thermo-elastic analysis

Best Corresponding displacement of

RMS
Fit focal point, [mm]
RMS Sum dx dy dz
[mm]
[mm]
Cold: -170K
0.482 0.424 1.212 -0.249 1.27e-4 1.186
uniform
Cold, Grad. In 0.491 0.418 1.186 -0.257 1.341e-4 1.158
Z
Hot, Grad. In 0.434 0.368 1.107 0.227 -1.19e-4 -1.083
Z
Fig. 11. First eigenmode of the reflector at 2,15Hz,
rotation about its Z-axis (eff. mass = 96%)
 &21&/86,216
 7KHUPRHODVWLFDQDO\VLVRIWKH60$57 The feasibility of creation of the flexible shell-
membrane reflecting surface for LDRs using triax
To study the behaviour of the SMART under carbon fibre reinforced silicone technology is proved.
temperature changes in total 10 thermal load cases
were defined and SMART was subjected to the SMART reflector concept have been presented for the
analysis. 4 to 8 m class and the credibility of RF and mechanical
concepts are demonstrated.
For all load cases thermal deformations for the whole
reflector were calculated in ANSYS. In Fig. 12 a Sample RF tests have shown that the selected triax
surface deformation plot is given for the worst load CFRS reflecting surface of SMART can be used up to
case which corresponds to the uniform temperature 10 GHz with small to moderate losses and nearly no
change of -170K and the gradient in Z direction depolarization effects.
(through thickness) of 20K. Therefore building of the SMART demonstrator with
triax CFRS reflecting surface has been initiated.

5()(5(1&(6
1. Stephen W. Tsai &RPSRVLWHV GHVLJQ   HGLWLRQ
WK

Think Composites: Dayton, Paris and Tokyo, 1988

2. Datashvili, L.; Nathrath, N.; Baier, H.; Lang, M.;
Fasold, D.; Pellegrino, S.; Soykasap, O.; Tan, L.T.;
Mangenot, C.; Santiago-Prowald, J 1HZ&RQFHSWVDQG
5HIOHFWLQJ 0DWHULDOV IRU 6SDFH %RUQH /DUJH
'HSOR\DEOH 5HIOHFWRU $QWHQQDV 28th ESA Antenna
Workshop on Space Antenna Systems and
Technologies, 31 May - 3 June 2005 ESA / ESTEC
Noordwijk, The Netherlands.

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Fig. 12. Top View Surface Deformations for LC09:
Cold Case with gradient through thickness The authors thank ESTEC/ESA for funding of the part
of this work.
Using an external to ANSYS tool RMS and Best Fit
RMS of the reflecting surface deformed shape were
also calculated. Weighting factors taking different

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