Interconnectable space station module and space station formed therewith

A plurality of manned space station modules are interconnected via end caps into a variety of space station configurations without need for dedicated interconnect modules. Each module preferably comprises an elongated module body, end caps mounted to respective ends of the body and the end caps being in the form of a four sided, truncated pyramid having a truncated side forming a flat, square central end face remote from the body and at right angles to the longitudinal axis of the body, and four flat oblique side faces integral with and about the four sides of the central end face. The body may be cylindrical in form or of cruciform configuration defined by paired right angle intersecting panels. Three modules may be interconnected at their ends to form a triad. Modules may be connected end-to-end by abutting end faces of the end caps, side-face-to-side-face or end-face-to-side-face. The modules may have their axes coplanar, or out of plane, as required.

FIELD OF THE INVENTION 
This invention relates to manned orbiting space stations, and more 
particularly to improved interconnectable modules capable of forming such 
space stations in a vast variety of configurations. 
BACKGROUND OF THE INVENTION 
Orbiting space stations have progressed in two stages. Initially, orbiting 
space stations were designed so that they could be placed in orbit in 
unitary form and sent aloft in one space shot and expanded or otherwise 
modified during deployment into operational configuration. These space 
stations were generally toroidal in form. U.S. Pat. Nos. 3,144,219, 
3,169,725, and 3,332,640 are exemplary of that earlier approach. 
U.S. Pat. No. 3,169,725 involves a high hybrid inflatable body/rigid body 
construction with rigid cylindrical sections joined by flexible connectors 
with the sections connected to a central hub and erectable to form a 
rigid, hexagonal, tubular ring thereabout, upon reaching the desired 
orbit. 
U.S. Pat. No. 3,326,640 involves a partly preconnected structure utilizing 
cylindrical sections which are hinged to each other such that upon 
reaching space, the segments which are clustered closely about the rocket 
carrier on launching, may be extended and joined together to form a 
toroidal structure. 
With the advent of the Space Transportation System Shuttle Launch Vehicle 
(STS), the sections or components of the station are transported into 
orbit in incremental stages constrained by the cargo bay configuration and 
weight limitations associated with the STS shuttle. Under such conditions, 
the incremental parts of the station are then assembled in space into a 
functional space station assembly. Attempts have been made to create an 
acceptable space vehicle module to be joined in space at a predetermined 
earth orbit by a number of other space vehicle modules and to be connected 
together to form a pressure tight space station which is sufficiently 
large and provisioned to support a research or construction crew for 
extended periods of time. 
U.S. Pat. No. 4,057,207 is directed to such a concept which is based on an 
earlier U.S. Pat. No. 3,953,948 permitting the resulting space station 
structure to conform to selected shapes possible in homohedral geometry; 
namely, two types of rings and four varieties of helicies. Structurally, 
each model consists of at least two joined, truncated icosahedra, the 
truncations occurring where up to three pentangular pyramids about 
nonadjacent vertices have been removed from each icosahedra; the 
connection occurring between two truncation surfaces, one from each 
icosahedra. In the system, the end truncation surfaces have alignment and 
docking means so that they can be brought to rigid physical contact with 
other similar truncation surfaces on other modules in up to five 
difference positions. 
The use of an icosahedra as the geometric basis limits the structural faces 
of the modules to being all flat plates which limits the modules to a 
strong, heavy structure to resist the internal pressurization required of 
the station and requires six configurations to build a completed 
structure. Obviously, this design is hardly weight efficient which is a 
primary criteria. Further, the configuration of the icosahedra is neither 
effectively nor efficiently matched to the cargo bay configuration of the 
STS shuttle. While docking ports are provided within one or more of the 
flat faces of the icosahedra module, the system requires another 
specialized module for access to the station interior. The modules fail to 
include provision for load paths to accommodate launch loads. Not only is 
the icosahedra concept complicated, but internal access with the space 
station structure is constrained by the relatively small size of the 
icosahedra units and the interior structural beams required in their 
manufacture. The concept of U.S. Pat. No, 4,057,207 does not permit easy 
accommodation of modules which are to be isolated from the general 
atmospheric circulation system of the station, makes no provision for 
accommodating elements such as air locks and the associated hyperbaric 
chambers and hangar areas for operational equipment such as manned 
maneuvering units, and makes no provision for accommodating logistics 
modules into the space station structure. 
It is, therefore, one object of the present invention to provide an 
improved, interconnectable space station module which is of simplified 
construction, has high strength to weight ratio, is of cylindrical body 
form, purposely sized and configurated to fit within the cargo bay of a 
STS orbiter, which can be interconnected into a variety of patterns 
without need for dedicated interconnect modules, and which has access 
ports to the individual modules which are always available for use as EVA 
air locks, logistics modules docking, etc. 
