Corrugated Diaphragm Actuator for Compliant Force and Linearity

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Solution Overview

Problem

Existing actuators, particularly soft actuators, face limitations in force generation and linearity, making them unsuitable for human-centered applications such as assistive devices and consumer products.

Innovation Solution

The development of corrugated diaphragm actuators that expand outwardly when pressure is applied within a cavity, utilizing a chamber body with corrugated diaphragms that can be made from flexible materials like polyurethane or silicone rubber, and optionally combined with rigid materials, to provide both displacement and force.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If soft actuators are used for human-centered applications, then compliance and safety are improved, but force generation capability deteriorates

Engineering Contradiction:

ImprovecomplianceVSAvoidforce generation capability

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

The patent employs a corrugated diaphragm made of flexible material that expands and contracts to generate actuation force. The diaphragm's flexible structure allows it to interface safely with human users while the corrugated geometry enables effective force transmission through pneumatic pressure, resolving the contradiction between compliance and force generation.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The actuator combines flexible materials (for compliance and safety) with rigid structural elements (for force generation and linearity). This composite approach allows the system to simultaneously achieve the compliance needed for human-centered applications and the force generation capability required for practical utility.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If soft actuators are used for human-centered applications, then compliance and safety are improved, but linearity deteriorates

Engineering Contradiction:

ImprovecomplianceVSAvoidlinearity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The corrugated diaphragm's structured geometry provides predictable expansion patterns that improve linearity. The repeating corrugation pattern creates a more linear relationship between applied pressure and resulting displacement compared to conventional soft actuators, while maintaining the compliance needed for human interfaces.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The corrugated diaphragm utilizes curved geometric features that provide more linear actuation characteristics. The specific curvature and corrugation pattern are designed to produce more linear expansion behavior, addressing the linearity deficiency of traditional soft actuators.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Force

If conventional actuators are used, then force generation capability is improved, but compliance and safety deteriorate

Engineering Contradiction:

Improveforce generation capabilityVSAvoidcompliance

Core Design Contradiction:

ForceVSEase of operation

Solution Approach 1:

The patent uses a flexible corrugated diaphragm instead of rigid actuator components. This flexible structure inherently provides compliance for safe human interfaces while the pneumatic actuation mechanism maintains adequate force generation capability, eliminating the need for rigid metallic or polymeric materials.

Inventive Principle:

Principle #30Flexible shells and thin films

4Strength

If rigid materials are used for actuators, then structural strength is improved, but compliance and safety deteriorate

Engineering Contradiction:

Improvestructural strengthVSAvoidcompliance

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The actuator is constructed primarily from flexible materials including the corrugated diaphragm and chamber body, eliminating rigid metallic or polymeric components. This flexible construction provides inherent compliance for safe human interfaces while maintaining sufficient structural strength through the pneumatic pressure containment design.

Inventive Principle:

Principle #30Flexible shells and thin films

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The corrugated diaphragm actuators offer enhanced force generation and linearity, enabling applications in robotics, exoskeletons, impact absorption, and robotic end-effectors, while being compatible with human interfaces.

Implementation Method 1

the corrugated diaphragm may be configured for expanding outwardly when a positive pressure is applied within the cavity

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

The plurality of walls may include a first wall including a first corrugated diaphragm defining at least one first corrugated channel

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20250223981A1Corrugated diaphragm actuator

Publication Date: 2025.07.10 BOARD OF RGT THE UNIV OF TEXAS SYST

AI summary

A corrugated diaphragm actuator may include a chamber body including a plurality of walls defining a cavity. The plurality of walls may include a first wall including a first corrugated diaphragm defining at least one first corrugated channel, and the corrugated diaphragm may be configured for expanding outwardly when a positive pressure is applied within the cavity.