1. A deployable mast assembly (100) for extending at least one payload (106) from a carrier structure (102), the assembly (100) comprising: at least one base plate (202) configured for attachment to the carrier structure (102); at least one roller (206) mounted rotatably on at least one roller mounting bracket (204) attached to the at least one base plate (202), and adapted to support at least one flexible composite boom (108) in a rolled configuration, wherein the at least one flexible composite boom (108) having a first end attached to the at least one roller (206) and a second end attached to at least one payload mounting plate (220); and at least one anti-blossoming guide (208) coupled to the at least one roller mounting bracket (204) through at least one tensioning spring (210) for guiding controlled unrolling of the at least one flexible composite boom (108); wherein the deployable mast assembly (100), when released from a restrained stowed configuration, is configured to passively deploy by utilising strain energy stored within the rolled configuration of the at least one flexible composite boom (108) to unroll the at least one flexible composite boom (108) and extend the at least one payload (106) away from the carrier structure (102), and wherein at least one enclosure (222) configured to accommodate components of the deployable mast assembly (100) in the restrained stowed configuration.

2. The deployable mast assembly (100) as claimed in claim 1, wherein the at least one anti-blossoming guide (208) comprises a set of curved links (226) connected through link pins (230) and fasteners (228) and having a set of anti-blossoming rollers (232) rotatably mounted thereon, and at least one tensioning spring (210) is coupled between the roller mounting bracket (204) and a spring interface bracket (224) of the anti-blossoming guide (208) to apply a controlled inward radial force on the rolled at least one flexible composite boom (108).

3. The deployable mast assembly (100) as claimed in claim 1, further comprises at least one pair of boom guides (212, 214) to guide unrolling of the at least one flexible composite boom (108) along a predetermined direction, wherein each boom guide (212, 214) comprises a guide roller bracket (216) having a set of guide rollers (218) rotatably mounted thereon, the set of guide rollers (218) being configured controlled extension of the at least one flexible composite boom (108).

4. The deployable mast assembly (100) as claimed in claim 1, wherein the at least one flexible composite boom (108) is configured to support a plurality of payload mounting hubs (502) each adapted to carry at least one payload (506) along a length of the at least one flexible composite boom (108), and wherein each payload mounting hub (502) comprises: a set of hub support rollers (508) configured to engage with and slide along an outer surface of the at least one flexible composite boom (108) during deployment; and a plurality of tensioning cable attachment points (510) disposed circumferentially around each payload mounting hub (502).

5. The deployable mast assembly (100) as claimed in claim 6, further comprises a plurality of tensioning cables (504) attached between the at least one base plate (202), the plurality of payload mounting hubs (502), and the at least one payload mounting plate (220), wherein the plurality of tensioning cables (504) are configured to uncoil and extend during unrolling of the at least one flexible composite boom (108) and to sequentially transmit deployment force from the at least one payload mounting plate (220) to successive payload mounting hubs (502).

6. The deployable mast assembly (100) as claimed in claim 1, wherein the at least one flexible composite boom (108) comprises a set of flexible composite booms (108) each configured to unroll from the corresponding roller (206) mounted on a multi-boom roller mounting bracket (702) attached to the at least one base plate (202).

7. The deployable mast assembly (100) as claimed in claim 8, further comprises at least one anti-blossoming guide (704) coupled to the multi-boom roller mounting bracket (702) through at least one tensioning spring (706) to prevent lateral expansion of the plurality of flexible composite booms (108) during deployment and for directing strain energy towards linear extension of the payload mounting plate (220).

8. The deployable mast assembly (100) as claimed in claim 8, wherein the set of flexible composite booms (108) is configured to support a plurality of payload mounting hubs (1002), each adapted to carry at least one payload (506) along a length of the set of flexible composite booms (108).

9. The deployable mast assembly (100) as claimed in claim 10, wherein each payload mounting hub (1002) comprises a plurality of hub support rollers (508) disposed on the plurality of payload mounting hub (1002), each hub support roller (508) being positioned to engage with the corresponding flexible composite boom (108) to facilitate guided linear motion of the payload mounting hub (1002) during deployment.

10. The deployable mast assembly (100) as claimed in claim 10, further comprises a plurality of tensioning cables (504) attached between the at least one base plate (202), the plurality of payload mounting hubs (1002), and the at least one payload mounting plate (220), the plurality of tensioning cables (504) being configured to uncoil and extend during unrolling of the plurality of flexible composite booms (108) and to sequentially transmit deployment force from the at least one payload mounting plate (220) to successive payload mounting hubs (1002).

11. The deployable mast assembly (100) as claimed in claim 1, wherein the deployable mast assembly (100) forms a part of a staggered mast assembly (1202) configured to sequentially deploy the at least one payload (106) along multiple directions from the carrier structure (102), wherein the staggered mast assembly (1202) comprises a plurality of deployable mast assemblies (100) connected to each other by at least one interface bracket (1402).

12. The deployable mast assembly (100) as claimed in claim 1, wherein the deployable mast assembly (100) forms a part of a multi-mast assembly (1502) configured to deploy multiple payloads (106) from the carrier structure (102), the multi-mast assembly (1502) comprising a multiple mast housing enclosing a plurality of deployable mast assemblies (100), each deployable mast assembly (100) comprising the at least one flexible composite booms (108) mounted on the rollers (206) for extending the corresponding payload (106).

13. The deployable mast assembly (100) as claimed in claim 1, further comprising a retaining mechanism configured to hold the deployable mast assembly (100) in a compact stowed configuration and to permit deployment of the deployable mast assembly (100) upon occurrence of a predefined condition of the carrier structure (102).

14. The deployable mast assembly (100) as claimed in claim 1, further comprising a mounting apparatus configured to mechanically couple the deployable mast assembly (100) to the carrier structure (102), the mounting apparatus comprising an orientation mechanism configured to set an angular orientation of the deployable mast assembly (100) relative to the carrier structure (102).

Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to deployable structural systems used in aerospace applications. More particularly, the disclosure pertains to a deployable mast assembly configured for extending one or more payloads from a carrier structure, such as a satellite or spacecraft.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.
[0003] A mast refers to a structural system that is attached to a spacecraft or satellite, primarily intended for extending one or more payloads by a predetermined distance from the spacecraft or satellite. One end of the mast assembly remains attached to the spacecraft or satellite, while the opposite end is connected to the payload to be extended. There also exist applications requiring multiple payloads to be extended such that they are positioned at predetermined distances from the spacecraft or satellite, and relative to each other, for achieving specific mission objectives.
[0004] Mast systems generally have an operational length that is significantly larger than the dimensions of the spacecraft or satellite, often determined by the required separation between the payload and the spacecraft. Owing to this large deployed length, these mast assemblies must be capable of being compactly stowed within limited storage volumes during transportation and launch, and subsequently deployable to their full operational configuration when the spacecraft/satellite is in space. Once deployed, the masts are typically latched to maintain rigidity and to prevent accidental retraction during operation.
[0005] Presently known technologies utilized for extending payloads from satellites include linkage-based deployable masts, telescoping masts, and coil-able masts. Linkage-based deployable masts are generally operated using active actuation systems such as electric motors, which increase weight and complexity of the deployment system. Telescoping masts employ multiple tube-like segments that extend sequentially; however, they often exhibit low stowage efficiency and involve mechanical complexity due to the requirement of precise alignment of multiple segments. Coil-able masts, on the other hand, rely on long flexible beams with transverse stiffeners that uncoil to axial deployment, but such systems exhibit an undesirable combination of rotary and axial motion, which may affect payload alignment accuracy.
[0006] The major drawbacks associated with the current state-of-the-art deployable masts include dependency on active actuators that consume electrical power from the spacecraft, increased system weight due to motor assemblies, reduced reliability caused by multiple moving parts, and limited stowage efficiency. Moreover, in certain coil-able mast configurations, the unavoidable twisting or rotational motion during deployment can lead to misalignment of payloads that are intended to maintain a fixed orientation relative to the spacecraft. These drawbacks make such systems less suitable for compact, power-efficient, and precision-critical missions.
[0007] Therefore, there is a need for a deployable mast assembly that overcomes limitations of existing active and coil-able deployment mechanisms by providing a reliable, lightweight, and stowage-efficient configuration capable of precisely extending single or multiple payloads from a spacecraft or satellite with minimal power consumption and high structural stability after deployment.

