Actuator device

Abstract

The invention relates to an actuator device (1) having a stationary housing (4) in which an interior (14) is formed, the interior (14) being formed by a base surface (15), a cover surface (16) opposite the base surface (15), which cover surface is spaced apart from the base surface (15) in a direction perpendicular to the base surface (15), and a side surface (17) connecting the base surface (15) to the cover surface (16), the housing (4) has an inner space (14), and has a rubber-like elastic membrane (18) arranged in the inner space (14), which membrane is integrally connected to the housing (4), the housing (4) and the membrane (18) being produced together by means of an additive production method, in particular a 3D printing method.

Description

Field of the Invention

[0001] The present invention relates to an actuator device having a shape-fixed housing in which an interior space is formed, the interior space being formed by a base surface, a cover surface opposite the base surface (the cover surface being spaced apart from the base surface in a direction perpendicular to the base surface), and side surfaces connecting the base surface and the cover surface, and having a rubber-elastic diaphragm disposed in the interior space. Background Art

[0002] Actuator devices are known from the prior art, in particular actuator devices implemented as diaphragm valves, in which a diaphragm disposed in the interior space of the housing serves as a switching element that can assume at least two positions, for which purpose the diaphragm must be constructed rubber-elastic. In contrast, the housing should be implemented shape-fixed such that when the actuator device is used according to the specifications, no deformation of the housing relevant to the function of the actuator device occurs. The specified use in particular provides for pressurizing the interior space with compressed air in order to cause targeted deformation of the diaphragm. The individual components of such an actuator device, in particular the housing and the diaphragm, are produced separately, that is, the housing is produced independently of the diaphragm, and these two components are combined into the actuator device in one or more subsequent production steps, which increases the production time as well as the manufacturing costs. Summary of the Invention

[0003] The object of the present invention is to provide an actuator device that can be manufactured in one production step.

[0004] According to the invention, this object is achieved in that the rubber-elastic diaphragm is connected to the housing in one piece, and the housing and the diaphragm are manufactured together by means of an additive manufacturing method, in particular a 3D printing method.

[0005] In this way, there is the advantageous possibility that the actuator device can be manufactured in one production step without having to provide an installation step. Furthermore, by using additive manufacturing methods, in particular 3D printing methods, it is possible to almost freely select the geometry of components, such as a shape-fixed housing and a rubber-like elastic diaphragm. Thus, for example, the diaphragm receiving space in the housing that partially receives the diaphragm can have one or more undercuts that cannot be manufactured or can only be manufactured at great expense by means of conventional production methods (such as by means of injection molding (Spritzgussverfahren, sometimes called injection molding) or machining methods). All suitable additive manufacturing methods can be used here, in particular methods such as fused deposition modeling, laser sintering, laser or electron beam melting. In the context of the present application, rubber-like elasticity is understood to mean that the diaphragm can be elastically deformed under the action of a force during the operation of the actuator device, for example to change from a first position to a second position and vice versa. This force action is caused in particular by loading the internal space with the pressure of compressed air; the pressure range for the compressed air provided for this purpose is in the range from a few millibars to 6 bar. The rubber-like elastic properties are achieved by appropriate material selection and by the geometry of the respective diaphragm. In contrast, shape fixation is currently understood to mean that no deformation or no significant deformation occurs during the operation of the actuator device, i.e., a deformation that affects the operation of the actuator device. For this purpose, appropriate materials for manufacturing the housing and / or the corresponding housing geometry can be provided.

[0006] The first position is currently understood to be the position in which the diaphragm is in its initial condition (Ausgangslage, sometimes called the initial position), i.e., the condition in which the diaphragm is manufactured, in particular printed. Correspondingly, this position can also be called the non-activated state or the manufacturing state. Conversely, the second position is the position that the diaphragm occupies or has occupied during and possibly after the action of the force. This position can also be called the activated state.

