Shape-Memory Flap Valve for Lightweight Conformal Flow Control

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Solution Overview

Problem

Conventional fluid valves are often bulky, heavy, and rigid, limiting their ability to conform to surrounding structures and restricting design flexibility in various applications.

Innovation Solution

A valve design incorporating a substrate with a shape-memory wire and conductive polymer, where the shape-memory wire and conductive polymer are coupled to flaps that can move between open and closed positions in response to temperature changes or electrical current, allowing for flexible and ergonomic fluid flow regulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If conventional valves are used, then fluid flow regulation function is provided, but the valve is bulky, heavy, and rigid

Engineering Contradiction:

Improvevalve weightVSAvoidvalve structure

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The patent replaces conventional mechanical valve components with shape-memory alloy (SMA) elements that utilize phase transformation under electrical current to control flap movement. This substitution eliminates heavy mechanical actuators, springs, and linkages, significantly reducing valve weight while maintaining the flow regulation function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs flexible substrate materials and thin-film structures for the valve body and flaps, replacing rigid metal components. This allows the valve to be lightweight, compact, and conformal to surrounding structures, directly addressing the weight and structural complexity issues of conventional valves.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If conventional valves are used, then fluid flow regulation function is provided, but the valve is rigid and unable to conform to surrounding structure

Engineering Contradiction:

Improveconformability to surrounding structureVSAvoidvalve rigidity

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The patent utilizes flexible substrate materials and thin-film constructions for the valve body and flaps, enabling the valve to conform to irregular or curved surfaces in the fluid passage. This flexibility allows adaptation to various surrounding structures while maintaining functional integrity.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent incorporates movable flaps that can dynamically adjust their position and shape in response to electrical stimulation of the SMA elements. This dynamic capability allows the valve to adapt its configuration to different flow conditions and surrounding geometries, enhancing versatility.

Inventive Principle:

Principle #15Dynamics

3Weight of moving object

If lighter and more compact valve materials are used, then weight and size are reduced, but valve strength and durability may be compromised

Engineering Contradiction:

Improvevalve weightVSAvoidvalve strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent employs composite structures combining flexible substrates with embedded shape-memory alloy elements and conductive polymer coatings. This composite approach provides both the weight reduction benefits of lightweight materials and the strength/durability of reinforced composite construction, resolving the trade-off between weight and strength.

Inventive Principle:

Principle #40Composite materials

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 solution provides a lightweight, compact, and conformal valve that can dynamically adjust fluid flow, enhancing design flexibility and user comfort, while maintaining reduced weight and improved ergonomics compared to traditional valves.

Implementation Method 1

The shape-memory wire is coupled to the at least one flap. The at least one flap moves between a closed position and an open position in response to a stimulus applied to the shape-memory wire

Methodology Applied

Scientific EffectShape memory effect: Shape Memory Alloy

Implementation Method 2

electrical current from the current source selectively energizes the shape-memory wire and the conductive polymer thereby moving the at least one flap

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

transitioning the conductive polymer from a rigid state to a flexible state

Methodology Applied

Scientific EffectElectroactive polymer response: Electroactive Polymer

Data Source

PatentUS11885428B2Valves and methods of operating valves

Publication Date: 2024.01.30 TOYOTA JIDOSHA KK

AI summary

A valve includes a substrate, a shape-memory wire, a conductive polymer, and a current source. The substrate defines an opening therethrough and includes at least one flap selectively extendable across the opening. The shape-memory wire is coupled to the at least one flap. The conductive polymer is coupled to the at least one flap. The current source is coupled to the shape-memory wire and the conductive polymer, such that electrical current from the current source selectively energizes the shape-memory wire and the conductive polymer thereby moving the at least one flap between a closed position and an open position.