SUMMARY OF THE INVENTION 
The invention, in part, is directed to a manned space station module which 
can be interconnected into a variety of patterns without need for 
dedicated interconnect modules, has high strength to weight ratio, and 
which, when the module is assembled into space station form, provides 
access ports which are always available for accommodating, on a temporary 
or extended length basis, associated equipment or hyperbaric chamber 
modules. The module comprises: 
an elongated module body, 
end caps mounted to respective ends of the elongated body, the end caps 
being in the form of a four sided truncated pyramid having a truncated 
side forming a flat, square, central end face and four flat oblique side 
faces integral therewith and about the four sides of the central end face. 
The elongated module body may be of elongated cylindrical form or the 
elongated module body may constitute a cruciform truss. Further, the side 
faces of the four sided, truncated pyramid of each end cap may be 
30.degree. to the axis of the module body.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
The present invention is directed principally to the creation of an 
improved interconnectable manned space station module to facilitate the 
interconnection of a plurality of such modules to make up a manned space 
station. 
Reference to FIG. 1 shows an embodiment of one such module, indicated 
generally at 10. The modules, such as module 10, are required to fit 
within the cargo bay of the STS orbiter. Module 10 is generally 
cylindrical in shape, of approximately 14' in diameter and from 20' to 40' 
in length. Once in orbit, a series of modules 10 are assembled and 
interconnected at their ends to build up the manned space station. 
The principal unique feature of the invention is the configuration provided 
to paired end caps, indicated generally at 14, which are fixed to the ends 
of a 14' diameter cylindrical barrel section 16. In the past, end caps 
were employed for modules taking the form of domed plates with a docking 
port in the center. The concept of the present invention replaces the 
domed end plates with a four sided pyramid with a truncated top. End caps 
14 are each composed of a cylindrical end cap base as at 18 and five faces 
of a truncated pyramid. In that respect, the end cap 14 is provided with a 
square, central, flat, truncated end face 20 which is the same dimension 
across as is the slant height of the four pyramid side faces 22. This 
geometry results in five flat surfaces on each end cap 14. Each of these 
surfaces 20, 22 can accommodate a circular port as at 30 for 
interconnecting with other modules or for attaching other external 
structures such as servicing platforms. The flat side faces 22 join the 
central square truncated end face integrally at edges 24 of end face 20. 
Further, lateral edges 26 of side face 22 join the side faces 22 together 
and extend from the corners of end face 20 in the direction of the 
cylindrical barrel section 16 of the module 10. Side faces 22 merge into 
cylindrical base 18 along proximal edges 28 thereof. 
The use of the end caps or end cap fixtures 14 for the modules 10 permits a 
variety of interconnecting configurations to be achieved between modules 
without requiring the use of extra, dedicated interconnecting modules or 
tunnels. A variety of interconnecting configurations forming space 
stations are illustrated in FIGS. 2-7 inclusive. 
FIG. 2 illustrates a manned space station 8a of such configuration that 
four modules 10 interconnect into a common intersection at two 
interconnect locations. The modules are given designations 10a, 10b, 10c, 
10d, 10e, 10f and 10g, and the seven modules are arranged such that with 
the two intersections, the modules form closed triangles. Modules 10a, 
10c, for instance, are connected end to end with access between the 
interior of the modules being achieved through ports 30 (not shown) borne 
by end faces 20 of respective modules 10a, 10c. Access from module 10a may 
also be had via ports, as at 30, FIG. 1, within side faces 22 of that 
module and end faces 20 for modules 10d, 10b to the left and right, 
respectively. Access may be had between the central in line module 10c and 
oblique modules 10d, 10b, to the left and right thereof, through 
cooperating circular ports 30 (not shown) within side faces 22 of the end 
caps of respective modules 10d, 10c, and 10b. In addition to dual four 
module interconnects 38, there are formed a pair of two module 
interconnects 34. It is not believed necessary to discuss with respect to 
the FIGS. 2-7 inclusive, the specific manner of access and interconnection 
facewise for the end caps of the modules achieving the interconnections. 
Turning to FIG. 3, this figure illustrates the combination of the two four 
module interconnects 38 of FIG. 2 with a further six module interconnect 
32 at the center of a space station, indicated generally at 8b. In space 
station 8b, while the basic assembly of the upper four module interconnect 
remains intact, module 10d is separated axially from axially aligned, end 
abutting modules 10a, 10c and the station adds additional modules at 10h 
through 10m, respectively. Modules 10c, 10f, 10j, 10g, 10i and 10e are 
joined together to form a six module interconnect 32 via respective end 
cap side faces 22 of these modules. The six module interconnect 32 is 
partially formed by modules which, in turn, define two module 
interconnects 34 for modules 10b, 10f, and 10j, 10k, respectively. 