[0007] The shape-fixed housing is preferably formed by a housing base side and a housing cover side, which are connected to each other via housing side walls. By way of pure example, the housing has a substantially rectangular basic shape, such that the housing side walls are formed by four sections, where two sections each are oriented parallel to each other and are oriented orthogonally to the other sections. The sections oriented orthogonally to each other can each be adjacent to each other here or be connected to each other by a transition section in the form of, for example, a rounded corner of the housing side wall. The housing has: a longitudinal axis along which the housing base side and the housing cover side are spaced apart from each other; a transverse axis extending orthogonally to the longitudinal axis, with the transverse direction of the housing coinciding with this transverse axis; and a vertical axis, which is oriented orthogonally to the longitudinal axis and orthogonally to the transverse axis.

[0008] If the actuator device according to the invention is manufactured by means of a 3D printing method, the printing starts at the base side of the housing, and the print head of the printer moves in a suitable manner along the X direction (the subsequent lateral axis of the housing coincides therewith) and along the Y direction (the subsequent vertical axis of the housing coincides therewith), wherein the first material layer is applied to the table of the printer. After the complete application of the first material layer, the print head moves away from the table along the Z direction (the subsequent longitudinal axis of the housing coincides therewith), and the print head again moves in a suitable manner along the X direction and along the Y direction, and a new material layer is applied to the previously applied material layer. Accordingly, the actuator device is printed along the subsequent longitudinal axis of the housing.

[0009] Manufacturing by means of an additive production method and in particular by means of a 3D printing method and manufacturing in only one process step furthermore has the following advantages: The actuator device can be manufactured at any location, provided that the manufacturing method used can be carried out at that location. Thus, for example, it is feasible that the manufacturer of the actuator device only provides the customer with the necessary CAD files and the necessary information about the material to be used, and the customer directly prints the actuator device on site after receiving this data and information. Thus, long delivery times in the case of a high load rate of the manufacturer's production capacity and long delivery routes and emissions resulting from transport to the customer can be avoided.

[0010] Advantageous refinements of the invention result from the dependent claims.

[0011] In a further design of the actuator device, the diaphragm is made of a first material and the housing is made of a second material. Thus, for example, it is feasible that the first material is softer than the second material, wherein in particular plastics or metals are suitable as the first material, while other plastics or other metals are suitable as the second material. The first material is selected such that it has the necessary rubber-like elastic properties in order to enable the diaphragm to deform under the action of force. Conversely, the use of a harder material as the second material enables the necessary shaping and fixing properties of the housing to be improved or at least retained with less material usage.

[0012] In the sense of this application, plastics are understood to be plastics that are suitable for being processed by means of a selected additive production method. Similarly, metals are understood to be metals that are suitable for being processed by means of a selected additive production method.

[0013] Preferably, the diaphragm is arranged in the interior space such that a first working space is formed between the diaphragm and the base surface, and the first working space is fluidly connected to a first fluid interface constructed in the housing. Via the first fluid interface, the first working space can be fluidly connected to a fluid source, in particular to a compressed air source, in order to guide a fluid (such as compressed air) into the first working space. By means of the introduced fluid, the pressure in the first working space increases, whereby a force is exerted on the diaphragm to transfer it from the first position to the second position, or vice versa.

[0014] Advantageously, a piston element that can move along a movement axis is arranged in the interior space, and the piston element is integrally connected to the diaphragm. The cover surface has a through-opening, and when the diaphragm is in the activated state, the piston element protrudes relative to the housing in sections through the through-opening. The piston element, together with the housing and the diaphragm, is manufactured by means of an additive manufacturing method, in particular a 3D printing method. Therefore, the actuator device can also be referred to as a diaphragm-type cylinder block, and the region where the piston element protrudes relative to the housing in sections can be used to manipulate an element connected to the piston element or that can be contacted by the piston element.

[0015] Preferably, a second working space is formed between the piston element and the cover surface, and the second working space is fluidly connected to a second fluid interface constructed in the housing. In this embodiment, the second working space can be supplied with a fluid, such as compressed air, via a fluid source (in particular a compressed air source) that can be connected to the second fluid interface. The actuator device constructed in this way can also be referred to as a double-acting diaphragm-type cylinder block. By introducing the fluid into the second working space, the pressure in the second working space increases, such that a force is exerted on the diaphragm, and this force is directed opposite to the force caused by the pressure in the first working space. If the force caused by the pressure in the second working space is greater than the force caused by the pressure in the first working space, the diaphragm moves from the second position back to the first position. Accordingly, the position of the diaphragm can be changed by adjusting the respective pressures in the first working space and the second working space. Advantageously, it can be provided that a pressure space (i.e., the pressure space through which a smaller force should be exerted on the diaphragm for the desired position of the diaphragm) is vented (entlüftet, sometimes called discharged) in order to reduce the pressure required for movement.

