Hydride-Actuated Deployable Structures for Compact Shape Retention

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Solution Overview

Problem

Existing deployable structures face challenges in achieving mass and volume efficiency, durability, and rapid assembly/disassembly, particularly when volume, mass, and size limitations are restrictive, and conventional actuation methods like mechanical energy and compressed gas systems are inefficient or weight-heavy.

Innovation Solution

A deployable structure utilizing a hydride material to generate hydrogen gas for inflation and plastic deformation, comprising a sheet material with multiple layers to withstand pressure and deform plastically, triggered by thermal, chemical, or electrical means.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If conventional actuation methods like mechanical energy and compressed gas systems are used, then the deployable structure can achieve deployment, but the mass and volume efficiency deteriorates due to weight-heavy components

Engineering Contradiction:

Improvemass efficiencyVSAvoiddeployment capability

Core Design Contradiction:

Weight of moving objectVSEase of operation

Solution Approach 1:

The patent replaces conventional mechanical actuation systems and compressed gas systems with a chemical energy storage system using metal hydrides. The metal hydride material undergoes a phase transition from solid to gas, generating the necessary pressure for deployment without requiring heavy mechanical components or compressed gas cylinders, thereby significantly reducing mass while maintaining deployment capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes the phase transition of metal hydride material from solid state to gaseous hydrogen. This phase transition provides a controlled, high-energy-density gas generation mechanism that eliminates the need for heavy compressed gas storage systems, achieving both mass efficiency and effective deployment actuation

Inventive Principle:

Principle #36Phase transitions

2Speed

If rapid assembly/disassembly is achieved, then the deployment speed improves, but the structural integrity and durability may worsen

Engineering Contradiction:

Improvedeployment speedVSAvoidstructural durability

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The metal hydride's controlled phase transition from solid to gas provides a gradual, sustained pressure generation mechanism rather than sudden expansion. This controlled phase change enables rapid deployment while maintaining structural integrity through progressive force application, preventing shock loads that would compromise durability

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent controls the decomposition temperature and pressure parameters of the metal hydride material to optimize the deployment process. By adjusting these parameters, the system achieves rapid deployment speed while maintaining pressure levels that preserve structural durability, avoiding excessive forces that would damage the structure

Inventive Principle:

Principle #35Parameter changes

3Volume of moving object

If volume limitations are restrictive, then the compactness improves, but the gas storage capacity deteriorates

Engineering Contradiction:

ImprovecompactnessVSAvoidhydrogen gas capacity

Core Design Contradiction:

Volume of moving objectVSQuantity of substance

Solution Approach 1:

The metal hydride material stores a large quantity of hydrogen in a compact solid form and releases it through phase transition to gas. This provides exceptional volumetric energy density, achieving both compact storage and high gas capacity within severe volume constraints, as the solid-to-gas transition expands the stored hydrogen in-place without requiring additional volume

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent optimizes the metal hydride material composition and decomposition parameters to maximize hydrogen gas yield from a minimal volume of solid material. By controlling temperature and pressure parameters, the system achieves high gas storage capacity within restrictive volume limitations, enabling compact deployment structures

Inventive Principle:

Principle #35Parameter changes

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 structure achieves high energy density and mass-efficiency with controlled gas pressure, enabling rapid deployment and retention of shape without continuous pressurization, suitable for space applications.

Implementation Method 1

converting and releasing the hydrogen gas to expand and plastically deform the sheet material

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 2

the sheet material is to be plastically deformed by the hydrogen gas to have an expanded structure

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS12459677B1Method of manufacturing and/or operating deployable structures using hydride material

Publication Date: 2025.11.04 HRL LAB

AI summary

A deployable structure includes a hydride material to be converted into hydrogen gas; and a sheet material encapsulating the hydride material; wherein the sheet material is to be plastically deformed by the hydrogen gas to have an expanded structure. A method of manufacturing a deployable structure includes: forming a sheet material comprising an outer shell structure and a hollow interior; placing a hydride material capable of being converted into hydrogen gas into the hollow interior; sealing the outer shell structure; and converting and releasing the hydrogen gas to expand and plastically deform the sheet material.