OBJECTS OF THE PRESENT DISCLOSURE
[0008] A general object of the present disclosure is to provide a deployable mast assembly capable of extending at least one payload from a spacecraft or satellite in a controlled and reliable manner.
[0009] An object of the present disclosure is to provide a compact and lightweight deployable mast assembly that offers high stowage efficiency for launch and transport.
[0010] An object of the present disclosure is to provide a deployable mast assembly that enables passive and power-efficient deployment without dependency on electrical or motorized actuation systems.
[0011] An object of the present disclosure is to provide a deployable mast assembly that facilitates precise alignment and stable positioning of single or multiple payloads during and after deployment.

SUMMARY
[0012] Aspects of the present disclosure relate to deployable structural systems used in aerospace applications. More particularly, the disclosure pertains to a deployable mast assembly configured for extending one or more payloads from a carrier structure, such as a satellite or spacecraft. The disclosure further relates to assembly that utilizes stored strain energy for passive extension of payloads, and to configurations supporting multi-boom, staggered, and multi-mast deployment of multiple payloads in various directions.
[0013] An aspect of the present disclosure relates to a deployable mast assembly configured for extending one or more payloads from a carrier structure, such as a spacecraft or satellite. The assembly includes a base plate attached to the carrier structure and a roller mounted on a roller mounting bracket attached to the base plate. A flexible composite boom is supported on the roller in a rolled configuration with one end connected to the roller and the other end to a payload mounting plate. An anti-blossoming guide is connected to the roller mounting bracket through a tensioning spring to enable controlled unrolling of the flexible composite boom. The stored strain energy in the rolled boom enables passive deployment of the payload when the assembly transitions from a restrained stowed configuration to an extended configuration.
[0014] In addition, an enclosure is provided to contain the mast components in the stowed state.
[0015] In an aspect, the anti-blossoming guide is formed by curved links joined by link pins and fasteners with anti-blossoming rollers mounted thereon, while the tensioning spring applies a controlled inward radial force through a spring interface bracket.
[0016] In an aspect, the unrolling path of the flexible composite boom is guided by a pair of boom guides consisting of guide roller brackets and guide rollers that regulate extension along a fixed direction.
[0017] In an aspect, the flexible composite boom supports multiple payload mounting hubs distributed along its length.
[0018] In an aspect, each payload mounting hub carries hub support rollers that slide along the surface of the boom and includes tensioning cable attachment points.
[0019] In an aspect, tensioning cables are connected between the base plate, the payload mounting hubs, and the payload mounting plate to ensure sequential transfer of deployment force as the boom unrolls.
[0020] In another aspect, multiple flexible composite booms are mounted on a multi-boom roller mounting bracket attached to the base plate. The multi-boom arrangement is accompanied by an anti-blossoming guide coupled through tensioning springs to prevent lateral expansion of the booms during deployment and direct strain energy toward linear extension of the payload mounting plate. Multiple payload mounting hubs with hub support rollers and tensioning cables are arranged along the booms for sequential extension of multiple payloads.
[0021] In another aspect, deployable mast assembly also forms part of a staggered mast assembly designed to sequentially deploy payloads along multiple directions from the carrier structure. The staggered mast assembly includes several deployable masts connected through interface brackets to obtain coordinated deployment.
[0022] In another aspect, the deployable mast assembly can be integrated into a multi-mast assembly that houses multiple deployable masts within a single mast housing. Each deployable mast extends a corresponding payload in a required direction and spacing, enabling deployment of multiple payloads from a single carrier structure in a compact, energy-efficient, and precise manner.
[0023] In another aspect, the deployable mast assembly further includes a hold-down and release mechanism configured to hold the deployable mast assembly in a compact stowed configuration and to permit deployment of the deployable mast assembly upon occurrence of a predefined condition of the carrier structure.
[0024] In another aspect, the deployable mast assembly further includes a mounting apparatus configured to mechanically couple the deployable mast assembly to the carrier structure, the mounting apparatus further including an orientation mechanism configured to set an angular orientation of the deployable mast assembly relative to the carrier structure.