[0016] The following embodiment is considered particularly advantageous, namely, in which a sealing element is arranged in the housing, and the sealing element is integrally connected to the piston element and the housing. The sealing element, together with the piston element, the housing, and the diaphragm, is manufactured by means of an additive manufacturing method. The sealing element is preferably arranged in a sealing element receiving space constructed in the housing. In this embodiment, the second working space is formed between the sealing element and the diaphragm, and the sealing element seals the second working space relative to the environment.

[0017] In another embodiment, the sealing element is made of a first material and the piston element is made of a second material. When the sealing element is made of the first material, the advantage is that the sealing element has rubber-like elastic properties similar to those of the diaphragm, in order to ensure not only the sealing of the piston element but also the mobility of the piston element. Similarly, when the second material is used for manufacturing the piston element, the piston element has the required properties of shape fixation. Advantageously, a separating layer made of a material different from the second material can be arranged between the piston element and the base surface of the internal space, by means of which the material-bonded connection between the piston element and the base surface can be prevented during manufacturing, especially during printing, even when no significant cooling phase is provided. It is also possible that the separating layer is made of a soluble material, especially a water-soluble material, so that the separating layer can be removed by post-treatment after the actuator device has been manufactured.

[0018] The sealing element is advantageously embodied as a spring element, especially as a bellows-shaped spring element. By means of the sealing element designed as a spring element, it is possible to achieve that when the first working space is evacuated accordingly, the piston element can be moved from the second position to the first position by the spring action of the sealing element.

[0019] In another design, the diaphragm has a self-retaining first position, for example a non-activated state, and a self-retaining second position different from the self-retaining first position, for example an activated state, where a first adjusting force (actuating force, sometimes called a driving force) must be applied in order to leave the self-retaining first position, and where a second adjusting force must be applied in order to leave the self-retaining second position. Here, in the sense of the present application, a self-retaining position is understood to be a position in which the diaphragm, after arrival, remains autonomously without the further application of force, especially without a holding force, and leaves this position when the applied adjusting force is exceeded, where the transition from the self-retaining first position to the self-retaining second position is achieved only by means of the elasticity of the diaphragm without having to apply any type of driving force to the diaphragm for this transition. Thus, for example, in this embodiment, only for switching, i.e. changing from the activated state to the non-activated state or from the non-activated state to the activated state, is it necessary to supply fluid to the first working space or the second working space, whereby the fluid consumption can be reduced.

[0020] Preferably, the angle formed between the base surface and each cover element forming the cover is in the range of 45° to 75° or 105° to 135°. If the ranges described above for the angles between the respective cover elements and the base surface are followed when manufacturing the cover elements forming the cover, the cover can be manufactured, in particular printed, without the use of a support structure, because within this angle range the currently manufactured material layer is also fully supported even when it exceeds the previously printed and sometimes already solidified or partially solidified material layer.

[0021] In an alternative embodiment, an opening is formed on the cover surface, the opening is surrounded by a diaphragm seat formed on the cover surface, a fluid space is formed between the diaphragm and the cover surface, the fluid space is fluidically connected to a second fluid interface formed in the housing, and in the activated state, the diaphragm closes the opening in a fluid-tight manner (fluiddicht, sometimes referred to as fluid-tight) by abutting against the diaphragm seat. In this regard, the actuator device can also be referred to as a diaphragm valve. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be explained in more detail below with reference to the accompanying drawings, in which

[0023] Figure 1 The actuator arrangement is shown in an isometric view,

[0024] Figure 2 The actuator device is shown in isometric view and in cross-section, and

[0025] Figure 3 The side view shows the Figure 2 A cross-sectional view of an actuator device. DETAILED DESCRIPTION