Additionally, to the opposite side, there are two or three module 
interconnects 36, formed by modules 10d, 10e, and 10h, and 10h, 10i, 10 m, 
respectively. The station 8b is completed by two, four module 
interconnects 38. 
In the six module interconnect 32 of FIG. 3, it should be noted that there 
is no direct communication between any of the end faces 20 for the six 
modules making up the six module interconnect 32. 
FIG. 4 illustrates a manned space station 8c in which the modules are 
arranged in the formation of parallel interconnects 39 of three modules at 
each joint. Modules 10a through 10i inclusive are joined solely by way of 
their side faces 22, and none of the end faces 20 of the end caps are 
connected to each other, or to side faces of adjacent modules. 
FIG. 5 shows a manned space station 8d characterized by two four module 
interconnects 38, with modules 10a through 10b inclusive forming triangle 
arrays or triads on alternate sides of the major axis C formed by a two 
module interconnect 34 and leading to a three module interconnect 36 at 
the top and a further two module interconnect 34 at the bottom of the 
station, as seen in the figure. The connections between respective faces 
of end caps for the modules 10a through 10j are achieved in similar 
fashion to the stations previously discussed in FIGS. 2-4 inclusive. 
FIG. 6 illustrates another space station 8e of a continuing and repeated 
form or pattern made up of triangular, three module sets or triads 
connected by partially completed or partially filled six module 
interconnects 32', respectively. Further, others of the modules 10a 
through 10k inclusive form three module interconnects 36 and two module 
interconnects 34, at the extreme top and bottom respectively, of the 
manned space station 8e. The configuration may be described, alternatively 
as a triad series station with partially filled six module interconnects. 
FIG. 7 shows a station 8f defined by triad series of modules 10a through 
10k inclusive with a number of four module interconnects 38. In this case, 
the modules 10a through 10k inclusive form a triad series or triangular 
sets of modules integrated by way of two four module interconnects 38, two 
three module interconnects 36 at the center of the array, and a number of 
two module interconnects 36 at the top and bottom thereof. Note the 
lateral offsetting of the triads relative to the longitudinal axis or 
center line C of the station 8f. 
It should be appreciated that all of the manned space stations of FIGS. 2-7 
inclusive have modules which lie in a common plane. However, with the 
pyramidal end caps 14 also having side 22 faces oriented out of the plane 
defined by the axes of respective modules 10, space stations may take 
forms or patterns which can be extended in three dimensions. 
For space station applications, inertial considerations dictate that the 
major distribution of the mass must be kept in the orbit plane. This also 
tells one that this concept requires all the basic station modules as 
generally indicated at 10, FIG. 1, to be of a standard length such that 
the modules will interconnect into equilateral triangles forming triads. 
However, there are still worthwhile applications for out of plane ports to 
attach a variety of modules which are not required to be in the orbit 
plane, and for which an end cap is needed on only one end. Examples are: 
(1) The logistic module (s). This module may be easily replaceable, and 
located in proximity to the habitation modules such as 10a through 10k, 
FIG. 7. At the end of a given resupply (90 day), a fresh logistics module 
would be brought and inserted in the diametrically opposite port to the 
exhausted logistics module which would then be removed for return to 
earth. This would preserve the same relationship of the replacement 
logistics module to the habitation area module. 
(2) Environmental control and life support (ECLS) module(s). These modules 
contain equipment which will, in all likelihood, need frequent ground 
refurbishment and update as new technologies become available. This 
consideration, along with the requirement to have these modules evenly 
distributed about the station, makes the ECLS module a good candidate for 
the single ended out-of-plane port locations. 
(3) Air lock module(s). For extra vehicular activity-egress from the 
station along with a sheltered hanger area for stowage of manned 
maneuvering units could be very efficiently located in such an 
out-of-plane port. This would allow the high pressure (3 to 5 atmoshperes) 
hyperbaric chamber to be accommodated in the air lock without causing 
major impact on the design requirements for the major modules. 
(4) Specialized laboratory module(s). Any laboratories which require 
isolation for the general atmospheric circulation of the station could be 
a candidate for the out-of-plane ports. 
The invention envisions as an additional feature, the incorporation into 
the end caps 14 of trunion pins (not shown) which provides the load path 
interface with the STS orbiter cargo bay. These trunion pins must support 
the loaded module during the launch environment. The internal truss 
structure necessary for the end cap may be designed to also provide these 
load paths. 
