A robust, large-force, large-deflection micro balloon actuator for aerodynamic (maneuvering) control of transonic aircraft has been developed. Using a novel process, high yield linear arrays of silicone balloons on a robust silicon substrate have been fabricated that can deflect vertically in excess of one 111111. Balloon actuators have been tested under cyclic conditions to assess reliability. The actuators have been characterized in a wind tunnel to assess their suitability as aerodynamic control surfaces and flight-tested on a jet fighter to assess their resistance to varied temperatures and pressures at high velocity.
Technologies for fabricating silicone rubber membranes and integrating them with other processes on silicon wafers have been developed. Silicone rubber has been found to have exceptional mechanical properties including low modulus, high elongation, and good sealing. Thermopneumatically actuated, normally open, silicone rubber membrane valves with optimized components have been designed, fabricated, and tested. Suspended silicon nitride membrane heaters have been developed for low-power thermopneumatic actuation. Composite silicone rubber on Parylene valve membranes have been shown to have low permeability and modulus. Also, novel valve seats were designed to improve sealing in the presence of particles. The valves have been extensively characterized with respect to power consumption versus flow rate and transient response. Low power consumption, high flow rate, and high pressure have been demonstrated. For example, less than 40 mW is required to switch a 1-slpm nitrogen flow at 33 psi. Water requires close to 100 mW due to the cooling effect of the liquid. [427]
Previously, we reported a thermopneumatic silicone rubber membrane valve [l].This valve combined thermopneumatic actuation with a low modulus silicone rubber membrane. However, the leakage of the working fluid through the membrane rendered the valve unusable in a day or two. Here, we present extensive optimization and characterization of a redesigned valve structure. This new design has a suspended membrane heater optimized for low power consumption, a composite silicone rubber on Parylene membrane that exhibits low permeability and modulus, and a novel valve seat designed to improve sealing in the presence of particles. The valve has been extensively characterized with respect to power consumption vs. flow rate and transient response. Very low power consumption has been demonstrated. For example, less than 40 mW is required to switch a one slpm nitrogen flow at 33 psi. Water requires close to 100 mW due to the cooling effect of the liquid. The previously reported valve required more than 280 mW to switch a similar air flow.
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