[0026] exist Figure 1 , an embodiment of an actuator device 1 is shown, which has a fixed housing 4 with a housing base side 2 and a housing cover side 3, which are connected to each other by a housing side wall 5. The housing 4 has a substantially rectangular basic shape, so that the housing side wall 5 is formed by four sections, of which two sections are oriented parallel to each other and are oriented orthogonally to the other sections. The sections oriented orthogonally to each other are connected to each other by way of example by transition sections that are designed as rounded corners. The actuator device 1 shown is produced by means of a 3D multi-component printing method, in which printing is carried out purely by way of example starting from the housing base side 2 to the housing cover side 3. For this purpose, material layers are applied one after another on a tool table of the printer that is not shown.

[0027] The housing 4 has a longitudinal axis 6, along which the housing base side 2 and the housing cover side 3 are spaced apart from one another. A transverse axis 7 runs orthogonally to the longitudinal axis 6, with which the transverse direction of the housing 4 coincides. A vertical axis 8 of the housing 4 is oriented orthogonally to the longitudinal axis 6 and orthogonally to the transverse axis 7. The longitudinal axis 6, the transverse axis 7 and the vertical axis 8 form a Cartesian coordinate system.

[0028] A first fluid interface 9 and a second fluid interface 10 are constructed at a section of the housing side wall 5, each in the form of a hole, which are surrounded by a contact surface 11, which is implemented to be essentially flat and extends parallel to the section of the housing side wall 5 and is spaced apart from it along the vertical axis 8. The first fluid interface 9 and the second fluid interface 10 are configured to accommodate a connecting element that is not shown, in particular a pneumatic quick connector, so that the first fluid interface 9 can be connected to a first fluid supply line that is not shown, and the second fluid interface 10 can be connected to a second fluid supply line that is not shown. A through opening 12 is constructed at the housing cover side 3, the central axis of which coincides with the longitudinal axis 6 of the housing 4, and a piston element 13 arranged in the housing 4 partially extends through the through opening.

[0029] If Figure 2 and Figure 3 As shown, the piston element 13 is accommodated in an inner space 14 formed in the housing 4, which is formed by a base surface 15, a cover surface 16 spaced apart from the base surface 15 along the longitudinal axis 6, and a side surface 17 connecting the base surface 15 and the cover surface 16. The rubber-elastic diaphragm 18 is connected to the piston element 13 and to the housing 4 in one piece, wherein the housing 4, the piston element 13 and the rubber-elastic diaphragm 18 are manufactured by means of an additive production method, in particular a 3D printing method. The diaphragm 18 is manufactured from a first material, while the housing 4 and the piston element 13 are manufactured from a second material. The diaphragm 18 is partially accommodated in a first diaphragm accommodation space 20 in a diaphragm section 19 of the piston element 13, and partially accommodated in a second diaphragm accommodation space 21 in a side surface 17. The first diaphragm accommodation space 20 extends from the outer side 22 of the diaphragm section 19 toward the longitudinal axis 6. The second diaphragm accommodation space 21 extends substantially parallel to and along the longitudinal axis 6. The section of the diaphragm 18 received in the first diaphragm receiving space 20 and the section received in the second diaphragm receiving space 21 are respectively designed accordingly. Due to the rubber-elastic design of the diaphragm 18, the piston element 13 can be moved in the housing 4 along a movement axis which coincides with the longitudinal axis 6 by way of example.

[0030] The rubber-like elastic sealing element 23 is connected in one piece to the piston element 13 and to the housing 4, wherein the sealing element 23 is likewise manufactured by means of an additive manufacturing method, in particular a 3D printing method, and is preferably made of a first material. The sealing element 23 is partially received in a first sealing element receiving space 25 constructed in a sealing element section 24 of the piston element 13, and is partially received in a second sealing element receiving space 26 constructed in a cover surface 16 of the inner space 14. A first section 27 of the first sealing element receiving space 25 extends from the outer side 28 of the sealing element section 24 of the piston element 13 towards the longitudinal axis 6, and a second section 29 of the first sealing element receiving space 25 following the first section 27 extends substantially along the longitudinal axis 6, such that the first sealing element receiving space is substantially T-shaped. The second sealing element receiving space 26 extends substantially perpendicular to the longitudinal axis 6 of the housing 4. The sections of the sealing element 23 received in the first sealing element receiving space 25 and in the second sealing element receiving space 26 are designed correspondingly.

