Reflective film assembled on a composite structure

Abstract

A space vehicle including a reflective component on the side thereof for reflecting electromagnetic radiation, such as a mirror, the composite being formed by the steps of providing a composite support structure; providing a release liner including a metallic layer having a thickness between 1 and 5 microns on a surface thereof; situating the release liner against the surface of the composite support structure so that the metallic layer of the release liner is placed in direct, physical contact with the surface of the support structure; removing the release liner so that the metallic layer remains attached to the surface of the support structure; and mounting the support structure on a support on the exterior of the space vehicle.

1 . A mirrored structure comprising:
 a composite support structure comprising a polymer matrix and fibers, and having a surface;   a uniform metal layer over the surface; and   a release layer covering the uniform metal layer, wherein the release layer has an adhesion to the uniform metal layer less than the adhesion of the uniform metal layer to the surface of the composite support structure such that the release layer can be peeled away and removed from the uniform metal layer to expose the uniform metal layer without disconnecting the uniform metal layer from the surface of the composite support structure.   
     
     
         2 . The mirrored structure of  claim 1  wherein the composite support structure comprises a plurality of laminated layers. 
     
     
         3 . The mirrored structure of  claim 1  wherein polymer matrix is a cyanate ester resin. 
     
     
         4 . The mirrored structure of  claim 1  wherein the composite support structure has a thickness between 1 mil and 20 mil. 
     
     
         5 . The mirrored structure of  claim 1  wherein the fibers are carbon fibers. 
     
     
         6 . The mirrored structure of  claim 1  wherein uniform metal layer comprises aluminum, silver, gold or a combination thereof. 
     
     
         7 . The mirrored structure of  claim 1  wherein uniform metal layer has a thickness between 1 micron and 5 microns. 
     
     
         8 . The mirrored structure of  claim 1  wherein the release liner comprise polyimide. 
     
     
         9 . The mirrored structure of  claim 1  wherein the release liner comprises 4,4′-oxydiphenylene-promellitimide. 
     
     
         10 . The mirrored structure of  claim 1  wherein the release liner has a thickness from 25 microns to 100 microns. 
     
     
         11 . The mirrored structure of  claim 1  wherein the composite support structure comprises 6 laminated layers of uni-directional plies arranged in sequential direction layup to provide quasi-isotropic properties, wherein the release liner comprises polyimide, and wherein the wherein uniform metal layer comprises aluminum, silver, gold or a combination thereof and has a thickness between 1 micron and 5 microns. 
     
     
         12 . The mirrored structure of  claim 1  wherein the surface has a spherical shape. 
     
     
         13 . The mirrored structure of  claim 1  wherein the surface has a planar shape. 
     
     
         14 . The mirrored structure of  claim 1  wherein the surface has a parabolic shape. 
     
     
         15 . A method for making a mirrored structure comprising:
 providing a composite support structure;   placing a metallized release liner comprising a release liner and a metal layer against the composite support structure with the metal layer against a surface of the composite support structure to provide direct, physical contact of the metal layer to the surface so as to uniformly adhere the metal layer over the entire surface of the support structure; and   peeling away and removing the release layer from the uniform metal layer to expose the uniform metal so that the metallic layer remains attached to the surface of the composite support structure.   
     
     
         16 . A spacecraft comprising:
 a support mounted on the spacecraft; and   a mirrored structure attached to the support and comprising a composite structure with a uniform metal layer with a thickness between 1 micron and 5 microns on a surface of the composite structure and functioning as a reflective element of electromagnetic radiation on the surface of the spacecraft, wherein the composite structure comprises a plurality of laminated layers with fibers in a polymer matrix.   
     
     
         18 . The spacecraft of  claim 16  wherein the spacecraft is a Cubesat with one or more cubic structures attached to each other. 
     
     
         19 . The spacecraft of  claim 16  further comprising solar cell assemblies attached to the support. 
     
     
         20 . The spacecraft of  claim 16  wherein the support comprises a polyimide layer.