Dynamic Flexible Circuit Shape Change via Actuator Wires

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Solution Overview

Problem

Existing flexible circuits are unable to change shape without external forces being applied, limiting their versatility and functionality in applications such as spacecraft deployable arrays and robotic systems.

Innovation Solution

A dynamic flexible circuit (DFC) is developed, which incorporates shape memory alloys (SMAs) and a plurality of hole sets to allow actuator wires to impart motion to the circuit upon heating or cooling, enabling shape change without external forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional flexible circuits are used, then the circuit structure is simple and easy to manufacture, but the circuit cannot change shape without external forces being applied

Engineering Contradiction:

Improveshape-changing capabilityVSAvoidcircuit structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The flexible circuit is divided into multiple segments or sections that can move relative to each other. Holes are strategically positioned at segment boundaries to allow actuator wires to pass through and create articulation points, enabling the circuit to bend and change shape in controlled ways while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Actuator wires serve as intermediary elements that transfer thermal energy into mechanical motion. These wires pass through holes in the flexible circuit substrate and use thermal expansion/contraction to impart bending forces, mediating between the heat source and the shape-changing requirement without requiring complex actuators.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If actuator wires are added to enable shape change, then the adaptability improves, but the device complexity increases

Engineering Contradiction:

Improvemotion capabilityVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The actuator wires serve multiple functions: they provide shape-changing capability, act as thermal pathways for heat distribution, and serve as structural reinforcement elements. This multi-functionality reduces the need for separate components and minimizes overall device complexity while maintaining high adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system exploits parameter changes in the actuator wires, specifically their thermal expansion and contraction properties. By changing the temperature parameter, the wires naturally expand or contract to impart motion, eliminating the need for complex mechanical actuators and reducing device complexity.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multiple hole sets are used to enable actuator wire integration, then the shape-changing versatility improves, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveconfiguration flexibilityVSAvoidhole positioning accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The holes are pre-positioned and pre-drilled in the flexible circuit substrate before actuator wire installation. This preliminary action ensures accurate hole placement without requiring high-precision alignment during assembly, as the holes serve as ready-made guides for wire insertion and positioning.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The actuator wires are nested through the holes in a systematic pattern, with wires passing through multiple holes in sequence to create articulated sections. This nesting approach allows complex shape-changing configurations to be achieved through simple, repeatable hole patterns that are easier to manufacture with standard precision.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 DFC can change shape in response to temperature changes, allowing for applications such as aiming cameras, grasping objects, and steering thruster nozzles, thereby enhancing the flexibility and functionality of traditional flexible circuits.

Implementation Method 1

flexible circuits using shape memory alloys (SMAs)

Methodology Applied

Scientific EffectShape memory alloy: Shape Memory Alloy

Implementation Method 2

Each of the plurality of actuator wires are configured to impart a motion onto the dynamic flexible circuit depending on the amount of heat applied to each of the plurality of actuator wires

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20250098073A1Dynamic flexible circuits

Publication Date: 2025.03.20 AEROSPACE CORP

AI summary

A dynamic flex circuit includes a plurality of hole sets arranged along the dynamic flexible circuit. The dynamic flex circuit also includes a plurality of actuator wires coupled to the dynamic flexible circuit by way of intertwining each of the plurality of actuator wires through each hole set in the plurality of hole sets arrange along the dynamic flexible circuit. Each of the plurality of actuator wires are configured to impart a motion onto the dynamic flexible circuit depending on the amount of heat applied to each of the plurality of actuator wires.