[0031] The diaphragm 18 is arranged in the inner space 14 such that a first working space 30 is formed between the diaphragm 18 and the base surface 15 of the inner space 14, and the first working space is fluidly connected to the first fluid interface 9 via a first fluid channel constructed in the housing 4 (not shown). The sealing element 23 is arranged in the inner space 14 such that a second working space 31 is formed between the sealing element 23 and the diaphragm 18, and the second working space is fluidly connected to the second fluid interface 10 via a second fluid channel constructed in the housing 4 (not shown).

[0032] When fluid is supplied to the first working space 30, the piston element 13 moves from the first position shown in the figure (which corresponds to the manufacturing state and can also be referred to as the non-activated state) to the second position (which can also be referred to as the activated state), and when fluid is supplied to the second working space 31 and the first working space 30 is correspondingly exhausted, it moves back from the second position to the first position.

[0033] In an alternative, not shown embodiment of the actuator device 1, the sealing element 23 can be implemented as a spring element, in particular as a bellows-shaped spring element, such that when the first working space 30 is correspondingly exhausted, the piston element 13 moves from the second position to the first position by the spring action of the sealing element 23 designed as a spring element.

[0034] Furthermore, the cover surface 16 of the internal space 14 is formed by a plurality of cover surface elements 32, 33, 34, 35, 36, 37, with an angle of 45° or 135° being present between the base surface 15 of the internal space 14 and each of the cover surface elements 32, 33, 34, 35, 36, 37, with the second seal element receiving space 26 being arranged between the cover surface elements 32 and 34 and 33 and 35, and with the seal element 23 bearing against the cover surface elements 34, 35, which cover surface elements 34, 35 can also be referred to as seal element bearing surfaces accordingly. The cover surface elements 36, 37 serve as stops, against which a stop surface 38 constructed at the piston element 13 bears in the second position, i.e., in the activated state, such that the cover surface elements 36, 37 limit the movement of the piston element 13 along the longitudinal axis 6 in order to prevent inadmissible high deformations of the diaphragm 18 or the seal element 23.

[0035] In the manufactured state of the actuator device 1 shown, the first diaphragm receiving space 20 and the second diaphragm receiving space 21 are spaced apart from one another along the longitudinal axis 6 such that the diaphragm region 39 not received in the first diaphragm receiving space 20 or the second diaphragm receiving space 21 forms an angle of 45° with the base surface 15 of the internal space 14. In the manufactured state of the actuator device 1 shown, the first seal element receiving space 25 and the second seal element receiving space 26 are spaced apart from one another along the longitudinal axis 6 such that the seal element region 40 not received in the first seal element receiving space 25 or the second seal element receiving space 26 forms an angle of 45° with the base surface 15 of the internal space 14. A design of this type enables the housing 4, the piston element 13, the diaphragm 18, and the seal element 23 to be manufactured jointly and integrally. Accordingly, these components do not have to be produced separately and combined into a device in subsequent production steps. For rapid production without a significant cooling phase, a separation layer 41 is arranged between the piston element 13 and the base surface 18 of the internal space 14, which separation layer 41 is made of a material different from the second material. This prevents the housing 4 and the piston element 13 from being connected to one another in a material-locking manner during manufacture. It can also be provided that the separation layer 41 assumes a further sealing function, or that the separation layer 41 is made of a soluble material, in particular a water-soluble material, which is removed from the housing 4 after manufacture, for example, by post-treating the actuator device 1 in a water bath.