BRIEF DESCRIPTION OF DRAWINGS
[0025] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which is not a limitation of the present disclosure.
[0026] FIG. 1A illustrates an exemplary view of proposed deployable mast assembly with a single composite boom and a single payload, shown in stowed configuration, in accordance with an embodiment of the present disclosure.
[0027] FIG. 1B illustrates an exemplary view of proposed deployable mast assembly with a single composite boom and a single payload, shown in deployed configuration, in accordance with an embodiment of the present disclosure.
[0028] FIGs. 2A, 2B, 2C and 2D, illustrate exemplary views of different parts of proposed deployable mast assembly with a single composite boom and a single payload, in accordance with an embodiment of the present disclosure.
[0029] FIGs. 3A and 3B illustrate exemplary views of proposed deployable mast assembly with a single composite boom and a single payload, where boom is rolled in same sense, in accordance with an embodiment of the present disclosure.
[0030] FIGs. 3C and 3D illustrate exemplary views of proposed deployable mast assembly with a single composite boom and a single payload, where boom rolled in an opposite sense, in accordance with an embodiment of the present disclosure.
[0031] FIGs. 4A, 4B, and 4C illustrate exemplary views of proposed deployable mast assembly with a single composite boom and a single payload through the various stages of deployment, i.e., in stowed configuration, partially deployed configuration, and fully deployed configuration respectively, in accordance with an embodiment of the present disclosure.
[0032] FIGs. 5A, 5B, 5C, 5D, and 5E, illustrate exemplary views of proposed deployable mast assembly with a single composite boom configured to deploy and extend multiple payloads, in accordance with an embodiment of the present disclosure.
[0033] FIGs. 6A, 6B, and 6C illustrate exemplary views of proposed deployable mast assembly with a single composite boom supporting multiple payloads, shown through the various stages of deployment, i.e., in stowed configuration, partially deployed configuration, and fully deployed configuration respectively, in accordance with an embodiment of the present disclosure.
[0034] FIGs. 7A, 7B, and 7C illustrate exemplary views of proposed deployable mast assembly with multiple composite booms configured to extend a single payload, in accordance with an embodiment of the present disclosure.
[0035] FIGs. 7D and 8A illustrates an exemplary view of proposed deployable mast assembly with multiple composite booms configured to extend a single payload, where boom rolled in same sense, in accordance with an embodiment of the present disclosure.
[0036] FIG. 7E and 8B illustrates an exemplary view of proposed deployable mast assembly with multiple composite booms configured to extend a single payload, where booms rolled in opposite sense, in accordance with an embodiment of the present disclosure.
[0037] FIGs. 9A, 9B, and 9C illustrate exemplary views of proposed deployable mast assembly with multiple composite booms extending a single payload, shown through the various stages of deployment, i.e., in stowed configuration, partially deployed configuration, and fully deployed configuration respectively, in accordance with an embodiment of the present disclosure.
[0038] FIGs. 10A, 10B, 10C, 10D, and 10E illustrate exemplary views of proposed deployable mast assembly with multiple composite booms configured to deploy and extend multiple payloads, in accordance with an embodiment of the present disclosure.
[0039] FIGs. 11A, 11B, and 11C illustrate exemplary views of proposed deployable mast assembly with multiple composite boom configured to deploy and extend multiple payloads, shown through the various stages of deployment, i.e., in stowed configuration, partially deployed configuration , and fully deployed configuration respectively, in accordance with an embodiment of the present disclosure.
[0040] FIGs. 12A, and 13 illustrate an exemplary view of proposed staggered mast assembly with multiple deployable masts that deploy sequentially to extend a payload, shown in a stowed configuration, in accordance with an embodiment of the present disclosure.
[0041] FIGs. 12B illustrates exemplary views of proposed staggered mast assembly, shown in deployed configurations, in accordance with an embodiment of the present disclosure.
[0042] FIGs. 14A, 14B, 14C, and 14D illustrate exemplary views of proposed staggered mast assembly, shown through the various stages of deployment, i.e., in a stowed configuration, a stage 1 deployment configuration, a stage 2 deployment configuration, a stage 3 deployment configuration respectively, in accordance with an embodiment of the present disclosure.
[0043] FIGs. 15A, 15B, and 15C illustrate exemplary views of proposed deployable multi-mast assembly with multiple masts configured to deploy and extend multiple payloads, shown through the various stages of deployment, i.e., in stowed configuration, partially deployed, and fully deployed configuration respectively, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0044] The following is a detailed description of embodiments of the disclosure represented in the accompanying drawings. The disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0045] Embodiments of the present disclosure relate to deployable structural systems used in aerospace applications. More particularly, the disclosure pertains to a deployable mast assembly configured for extending one or more payloads from a carrier structure, such as a satellite or spacecraft. The disclosure further relates to an assembly that utilizes stored strain energy for passive extension of payloads, and to configurations supporting multi-boom, staggered, and multi-mast deployment of multiple payloads in various directions.
[0046] An embodiment of the present disclosure relates to a deployable mast assembly configured for extending one or more payloads from a carrier structure such as a spacecraft or satellite. The assembly includes a base plate attached to the carrier structure and a roller mounted on a roller mounting bracket. A flexible composite boom is supported on the roller in a rolled configuration with one end connected to the roller and the other end to a payload mounting plate. An anti-blossoming guide is connected to the roller mounting bracket through a tensioning spring to enable effective unrolling of the flexible composite boom. The stored strain energy in the rolled boom enables passive deployment of the payload when the assembly transitions from a restrained stowed configuration to an extended configuration.
[0047] In addition, an enclosure is provided to contain the mast components in the stowed state.
[0048] In an embodiment, the anti-blossoming guide is formed by curved links joined by link pins and fasteners with anti-blossoming rollers mounted thereon, while the tensioning spring applies a controlled inward radial force through a spring interface bracket.
[0049] In an embodiment, the unrolling path of the flexible composite boom is guided by a pair of boom guides consisting of guide roller brackets and guide rollers that regulate extension along a fixed direction.
[0050] In an embodiment, the flexible composite boom supports multiple payload mounting hubs distributed along its length.
[0051] In an embodiment, each payload mounting hub carries hub support rollers that slide along the surface of the boom and includes tensioning cable attachment points.
[0052] In an embodiment, tensioning cables are connected between the base plate, the payload mounting hubs, and the payload mounting plate to ensure sequential transfer of deployment force as the boom unrolls.
[0053] In another embodiment, multiple flexible composite booms are attached to rollers mounted on a multi-boom roller mounting bracket attached to the base plate. The multi-boom arrangement is accompanied by an anti-blossoming guide coupled through tensioning springs to prevent lateral expansion of the booms during deployment and direct strain energy toward linear extension of the payload mounting plate. Multiple payloads mounting hubs with hub support rollers and tensioning cables are arranged along the booms for simultaneous or sequential payload extension.
[0054] In another embodiment, deployable mast assembly also forms part of a staggered mast assembly designed to sequentially deploy payloads along multiple directions from the carrier structure. The staggered mast assembly includes several deployable masts connected through interface brackets to obtain coordinated deployment.
[0055] In another embodiment, the deployable mast assembly can be integrated into a multi-mast assembly that houses multiple deployable masts within a single mast housing. Each deployable mast extends a corresponding payload in a required direction and spacing, enabling deployment of multiple payloads from a single carrier structure in a compact, energy-efficient, and precise manner.
[0056] The various embodiments throughout the disclosure will be explained in more detail with reference to FIGs. 1A-15C.
[0057] Referring to FIG. 1A, an exemplary view of proposed deployable mast assembly with a single composite boom and a single payload, in stowed configuration, is disclosed.
[0058] Referring to FIG. 1B, an exemplary view of proposed deployable mast assembly with a single composite boom and a single payload, in deployed configuration, is disclosed.
[0059] Referring to FIGs. 2A, 2B, 2C and 2D, exemplary views of different parts of proposed deployable mast assembly with a single composite boom and a single payload are disclosed.
