Valve Singulation Using Joule Heating for High-Frequency Operation
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Solution Overview
Problem
Conventional valves are unable to operate effectively at high frequencies required for small, portable electronic devices, such as medical devices, as they produce audible noise and are not capable of handling high-frequency fluid flow, necessitating the development of valves that can function at frequencies beyond human hearing.
Innovation Solution
A valve design featuring a flap movable between two plates with offset apertures, facilitated by a lead-frame technology for fabrication and handling, allowing for high-frequency operation by responding to differential pressure changes to control fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional valves are used to control fluid flow, then the valve structure is simple and easy to manufacture, but the valve cannot operate at high frequencies required for portable devices and produces audible noise
Solution Approach 1:
The valve employs a dynamic flap mechanism that responds to high-frequency oscillating pressure differentials, enabling the valve to operate at frequencies up to 20 kHz and above. The flap's ability to rapidly transition between open and closed states in response to pressure changes allows the valve to function at ultrasonic frequencies, resolving the contradiction between operating speed and noise generation.
Solution Approach 2:
The valve design changes the operating parameters by utilizing high-frequency pressure oscillations rather than traditional low-frequency mechanical actuation. By responding to pressure differentials at frequencies above human hearing (20 kHz+), the valve achieves ultrasonic operation that eliminates audible noise while maintaining effective fluid flow control.
2Volume of moving object
If conventional valves operate at low frequencies, then the valve design is straightforward, but the valve size becomes large and is unsuitable for portable electronic devices
Solution Approach 1:
The valve is segmented into thin, planar components including a first valve plate, second valve plate, and flap, all constructed using lead-frame technology. This segmentation allows for miniaturization while maintaining structural integrity and enabling high-frequency operation, as the thin-walled construction reduces mass and allows rapid response to pressure changes.
Solution Approach 2:
The invention replaces traditional mechanical valve actuation mechanisms with a pressure-responsive flap system that opens and closes in response to oscillating pressure differentials. This substitution eliminates the need for bulky mechanical actuators, springs, and linkages, enabling compact valve design suitable for portable devices while achieving ultrasonic operating frequencies.
3Speed
If high-frequency operation is achieved through traditional means, then the valve can operate at required frequencies, but the valve becomes complex and difficult to manufacture
Solution Approach 1:
The valve plates and flap are merged into a single integrated lead-frame structure, allowing all components to be fabricated simultaneously using standard PCB manufacturing techniques. This merging eliminates the need for separate manufacturing and assembly steps for multiple valve components, significantly simplifying production while enabling the complex thin-walled geometry required for high-frequency operation.
Solution Approach 2:
The lead-frame technology serves multiple functions: it provides the structural framework for the valve plates, creates the thin-walled cavity geometry, establishes electrical connectivity for actuation, and enables precise alignment of apertures. This multi-functionality reduces manufacturing complexity by consolidating what would otherwise require multiple specialized fabrication processes.
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 valve effectively operates at frequencies up to 20 kHz, ensuring inaudible operation and compact size, suitable for integration into portable devices by cycling between open and closed positions based on differential pressure changes, enhancing the efficiency and silence of fluid pumps.
Implementation Method 1
An electrical current is applied to the lead-frame and the valve plate to fuse the tabs and singulate the valve plate from the lead-frame.
Data Source
AI summary
A method and apparatus for the singulation of valve plates and/or assembled valves from a lead-frame are described. The method and apparatus utilizes an electric current to fuse tabs which join the valve plate and/or the assembled valve to the lead-frame. The valve comprises a first and second valve plate with offsetting apertures and a flap disposed and movable between the first and second plates.