[0036] In an embodiment of the actuator device 1 not shown, the actuator device 1 is implemented as a diaphragm valve. For this purpose, an opening is constructed at the cover surface 16, which is surrounded by a diaphragm seat constructed at the cover surface 16, wherein a fluid space is formed between the diaphragm 18 and the cover surface 16, which fluid space is fluidly connected to a second fluid interface constructed in the housing 4, and wherein the diaphragm 18 in the activated state fluid-tightly closes the opening by abutting against the diaphragm seat. Thus, for example, the fluid flow from the second fluid interface to the opening by means of the diaphragm 18 can be released when the diaphragm 18 is in the non-activated state and can be correspondingly closed when the diaphragm 18 is in the activated state. In this embodiment, the diaphragm 18 is in the activated state when there is a greater pressure in the first working space (which in this embodiment is also formed between the base surface 15 of the interior space 14 and the diaphragm 18) than in the fluid space. Accordingly, switching, i.e., changing from the activated state to the non-activated state or from the non-activated state to the activated state, can be achieved by adjusting the pressure in the fluid space and / or the first working space. Alternatively, the diaphragm 18 can also be arranged in the housing 4 such that the diaphragm 18 fluid-tightly closes the diaphragm seat in the non-activated state and releases the diaphragm seat in the activated state.

Claims

1. An actuator device (1) having a fixed-shape housing (4) in which an interior space (14) is constructed, wherein the interior space (14) is formed by a base surface (15), a cover surface (16) opposite the base surface (15), and a side surface (17) connecting the base surface (15) to the cover surface (16), the cover surface (16) being spaced apart from the base surface (15) in a direction perpendicular to the base surface (15), and having a rubber-elastic diaphragm (18) arranged in the interior space (14) and connected in one piece to the housing (4), wherein the housing (4) and the diaphragm (18) are manufactured together by means of an additive production method, in particular a 3D printing method.

2. The actuator device according to claim 1, characterized in that The diaphragm (18) is manufactured from a first material and the housing (4) is manufactured from a second material.

3. The actuator device according to claim 1 or 2, characterized in that: The diaphragm (18) is arranged in the interior space (14) in such a way that a first working space is formed between the diaphragm (18) and the base surface (15), which first working space is fluidically connected to a first fluid connection (9) formed in the housing (4).

4. Actuator device according to any one of the preceding claims, characterized in that A piston element (13) is arranged in the inner space (14) and is movable along a movement axis. The piston element is integrally connected to the diaphragm (18), wherein the cover surface (16) has a through-opening through which the piston element (13) partially protrudes relative to the housing (4) when the diaphragm (18) is in an activated state, and wherein the piston element (13) is manufactured together with the housing (4) and the diaphragm (18) by means of an additive manufacturing method.

5. The actuator device according to claim 4, characterized in that A second working space (31) is formed between the piston element (13) and the cover surface (16), which second working space is fluidically connected to a second fluid connection (10) formed in the housing (4).

6. The actuator device according to claim 4 or 5, characterized in that A sealing element (23) is arranged in the housing and is connected integrally to the piston element (13) and the housing (4), wherein the sealing element (23) is manufactured together with the piston element (13), the housing (4) and the diaphragm (18) by means of an additive manufacturing method.

7. The actuator device according to claim 6, characterized in that The sealing element (23) is produced from the first material and the piston element (13) is produced from the second material.

8. The actuator device according to claim 6 or 7, characterized in that The sealing element (23) is designed as a spring element.

9. Actuator device according to any one of the preceding claims 1 to 7, characterized in that The diaphragm (18) has a first self-retaining position and a second self-retaining position different from the first self-retaining position, wherein a first adjustment force must be applied to leave the first self-retaining position, and wherein a second adjustment force must be applied to leave the second self-retaining position.

10. Actuator device according to any one of the preceding claims, characterized in that The angle formed between the base surface (15) and each covering surface element (32, 33, 34, 35, 36, 37) forming the covering surface (16) lies in the range of 45° to 75° or 105° to 135°.

11. The actuator device according to claim 3, characterized in that An opening is formed on the cover surface (16), the opening being surrounded by a diaphragm seat formed on the cover surface (16), wherein a fluid space is formed between the diaphragm (18) and the cover surface (16), the fluid space being fluidically connected to a second fluid interface formed in the housing (4), and wherein the diaphragm (18) closes the opening in a fluid-tight manner in an activated state by abutting against the diaphragm seat.

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