[0060] In an embodiment, a deployable mast assembly (100) (interchangeably referred to as mast assembly (100), hereinafter) is disclosed for extending at least one payload (106) by a predetermined distance from a carrier structure (102). The carrier structure (102) can be a spacecraft, a satellite, or any other carrier platform configured to house and deploy payload (106) in space or other operational environments. The mast assembly (100) includes at least one base plate (202) configured to be mounted on the carrier structure (102), at least one roller (206) mounted rotatably on at least one roller mounting bracket (204) attached to the at least one base plate (202), and adapted to support at least one flexible composite boom (108) in a rolled configuration, as shown in FIG. 2A. The composite boom (108) having a first end attached to the roller (206) and a second end attached to at least one payload mounting plate (220) that supports the payload (106). In this configuration, the flexible composite boom (108) is stored in a compact rolled state during stowage and configured to unroll in a controlled manner during deployment, as shown in FIGs. 1A and 1B, without the use of any active actuation mechanisms such as electric motors.
[0061] In an embodiment, the mast assembly (100) includes at least one anti-blossoming guide (208) coupled to the roller mounting bracket (204) through at least one tensioning spring (210) to facilitate controlled unrolling of the flexible composite boom (108). The mast assembly (100) further includes at least one pair of boom guides (212, 214) configured to guide unrolling of the flexible composite boom (108) along a predetermined direction, as shown in FIG. 2B. Each boom guide (212, 214) comprises a guide roller bracket (216) having a set of guide rollers (218) rotatably mounted thereon, as shown in FIG. 2C, the guide rollers (218) being configured to ensure smooth and controlled extension of the boom (108) with minimal friction. The pair of boom guides (212, 214) directs the boom (108) along a specific deployment path that is typically, but not necessarily, perpendicular to the plane of the base plate (202). The distal end of the boom (108) is connected to a payload mounting plate (220) that supports at least one payload (106) and extends away from the carrier structure (102) as the mast assembly (100) transitions from the stowed configuration to the deployed operational configuration. The entire mast assembly (100) is housed within an enclosure (222) configured to accommodate and protect all components during stowage and launch.
[0062] In an embodiment, the mast assembly (100) further includes an anti-blossoming assembly configured to channelize the release of strain energy stored in the rolled boom (108) into a linear unrolling motion, while preventing an undesired energy-dissipative phenomenon known as “blossoming,” in which the rolled boom expands radially without effective extension. The anti-blossoming assembly includes the anti-blossoming guide (208) and the tensioning spring (210). The anti-blossoming guide (208) comprises a set of curved links (226) interconnected through link pins (230) and fasteners (228), with a plurality of anti-blossoming rollers (232) rotatably mounted on the curved links (226), as shown in FIG. 2D. The tensioning spring (210) is coupled between the roller mounting bracket (204) and a spring interface bracket (224) of the anti-blossoming guide (208) to apply a controlled inward radial force on the rolled boom (108), thereby maintaining compactness and stability during unrolling.
[0063] During stowage, the proximal end of the flexible composite boom (108) is rolled onto the roller (206), flattening from its initial semicircular shape and forming a tightly coiled spiral configuration. As the boom (108) is rolled, the anti-blossoming rollers (232) are pressed against the outer surface of the rolled boom due to the tension applied by the springs (210). The rolling process causes the anti-blossoming guide (208) to move radially outward, thereby extending the tensioning springs (210). The spring force transmitted through the anti-blossoming guide (208) prevents radial expansion of the rolled boom (108) that may otherwise occur due to strain energy release. Consequently, the strain energy stored in the flexible composite boom (108) during rolling-induced deformation is effectively released as a controlled linear unrolling motion, thereby ensuring precise extension of the distal end of the boom (108) and the payload mounting plate (220).
[0064] In an embodiment, the mast assembly (100) includes at least one enclosure (222) configured to accommodate and secure components of the mast assembly (100) in the restrained stowed configuration. The enclosure (222) ensures safe containment of the base plate (202), roller mounting bracket (204), roller (206), and the flexible composite boom (108) during storage and launch, preventing accidental deployment or mechanical interference until intentional activation of the deployment sequence.
[0065] The mast assembly (100), when released from the restrained stowed configuration, passively deploys by utilising the strain energy stored within the rolled configuration of the flexible composite boom (108), resulting in unrolling of the boom (108) and extension of the payload (106) away from the carrier structure (102).
[0066] Referring to FIGs. 3A to 3D, exemplary views of the deployable mast assembly (100) with a single flexible composite boom (108) and a single payload (106) are illustrated, in accordance with an embodiment of the present disclosure. The figures depict two alternative rolling configurations of the flexible composite boom (108), namely, a same-sense rolling configuration (FIGs. 3A, 3B) and an opposite-sense rolling configuration (FIGs. 3C, 3D). In the same-sense rolling configuration, the flexible composite boom (108) is rolled onto the concave surface of its semi-cylindrical section, whereas in the opposite-sense rolling configuration, the flexible composite boom (108) is rolled onto the convex surface of the semi-cylindrical section. Based on the selected rolling configuration, the mounting arrangement of the proximal end of the boom (108) to the roller (206) varies accordingly.
[0067] In the same-sense configuration, as shown in FIGs. 3A and 3B, the proximal end of the flexible composite boom (108) is mounted to the roller (206) by means of a fastener or rivet positioned near the proximal end. Since a portion of the boom (108) may interfere with the roller (206) in the fully deployed configuration, a trimmed region is provided around the mounting point such that the boom (108) conforms to the curvature of the roller (206).
[0068] In the opposite-sense configuration, as shown in FIGs. 3C and 3D, a similar mounting arrangement is employed using the fastener; however, since the boom (108) unrolls away from the roller (206), trimming of the boom (108) around the mounting point is not required.
[0069] Although a cylindrical flexible composite boom (108) has been illustrated for clarity, the flexible composite boom (108) may alternatively be configured with various cross-sectional geometries such as elliptical, lenticular, or double-omega profiles, depending on structural and deployment requirements. The boom (108) may be fabricated from high-strain composite materials reinforced with fibers such as glass, Kevlar, or carbon, combined with a suitable polymeric resin matrix to obtain required flexibility, stiffness, and strain energy storage characteristics. The boom (108) may also be fabricated from thin metallic sheets comprising of metals suitable for space usage such as Titanium alloys, Berrylium Copper etc.
[0070] Referring to FIGs. 4A, 4B, and 4C, exemplary views of the deployable mast assembly (100) with the single flexible composite boom (108) and the single payload (106) are illustrated in a stowed configuration, a partially deployed configuration, and a fully deployed configuration, respectively, in accordance with an embodiment of the present disclosure. The sequence shown (from left to right) represents the progressive deployment of the mast assembly (100) from a compact stowed state to a fully extended configuration.
[0071] In an exemplary implementation, when the satellite or carrier structure (102) reaches the required orbital or spatial location, a hold down and release mechanism that secures the deployable mast assembly (100) in the stowed configuration by constraining an end plate is actuated by a single pulse or signal. Actuation of the hold down and release mechanism releases the payload mounting plate (220), which subsequently extends outward as a result of the strain energy driven unrolling of the flexible composite booms (108). The anti-blossoming guide (208) and tensioning springs (210), functions to prevent undesired lateral expansion or blossoming of the booms (108) during deployment. This ensures that the stored strain energy is efficiently converted into linear extension of the distal end of each boom (108), thereby propelling the payload mounting plate (220) away from the base plate (202). The set of boom guides (212, 214), in conjunction with the guide roller bracket (216) carrying guide rollers (218), further ensures that the flexible composite booms (108), and consequently the payload mounting plate (220), extend along a predetermined path, typically but not necessarily perpendicular to the plane of the base plate (202). Although not explicitly shown in the figures, an optional rotary damper may be operatively coupled to the roller (206) to regulate its angular velocity and thereby control the deployment rate of the flexible composite booms (108), resulting in smooth and uniform extension of the payload mounting plate (220). Upon complete deployment, the flexible composite booms (108) fully unroll from the roller (206) and attain a semi-cylindrical cross-section along their entire length, transitioning from their flattened stowed configuration as depicted in FIGs. 3A to 3D. At this stage, the booms (108) in both same sense and opposite sense rolling configurations cannot be retracted without the application of an external torque to the roller (206) and are therefore latched in the fully deployed configuration. The separation distance between the payload (106) and the carrier structure (102) can be precisely tailored by adjusting the length of the flexible composite booms (108), thereby enabling the deployable mast assembly (100) to be customised for any required spacing between the payload (106) and the carrier structure (102).
