Skin-Constrained Inflatable Bellows for Rigid 3D Deployment
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Solution Overview
Problem
Existing inflatable structures face challenges in maintaining structural capabilities while reducing weight, cost, and manufacturing complexity, while also providing a rigid deployment in multiple degrees of freedom and a smooth external surface.
Innovation Solution
The development of a skin-constrained inflatable bellows system that includes a top and bottom end cap, a bellows separating them, and an inextensible skin attached to these components, which constrains the bellows into a predefined rigid three-dimensional shape upon inflation, using materials like silicone and thermoplastic polyurethane, and featuring radially-extending bellows flanges and replaceable skins for varying geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If internally-tensioned inflatable structures are used to achieve high compressive strength, then structural capability is improved, but weight and manufacturing complexity increase
Solution Approach 1:
The bellows structure is divided into multiple expandable chambers separated by internal diaphragms, allowing the structure to achieve high compressive strength through segmented expansion rather than requiring a single heavy-walled chamber. Each chamber can independently expand and contribute to the overall structural strength.
Solution Approach 2:
The patent uses thin-walled flexible bellows chambers instead of rigid structures. The bellows are made from flexible materials that can expand and contract while maintaining structural integrity, providing high strength-to-weight ratio without requiring thick walls or heavy reinforcement.
2Strength
If internally-tensioned inflatable structures are used to achieve high compressive strength, then structural capability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the single bellows structure: the bellows walls provide both the expandable volume and the structural strength, while internal diaphragms serve both as separators between chambers and as structural reinforcement elements. This integration reduces the number of separate components and simplifies manufacturing.
Solution Approach 2:
The bellows structure serves multiple purposes simultaneously: it provides the expandable volume for the inflatable structure, acts as a structural element for compressive strength, and the folded portions provide both flexibility and structural reinforcement. This multi-functionality reduces the need for additional specialized components.
3Volume of moving object
If conventional inflatable structures are used, then packaging size is reduced, but deployment rigidity in multiple degrees of freedom is insufficient
Solution Approach 1:
The bellows is divided into multiple chambers with internal diaphragms, creating a segmented structure that can expand in multiple directions. This segmentation allows the structure to achieve rigid deployment in multiple degrees of freedom while maintaining a compact folded state for small packaging size.
Solution Approach 2:
The patent utilizes three-dimensional expansion capability through the multi-chamber bellows design, allowing the structure to rigidly deploy not just in one direction but in multiple dimensions. The folded portions and internal diaphragms enable expansion along axial, radial, and tangential directions simultaneously.
4Strength
If conventional inflatable structures are used, then structural capabilities are maintained, but external surface smoothness for cleaning is reduced
Solution Approach 1:
The patent employs a smooth flexible skin or membrane that envelops the bellows structure. This outer skin provides a smooth, continuous surface that is easy to clean while the underlying bellows structure maintains the structural capabilities. The skin acts as a separate layer that can be made from easily cleanable 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
This solution enhances structural capabilities, reduces weight and cost, simplifies manufacturing, and provides a smooth external surface with increased shear resistance, allowing for flexible deployment without significant increases in cost or storage size.
Implementation Method 1
hold pressurized fluid between the top and bottom end caps
Implementation Method 2
As the bladder is inflated, pressure within the bladder causes the bladder to expand outward and thereby applies tension to the threads
Implementation Method 3
the threads are typically attached to internal surfaces of the bladder. As the bladder is inflated, pressure within the bladder causes the bladder to expand outward and thereby applies tension to the threads which in turn limits expansion of the bladder
Implementation Method 4
the one or more top portions and the one or more bottom portions are heat sealed to one another only about the perimeter edge through use of a removable mask
Data Source
AI summary
An incrementally assembled skin-constrained inflatable bellows system includes a top end cap, a bottom end cap, and a bellows attached to and separating the top end cap and the bottom end cap and configured to hold pressurized fluid between the top and bottom end caps. The system further includes a nozzle configured to allow fluid to enter and exit the bellows, and an inextensible skin attached to each of the top end cap, the bottom end cap, and to the bellows. The top end cap assumes a first position when the bellows is inflated via the nozzle and, when the top end cap is adjusted from the first position to a second position, the skin is configured to maintain the top end cap in the second position and constrains the bellows into a predefined rigid three-dimensional shape.