It should be noted that while each of the five flat faces 20, 22 on end cap 
14 can accommodate an interconnect docking port 30, there is no 
requirement that each face 20, 22 be so equipped. Only those faces which 
are planned to be used need to be outfitted with a docking port prior to 
transport to the manned space station locale. Further, such blank face 
could be retrofitted with a port on orbit if a change in plan called for a 
port where none had been installed. 
By reference to FIG. 8, there is shown one form of unpressurized module, 
indicated generally at 10', which utilizes essentially identical end caps 
14' which may be solid, or at least totally enclosed, if hollow. 
Respective end caps 14' are joined by mechanical attachment to the ends of 
a cruciform truss, indicated generally at 40, formed of two right angle, 
intersecting elongated rectangular panels 42, 44 fixed, at their ends, to 
circular end faces 46 of respective end caps 14'. Additionally, the end 
caps 18' each include a flat end face 20' and oblique angled side faces 
22' which side faces 22' merge into or integrate with cylindrical base 18' 
of the respective end caps. Thin circular projections as at 48 on these 
faces, facilitate docking with other modules. The modules 10' may be 
employed for attaching subsystem modules. 
Attachment of servicing structures and fuel depots may be in general 
accomplished by attaching on the standard end caps 18 to the structure and 
locating it at one of the outboard facing ports in the orbit plane and in 
one of the out-of-plane ports of a given module forming the station. If 
EVA operations are required, it would be possible to incorporate an EVA 
air lock along with the end cap to facilitate access to the servicing 
structure. 
If robotic servicing mechanisms are utilized, it would be possible to 
incorporate the pressurized control station inside a dedicated portion of 
the servicing module. Docking of the space shuttle orbiter would utilize 
one of the outward facing ports in the orbit plane. 
FIG. 9 is an isometric drawing of a manned space station indicated 
generally at 8g, which starting from the top, utilizes an in line series 
interconnect 50, followed by a four module interconnect 30, followed by a 
six module interconnect 32. Single end modules 10" are shown attached to 
the out-of-plane side face ports 30 at both types of interconnects as, for 
instance, at 32 and 39. The space station 8g other than the single end 
modules 10" is formed by a series of modules 10a through 10i inclusive as 
shown which are identical to the basic module 10 in FIG. 1. Modules 10' 
are respectively angled up or down in terms of their inclination relative 
to the axis of symmetry of the assembly and, of course, dependent upon the 
connection between an end face thereof of the singular end cap thereof, 
and the side faces of the module 10d. The single end service modules 10" 
are attached to out-of-plane ports 30 of the in line series module 10d, 
from which they project. 
As may be appreciated, the concept provides an improved manned space 
station module concept and stations formed thereof for effectively 
interconnecting a number of modules of similar or identical form to make 
up a manned space station. The improvement consists principally in the 
design of the end caps attached to elongated cylindrical module bodies, 
with the end caps consisting of preferably separately constructed 
structures attached to the respective ends of a cylindrical barrel 
section. Each consists of a truncated four sided pyramid shape, emanating 
from an end cap base which base is directly attached to the end of the 
barrel section. In the illustrated embodiment, the side faces of the 
pyramid form an angle of 30.degree. with the side of the cylindrical 
barrel section. Not only does the configuration permit the module to be 
interconnected into a variety of patterns or station configurations, but 
the patterns are structurally rigid and provide closed "race track" 
circuits with only three modules defining a triad. The concept may be 
employed to attach payload modules to a platform space craft bus in the 
same manner as the station modules of the drawings. Using a four sided 
truncated pyramid to give a fifth flat side perpendicular to the axis of 
the module for each end cap provides a highly effective but simplified 
connection concept at both ends of the cylindrical module barrel section 
or body. The cylindrical barrel section is extremely weight efficient, 
maximizing the strength of the pressure vessel when employed in that form, 
and may be efficiently matched to the cargo bay configuration of the 
shuttle. The invention employs end caps which provide inherent access 
through the outer faces thereof and access to the interior at any desired 
point through respective out-of-plane faces. The concept leaves a 
significantly large internal volume of the cylindrical module clear for 
unimpeded access and for installation of desired outfitting. The 
configuration and formation of the end caps applied to the ends of the 
cylindrical barrel section permits ready accommodation of elements such as 
air locks and associated hyperbaric chambers and hangar areas for 
operational equipment with the elements easily accommodated in a flexible 
way by locating them at the out-of-plane ports most convenient to the area 
where they stand required. Logistic modules may be connected and readily 
interchanged at the logistic resupply intervals without major perturbation 
at the station structure. 
While the invention has been particularly shown and described with 
reference to preferred embodiments thereof, it will be understood by those 
skilled in the art that the foregoing and other changes in forms and 
details may be made therein without departing from the spirit and scope of 
the invention.