[0072] Referring to FIGs. 5A, 5B, 5C, 5D, and 5E, exemplary views of the proposed deployable mast assembly (100) with the single flexible composite boom (108) configured to deploy and extend multiple payloads (506) are illustrated, in accordance with an embodiment of the present disclosure. These figures illustrate second embodiment of the deployable mast assembly (100), that represents the mast assembly (100) consisting of the single flexible composite boom (108) that deploys to extend the multiple payloads (506) from the satellite or spacecraft (102), and includes certain parts and features in addition to the configuration of the above embodiments.
[0073] In an embodiment, the boom (108) supports a plurality of payload mounting hubs (502) arranged along its length, each adapted to carry at least one payload (506). Each payload mounting hub (502) includes a set of hub support rollers (508) configured to engage with and slide along the outer surface of the flexible composite boom (108) during deployment. A tensioning cable attachment points (510) are disposed circumferentially around each payload mounting hub (502) for connecting tensioning cables (504). In addition, tensioning cables (504) are attached between the base plate (202), the plurality of payload mounting hubs (502), and the payload mounting plate (220). The tensioning cables (504) are coiled within the enclosure (222) in the stowed configuration and are configured to uncoil sequentially during deployment. These cables transmit deployment force from the payload mounting plate (220) to successive payload mounting hubs (502) in a controlled manner. The payload mounting hubs (502) are guided along the flexible composite boom (108) by means of the hub support rollers (508) mounted on each hub (502). Additional payloads (506) can be mounted on the payload mounting hubs (502), apart from the primary payload (106) supported on the payload mounting plate (220).
[0074] When the satellite or spacecraft (102) reaches the required orbital or spatial location, the hold down and release mechanism that secures the deployable mast assembly (100) in the stowed configuration by constraining the payload mounting plate (220) is actuated by a single electrical pulse or signal. Actuation of the release mechanism allows the payload mounting plate (220) to extend outward due to the strain energy-driven unrolling of the flexible composite boom (108). As the payload mounting plate (220) extends away from the base plate (202), the tensioning cables (504) between the payload mounting plate (220) and the nearest payload mounting hub (502) extend from their coiled position. Once these cables reach full extension, the deployment force is transmitted to the nearest payload mounting hub (502), causing it to move outward along the boom (108).
[0075] Referring now to FIGs. 6A, 6B, and 6C, which illustrate the stowed, partially deployed, and fully deployed configurations respectively, the deployable mast assembly (100) extends sequentially from left to right. As the payload mounting plate (220) continues to extend, each subsequent payload mounting hub (502) is pulled outward in sequence through the tensioning cables (504) connecting adjacent hubs (502). The hub support rollers (508) guide each payload mounting hub (502) smoothly along the flexible composite boom (108) as it transitions from the stowed to the deployed configuration. At the end of deployment, the flexible composite boom (108) is fully unrolled, and all tensioning cables (504) are in a taut state. The taut cables (504) perform two functions: first, they structurally connect the base plate (202) to the payload mounting plate (220) through the intermediate hubs (502), providing rigidity to the extended mast; and second, they maintain the positions of the payload mounting hubs (502) along the deployed boom (108). The spacing between the payload mounting hubs (502) and the base plate (202) can be precisely controlled by adjusting the lengths of the corresponding tensioning cables (504).
[0076] Although FIGs. 6A to 6C illustrate an embodiment with three payload mounting hubs (502), it is to be understood that any practical number of hubs (502) can be accommodated along the flexible composite boom (108) depending on mission requirements.
[0077] Referring to FIGs. 7A, 7B, and 7C, exemplary views of the proposed deployable mast assembly (100) with multiple flexible composite booms (108) configured to extend the single payload (106) are illustrated, in accordance with an embodiment of the present disclosure. In this embodiment, the deployable mast assembly (100) includes a set of flexible composite booms (108), each configured to unroll from the corresponding roller (206) mounted on a multi-boom roller mounting bracket (702) attached to the base plate (202). This deployable mast assembly (100) further includes at least one anti-blossoming guide (704) coupled to the multi-boom roller mounting bracket (702) through at least one tensioning spring (706). The anti-blossoming guide (704) prevents lateral expansion of the plurality of flexible composite booms (108) during deployment and directs the strain energy stored within the rolled configuration of the booms (108) toward linear extension of the payload mounting plate (220).
[0078] Referring to FIGs. 7D and 8A, exemplary views of the proposed deployable mast assembly (100) with multiple flexible composite booms (108) configured to extend a single payload (106), where the booms (108) are rolled in the same sense, are illustrated, in accordance with an embodiment of the present disclosure. These figures illustrate third embodiment of the deployable mast assembly (100), in this configuration, each flexible composite boom (108) is rolled onto its corresponding roller (206) mounted on the multi-boom roller mounting bracket (702) in the same direction, such that all booms unroll synchronously from their concave surfaces during deployment.
[0079] Referring to FIGs. 7E and 8B, exemplary views of a proposed deployable mast assembly (100) with multiple flexible composite booms (108) configured to extend a single payload (106), where the booms are rolled in opposite senses, are illustrated, in accordance with another embodiment of the present disclosure. In this configuration, the flexible composite booms (108) are rolled alternately in opposite directions onto their respective rollers (206) mounted on the multi-boom roller mounting bracket (702). The opposite sense rolling provides enhanced deployment stability and minimizes torsional imbalance during extension of the payload mounting plate (220). Similar to the previous configuration, at least one anti-blossoming guide (704) is coupled to the multi-boom roller mounting bracket (702) through at least one tensioning spring (706) to control radial expansion and ensure directed energy release toward linear extension of the payload mounting plate (220).
[0080] Referring to FIGs. 9A, 9B, and 9C, exemplary views of the proposed deployable mast assembly (100) with multiple flexible composite booms (108) extending a single payload (106), shown respectively in stowed configuration, partially deployed configuration, and fully deployed configuration, are illustrated, in accordance with an embodiment of the present disclosure. FIGs. 9A, 9B, and 9C depicts the sequential deployment of the multi-boom mast from the compact stowed configuration to the fully extended deployed configuration (from left to right). When the deployable mast assembly (100) is to be extended, the hold down and release mechanism that secures the deployable mast assembly (100) in the stowed configuration by constraining the payload mounting plate (220) is actuated by a single electrical pulse or signal. Upon actuation, the hold down and release mechanism transitions to a release state, freeing the payload mounting plate (220). The payload mounting plate (220) then extends outward due to the strain energy-driven unrolling of the flexible composite booms (108). All the flexible composite booms (108) unroll simultaneously from their respective rollers (206), thereby extending the payload mounting plate (220) away from the base plate (202).
[0081] Although FIGs. 7A to 9C illustrate an embodiment having three flexible composite booms (108) arranged circumferentially around the payload mounting plate (220), it is to be understood that the present embodiment can accommodate any number of flexible composite booms (108) in various circumferential or spatial arrangements, depending on the required deployment configuration and mission requirements.
[0082] Referring to FIGs. 10A, 10B, 10C, 10D, and 10E, exemplary views of the proposed deployable mast assembly (100) with multiple flexible composite booms (108) configured to deploy and extend multiple payloads (506) are illustrated, in accordance with an embodiment of the present disclosure. These figures illustrate the fourth embodiment of the deployable mast assembly (100) in stowed and partially deployed configurations. This embodiment represents the mast assembly (100) consisting of multiple flexible composite booms (108) that deploy to extend multiple payloads (506) from a satellite or spacecraft (102) and includes certain parts and features in addition to those of the third embodiment.
[0083] The deployable mast assembly (100) of the present embodiment includes the base plate (202) configured to be attached to the satellite or spacecraft (102). The rollers (206) are mounted on multi-boom roller mounting brackets (702) attached to the base plate (202) and serve as structures onto which the flexible composite booms (108) are rolled and secured. The anti-blossoming guide (704) is coupled to the roller mounting brackets (702) via tensioning springs (708) to prevent lateral expansion of the flexible composite booms (108) during deployment. The distal ends of the flexible composite booms (108) are attached to a payload mounting plate (220) that extends outward as the booms unroll. The features and deployment functionality of this configuration are similar to those of the third embodiment.
[0084] In addition, multiple payloads (506) spaced apart from the satellite or spacecraft (102) and from each other are deployed from the stowed configuration in a sequential manner. A payload mounting hub (1002) is provided, including ribs on which hub support rollers (508) are mounted. These hub support rollers (508) are positioned to slide along the length of the deployed flexible composite booms (108). The number of rib-mounted hub support rollers (508) equals the number of flexible composite booms (108) employed, and their radial locations are fixed such that each hub support roller (508) engages the central spine region of the corresponding flexible composite boom (108).
[0085] Further, multiple tensioning cable attachment points (510) are provided on the periphery of each payload mounting hub (1002). The tensioning cables (504) are attached between the payload mounting plate (220) and the adjacent payload mounting hub (1002), between successive payload mounting hubs (1002), and between the payload mounting hub (1002) nearest to the base plate (202) and corresponding mounting points on the base plate (202). Each payload mounting hub (1002) includes attachment points for additional payloads (506), apart from the payload (106) mounted on the payload mounting plate (220). The entire deployable assembly is compactly stowed within an enclosure (222), with the tensioning cables (504) coiled for compact storage.
[0086] When the mast is to be extended, the hold down and release mechanism that secures the deployable mast assembly (100) in the stowed configuration by constraining the payload mounting plate (220) is actuated by a single electrical pulse or signal. This actuation releases the payload mounting plate (220), which further extends outward due to the strain energy-driven unrolling of all the flexible composite booms (108) simultaneously. As the payload mounting plate (220) extends away from the base plate (202), the tensioning cables (504) attached between the payload mounting plate (220) and the adjacent payload mounting hub (1002) uncoil from their stored position. Once the distance between the payload mounting plate (220) and the adjacent payload mounting hub (1002) equals the length of the tensioning cable (504), further extension of the payload mounting plate (220) causes the tensioning cable (504) to become taut and transfer deployment force to the adjacent payload mounting hub (1002), thereby extending it outward. Each payload mounting hub (1002) thus moves along the direction of deployment, guided by its hub support rollers (508) along the flexible composite booms (108).
[0087] Referring to FIGs. 11A, 11B, and 11C, exemplary views of the proposed deployable mast assembly (100) with multiple flexible composite booms (108) configured to deploy and extend multiple payloads (506) are illustrated, showing stowed, partially deployed, and fully deployed configurations respectively, in accordance with an embodiment of the present disclosure. The set of flexible composite booms (108) supports a plurality of payload mounting hubs (1002), each adapted to carry at least one payload (506) along the length of the flexible composite booms (108). Each payload mounting hub (1002) comprises a plurality of hub support rollers (508) positioned to engage corresponding flexible composite booms (108) for guided linear motion during deployment. A plurality of tensioning cables (504) are attached between the base plate (202), the plurality of payload mounting hubs (1002), and the payload mounting plate (220). These cables uncoil and extend during unrolling of the flexible composite booms (108) and sequentially transmit deployment force from the payload mounting plate (220) to successive payload mounting hubs (1002).
[0088] During deployment, the payload mounting plate (220) extends outward, causing the tensioning cables (504) between the payload mounting plate (220) and the nearest payload mounting hub (1002) to uncoil. Once the cable reaches its full length, further extension of the payload mounting plate (220) transfers the deployment force to the adjacent payload mounting hub (1002), resulting in its guided outward motion along the flexible composite booms (108). Continued extension leads to sequential deployment of subsequent payload mounting hubs (1002) from the enclosure (222) in the direction of extension.
[0089] At full deployment, the flexible composite booms (108) are completely unrolled and all tensioning cables (504) are taut. The taut cables provide structural rigidity to the mast assembly by forming tensile linkages between the base plate (202) and the payload mounting plate (220), while maintaining the longitudinal positions of the payload mounting hubs (1002) along the mast length. The spacing between the payload mounting hubs (1002) and the base plate (202) can be customized by adjusting the lengths of the tensioning cables (504) interconnecting the hubs, the base plate (202), and the payload mounting plate (220).
[0090] Although the embodiment illustrated in FIGs. 10A to 11C shows three payload mounting hubs (1002). The configuration can be adapted to accommodate any number of hubs and payloads as required.
[0091] Referring to FIGs. 12A, 12B, and 13, exemplary views of a staggered mast assembly (1202) are illustrated in stowed and deployed configurations, in accordance with an embodiment of the present disclosure. The staggered mast assembly (1202) represents a fifth embodiment of the deployable mast assembly (100), consisting of multiple deployable masts arranged sequentially to extend a payload (106) from a satellite or spacecraft. This configuration is suited for applications requiring translation of the payload (106) along multiple directions due to engineering requirements or spatial constraints imposed by other subsystems or components of the spacecraft. The staggered mast assembly (1202) includes additional parts and features beyond those described in the previous embodiments while maintaining compatibility with the assembly architecture.
[0092] As shown in FIG. 13, the staggered mast assembly (1202) includes base plate (202) attached to the satellite or spacecraft (102). Multiple deployable masts are interconnected by interface brackets (1402) such that each mast deploys along a particular direction, collectively obtaining the required spatial separation of the payload (106) from the spacecraft (102). Each individual deployable mast of the staggered mast assembly (1202) can be configured according to any of the embodiments described previously or a combination thereof.
[0093] Each deployable mast includes rollers (206) mounted on roller mounting brackets (204/702) secured to the corresponding base plate (202). The rollers (206) serve as attachment structures for the flexible composite booms (108). The anti-blossoming guide (208 or 704) is coupled to the roller mounting brackets (204) via tensioning springs (210 or 708) to guide controlled unrolling of the booms. The opposite ends of the flexible composite booms (108) are attached to the payload mounting plate (220), which extends as the booms unroll. The payload mounting plate (220) of the outermost deployable mast supports the payload (106), while the payload mounting plates (220) of the intermediate deployable masts are connected to the interface brackets (1402) that support the base plates (202) of the adjacent deployable masts. This configuration enables each deployable mast to extend the base plate (202) of the subsequent mast, thereby sequentially extending the payload (106) away from the satellite or spacecraft (102). Each deployable mast further includes an enclosure (222) to accommodate its components and protect them from external environmental conditions.
[0094] Referring to FIGs. 14A, 14B, 14C, and 14D, exemplary views of the staggered mast assembly (1202) are illustrated respectively in stowed, stage 1, stage 2, and stage 3 deployed configurations, in accordance with an embodiment of the present disclosure. The sequence of deployment progresses from a compact stowed configuration to a fully extended configuration in multiple stages. Multi-stage deployment can be obtained either by integrating individual hold down and release actuators with each deployable mast or by employing a stagewise hold down and release mechanism that releases each subsequent deployable mast only after the complete deployment of the preceding mast.
[0095] When extension is initiated, the hold down and release mechanism securing the staggered mast assembly (1202) in the stowed configuration is actuated by a single electrical pulse or signal. This actuation releases the payload mounting plate (220) of the deployable mast positioned closest to the base plate (202), allowing it to extend through strain-energy-driven unrolling of the flexible composite booms (108). Upon full deployment, the flexible composite booms (108) of the first mast unroll completely from the roller (206), transitioning from a flattened rolled shape to a semi-cylindrical configuration along their entire length. At this stage, the booms cannot re-roll onto the roller (206) without external torque and are therefore latched in the deployed position.
[0096] Following this, the payload mounting plate (220) of the next deployable mast is released either by a separate actuator or by the stagewise release mechanism, leading to its extension through the same strain-energy-driven unrolling process. This sequential deployment continues until all deployable masts within the staggered mast assembly (1202) are fully extended, obtaining the required spatial separation between the payload (106) and the spacecraft (102). The degree of spatial separation is controlled by adjusting the lengths of the flexible composite booms (108) in each deployable mast, allowing the assembly to be tailored for mission-specific requirements.
[0097] Although FIGs. 14A-14D illustrate a three-stage deployment, the staggered mast assembly (1202) can include any number of deployable masts with corresponding deployment stages, and each mast can employ any configuration described in embodiments first, second, third, and fourth, enabling multi-directional extension in practical realizations.
[0098] Referring to FIGs. 15A, 15B, and 15C, exemplary views of a deployable multi-mast assembly (1502) are illustrated in stowed, partially deployed, and fully deployed configurations, in accordance with an embodiment of the present disclosure. The deployable mast assembly (100) forms part of the multi-mast assembly (1502), which is configured to deploy multiple payloads (106) from the carrier structure (102). The multi-mast assembly (1502) comprises a multiple-mast housing enclosing a plurality of deployable masts, each mast including the composite boom (108) mounted on rollers (206) for extending the corresponding payload (106). The multi-mast assembly (1502) represents a sixth embodiment of the deployable mast assembly (100). This embodiment includes multiple deployable masts that can operate concurrently or sequentially to extend multiple payloads (106) from the satellite or spacecraft (102). Each payload can be translated along a different direction based on practical application requirements. The multi-mast assembly (1502) integrates multiple instances of the previously described deployable mast embodiments within a single enclosed structure.
[0099] Each deployable mast within the multi-mast assembly (1502) includes rollers (206) mounted on roller mounting brackets (204 or 702) attached to the corresponding base plate (202). The rollers (206) serve as mounting structures for the flexible composite booms (108). An anti-blossoming guide (208 or 704) is connected to the roller mounting brackets (204 or 702) through tensioning springs (210 or 708). The opposite ends of the flexible composite booms (108) are fixed to the payload mounting plates (220), which extend as the booms unroll. This results in the extension of each deployable mast, thereby positioning the corresponding payload (106) at a required spacing from the satellite or spacecraft (102). The multi-mast housing (1502) provides enclosure and protection for all deployable masts during stowage and deployment.
[00100] The sequence of deployment of the multi-mast assembly (1502), as shown in FIGs. 15A to 15C, progresses from a compact stowed configuration to the fully deployed configuration. Each individual deployable mast, along with its corresponding payload mounting plate (220) and optionally payload mounting hubs (502 or 1002), can be deployed independently, concurrently, or sequentially as required. Deployment is obtained by actuating a hold down and release mechanism that constrains each payload mounting plate (220).
[00101] When a deployable mast within the multi-mast assembly (1502) is to be extended, the corresponding hold down and release actuator is triggered by a single electrical pulse or signal. Upon actuation, the mechanism releases the payload mounting plate (220), allowing it to extend due to the strain-energy-driven unrolling of the flexible composite booms (108). Once fully extended, the flexible composite booms (108) unroll completely from the rollers (206) and latch in position, forming a rigid deployed structure. Each deployable mast can thus be individually actuated to obtain the required deployment sequence.
[00102] The spatial separation between each payload (106) and the satellite or spacecraft (102) can be precisely controlled by varying the lengths of the flexible composite booms (108) corresponding to each deployable mast. In configurations involving multiple payloads (506) on a single deployable mast, the separation between the payloads (506) and the spacecraft (102) is determined by the lengths of the tensioning cables (504) associated with that mast.
[00103] Although FIGs. 15A-15C illustrates an embodiment with four deployable masts, the multi-mast assembly (1502) can include any number of deployable masts, each configured according to any of the embodiments above explained, in a practical realization.
[00104] In an embodiment, the deployable mast assembly (100) includes a hold-down and release mechanism (not shown) to maintain the deployable mast assembly (100) in a compact stowed configuration during launch, handling, and non-operational phases. For instance, the hold-down and release mechanism can be a mechanical locking arrangement including a latch element engaged with a structural portion of the deployable mast assembly (100) to restrict relative movement between a deployable component and a fixed component. This retaining mechanism engages at least one of a base plate (202), a payload mounting plate (220), or a roller mounting bracket (204 or 702) to prevent extension of the flexible composite booms (108) while the deployable mast assembly (100) is in the stowed configuration.
[00105] In addition, the hold-down and release mechanism restrains the deployable mast assembly (100) against unintended movement or deployment while the carrier structure (102) is not in an operational state. The retaining mechanism is further configured to allow deployment of the deployable mast assembly (100) utilizing a hold-down and release actuator when a predefined condition of the carrier structure (102) occurs. Such a predefined condition corresponds to the carrier structure (102) reaching a specified orbital position or spatial state suitable for deployment. Upon occurrence of this predefined condition, the retaining mechanism permits transition of the deployable mast assembly (100) from the stowed configuration to the deployed configuration, thereby enabling controlled and intentional extension of the deployable mast assembly (100).
[00106] In an embodiment, the deployable mast assembly (100) further includes a mounting apparatus (not shown) configured to mechanically couple the deployable mast assembly (100) to the carrier structure (102). For instance, the mounting apparatus can be implemented as a structural interface comprising a mounting plate, bracket, or flange that is fixed to a load-bearing portion of the carrier structure (102). The mounting apparatus is configured to transfer structural loads generated during launch, handling, and deployment between the deployable mast assembly (100) and the carrier structure (102).
[00107] This mounting apparatus includes an orientation mechanism configured to set an angular orientation of the deployable mast assembly (100) relative to the carrier structure (102). The orientation mechanism can include a rotatable interface, indexed positioning features, or adjustable fastener locations that enable the deployable mast assembly (100) to be mounted at a predetermined angular orientation. The angular orientation can be set prior to deployment to define a deployment direction, adjusted during deployment to accommodate clearance requirements, or set after deployment to align the deployed mast with a target operational orientation. The orientation mechanism maintains the selected angular orientation throughout deployment and operation, thereby ensuring controlled positioning of the deployable mast assembly (100) with respect to the carrier structure (102).
[00108] Thus, the disclosure provides the versatile and modular deployable mast assembly capable of extending single or multiple payloads along customizable directions with precise spatial control. The configuration ensures compact stowage, reliable deployment, and structural rigidity, making it suitable for a wide range of satellite and space applications.
[00109] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable those having ordinary skill in the art to make and use the invention when combined with information and knowledge available to those having ordinary skill in the art.

ADVANTAGES OF THE PRESENT DISCLOSURE
[00110] The present disclosure enables reliable extension of payloads from carrier structure through a structurally stable and repeatable deployment mechanism.
[00111] The present disclosure obtains significant reduction in weight and storage volume, thereby improving stowage efficiency and integration within carrier structure.
[00112] The present disclosure provides a deployment assembly that operates without external power consumption, enhancing operational simplicity, energy efficiency, and system reliability.
[00113] The present disclosure ensures precise directional control and stable positioning of payloads, minimizing undesired motion or misalignment during deployment and operation. , Claims:1. A deployable mast assembly (100) for extending at least one payload (106) from a carrier structure (102), the assembly (100) comprising:
at least one base plate (202) configured for attachment to the carrier structure (102);
at least one roller (206) mounted rotatably on at least one roller mounting bracket (204) attached to the at least one base plate (202), and adapted to support at least one flexible composite boom (108) in a rolled configuration, wherein the at least one flexible composite boom (108) having a first end attached to the at least one roller (206) and a second end attached to at least one payload mounting plate (220); and
at least one anti-blossoming guide (208) coupled to the at least one roller mounting bracket (204) through at least one tensioning spring (210) for guiding controlled unrolling of the at least one flexible composite boom (108);
wherein the deployable mast assembly (100), when released from a restrained stowed configuration, is configured to passively deploy by utilising strain energy stored within the rolled configuration of the at least one flexible composite boom (108) to unroll the at least one flexible composite boom (108) and extend the at least one payload (106) away from the carrier structure (102), and wherein at least one enclosure (222) configured to accommodate components of the deployable mast assembly (100) in the restrained stowed configuration.
2. The deployable mast assembly (100) as claimed in claim 1, wherein the at least one anti-blossoming guide (208) comprises a set of curved links (226) connected through link pins (230) and fasteners (228) and having a set of anti-blossoming rollers (232) rotatably mounted thereon, and at least one tensioning spring (210) is coupled between the roller mounting bracket (204) and a spring interface bracket (224) of the anti-blossoming guide (208) to apply a controlled inward radial force on the rolled at least one flexible composite boom (108).
3. The deployable mast assembly (100) as claimed in claim 1, further comprises at least one pair of boom guides (212, 214) to guide unrolling of the at least one flexible composite boom (108) along a predetermined direction, wherein each boom guide (212, 214) comprises a guide roller bracket (216) having a set of guide rollers (218) rotatably mounted thereon, the set of guide rollers (218) being configured controlled extension of the at least one flexible composite boom (108).
4. The deployable mast assembly (100) as claimed in claim 1, wherein the at least one flexible composite boom (108) is configured to support a plurality of payload mounting hubs (502) each adapted to carry at least one payload (506) along a length of the at least one flexible composite boom (108), and wherein each payload mounting hub (502) comprises:
a set of hub support rollers (508) configured to engage with and slide along an outer surface of the at least one flexible composite boom (108) during deployment; and
a plurality of tensioning cable attachment points (510) disposed circumferentially around each payload mounting hub (502).
5. The deployable mast assembly (100) as claimed in claim 6, further comprises a plurality of tensioning cables (504) attached between the at least one base plate (202), the plurality of payload mounting hubs (502), and the at least one payload mounting plate (220), wherein the plurality of tensioning cables (504) are configured to uncoil and extend during unrolling of the at least one flexible composite boom (108) and to sequentially transmit deployment force from the at least one payload mounting plate (220) to successive payload mounting hubs (502).
6. The deployable mast assembly (100) as claimed in claim 1, wherein the at least one flexible composite boom (108) comprises a set of flexible composite booms (108) each configured to unroll from the corresponding roller (206) mounted on a multi-boom roller mounting bracket (702) attached to the at least one base plate (202).
7. The deployable mast assembly (100) as claimed in claim 8, further comprises at least one anti-blossoming guide (704) coupled to the multi-boom roller mounting bracket (702) through at least one tensioning spring (706) to prevent lateral expansion of the plurality of flexible composite booms (108) during deployment and for directing strain energy towards linear extension of the payload mounting plate (220).
8. The deployable mast assembly (100) as claimed in claim 8, wherein the set of flexible composite booms (108) is configured to support a plurality of payload mounting hubs (1002), each adapted to carry at least one payload (506) along a length of the set of flexible composite booms (108).
9. The deployable mast assembly (100) as claimed in claim 10, wherein each payload mounting hub (1002) comprises a plurality of hub support rollers (508) disposed on the plurality of payload mounting hub (1002), each hub support roller (508) being positioned to engage with the corresponding flexible composite boom (108) to facilitate guided linear motion of the payload mounting hub (1002) during deployment.
10. The deployable mast assembly (100) as claimed in claim 10, further comprises a plurality of tensioning cables (504) attached between the at least one base plate (202), the plurality of payload mounting hubs (1002), and the at least one payload mounting plate (220), the plurality of tensioning cables (504) being configured to uncoil and extend during unrolling of the plurality of flexible composite booms (108) and to sequentially transmit deployment force from the at least one payload mounting plate (220) to successive payload mounting hubs (1002).
11. The deployable mast assembly (100) as claimed in claim 1, wherein the deployable mast assembly (100) forms a part of a staggered mast assembly (1202) configured to sequentially deploy the at least one payload (106) along multiple directions from the carrier structure (102), wherein the staggered mast assembly (1202) comprises a plurality of deployable mast assemblies (100) connected to each other by at least one interface bracket (1402).
12. The deployable mast assembly (100) as claimed in claim 1, wherein the deployable mast assembly (100) forms a part of a multi-mast assembly (1502) configured to deploy multiple payloads (106) from the carrier structure (102), the multi-mast assembly (1502) comprising a multiple mast housing enclosing a plurality of deployable mast assemblies (100), each deployable mast assembly (100) comprising the at least one flexible composite booms (108) mounted on the rollers (206) for extending the corresponding payload (106).
13. The deployable mast assembly (100) as claimed in claim 1, further comprising a retaining mechanism configured to hold the deployable mast assembly (100) in a compact stowed configuration and to permit deployment of the deployable mast assembly (100) upon occurrence of a predefined condition of the carrier structure (102).
14. The deployable mast assembly (100) as claimed in claim 1, further comprising a mounting apparatus configured to mechanically couple the deployable mast assembly (100) to the carrier structure (102), the mounting apparatus comprising an orientation mechanism configured to set an angular orientation of the deployable mast assembly (100) relative to the carrier structure (102).