Valve unit
The valve unit addresses inefficiencies in airflow management by employing a spring-supported, compact design with a through-hole connection and diaphragm-like spring unit, ensuring efficient actuation and leak prevention in inflatable cushion systems.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- CONTINENTAL AUTOMOTIVE TECHNOLOGIES GMBH
- Filing Date
- 2025-11-05
- Publication Date
- 2026-05-21
AI Technical Summary
Existing valve units for inflatable cushions in vehicles face inefficiencies due to high actuation cycles and the inability to detect unintentional inflation from leakage, often using normally open or closed valves that do not effectively manage airflow.
A valve unit design featuring a spring unit supported against the housing outer wall, with a compact and flat structure, utilizing a through-hole connection and a diaphragm-like spring unit to manage airflow efficiently, allowing for a compact and efficient 2/2-NO or 3/3-NO valve configuration.
The design achieves a compact and efficient airflow management, preventing unintentional inflation and reducing installation space, while maintaining effective actuation cycles and leak detection.
Smart Images
Figure EP2025082046_21052026_PF_FP_ABST
Abstract
Description
[0001] 202405046
[0002] 1
[0003] Description
[0004] Valve unit
[0005] The invention relates to a valve unit.
[0006] In vehicles, inflatable, elastic cushions are used to shape seat contours. These cushions are typically filled with air. Electrically actuated valves are used to control the airflow. Shape memory alloy (SMA) wire can be used as the actuator element for such valves; this wire shortens in length when an electric current flows and the resulting heat is generated. A high number of actuation cycles is required for dynamic contour adjustment applications. At the same time, pressure sensors that measure cushion pressure are often omitted. Unintentional inflation of the cushions due to leakage cannot be detected and must therefore be prevented by design. Normally open (NO) valves are typically used for this purpose. Alternatively, normally closed (NC) valves are designed so that, even in the event of leakage, there is no connection between the pressure supply and the cushion when the valve is closed.
[0007] German patent application DE 102018216874 B4 describes a valve unit of this type known in this context. Furthermore, DE 102019208051 B4 discloses a valve unit with an SMA actuator. German patent application DE 102022207882 B3 describes another valve unit known in this context.
[0008] The object of the invention is, in particular, to achieve an efficient design. This object is achieved according to the invention by the features of claim 1, while advantageous embodiments and further developments of the invention can be found in the dependent claims.
[0009] The invention relates to a valve unit with at least one actuator, at least one housing outer wall, which separates the valve unit from a 202405046
[0010] 2
[0011] The surrounding area of the valve unit is defined as a first spatial area, at least a second spatial area in which the actuator is at least partially arranged, at least a connection which fluidly connects the first spatial area and the second spatial area in at least a first operating state, at least a seal which at least partially closes the connection in at least a second operating state, and at least a spring unit which exerts a force on the seal at least in the second operating state and which is at least partially arranged in the first spatial area.
[0012] It is proposed that the spring unit be supported against the outer wall of the housing. The phrase "fluidically connected" between a first and second chamber means, in particular, that a fluid can move from the first chamber to the second chamber and / or from the second chamber to the first. This allows for an efficient design. In particular, compared to valves where the spring is located in a separate chamber, a compact and flat design can be achieved.
[0013] In particular, the valve unit can be a pneumatic valve unit. Specifically, the spring unit can be designed as a diaphragm.
[0014] Furthermore, it is proposed that the connection be at least a through-hole in a one-piece component of the valve unit, and that the component forms at least part of an outer wall of the valve unit and / or a support for at least part of a circuit board of the valve unit and / or at least part of a connection of the valve unit. "One-piece" is understood to mean, in particular, cast in one piece and / or injection molded and / or separable only by destruction. This allows for a design with a small number of components. In particular, the connection can be a consumer connection. 202405046
[0015] 3
[0016] Advantageously, the connection consists of at least one through-hole, and the opening of the through-hole into the second room area is free of any projections extending into the second room area with respect to the surface surrounding the opening. This saves construction space.
[0017] Furthermore, it is proposed that the spring unit be arranged in a three-dimensional half-space bounded by an imaginary plane that intersects a circuit board of the valve unit located in the second spatial region and / or a spring bender of the actuator, and is perpendicular to an axial direction of a screw of the valve unit that fastens the circuit board and / or the spring bender, and / or to an axial direction of a plunger of the valve unit. This half-space differs from a three-dimensional half-space bounded by the plane in which an SMA wire of the actuator is arranged. A "half-space" is understood to be, in particular, a half of the three-dimensional space bounded only by the plane. An "SMA wire" is understood to be, in particular, a wire that consists at least partially, and especially entirely, of shape memory wire.This allows for a small spatial dimension of the valve unit with respect to the axial direction of the screw or the axial direction of the plunger. In particular, a large installation space requirement in the axial direction of the screw or the axial direction of the plunger can be avoided by positioning the actuator based on the position or spatial dimension of the spring unit.
[0018] In an advantageous embodiment of the invention, the spring unit has the shape of a spherical cap with at least one recess or the shape of a spherical cap. This allows for simple manufacturability. In particular, simultaneous manufacturability with a plunger can be achieved.
[0019] In particular, the spring unit can form the seal. Specifically, a spring unit designed as a spherical cap can have a thickened central area that forms the seal. 202405046
[0020] 4
[0021] Advantageously, the valve unit features a fluid chamber located between the outer wall of the housing and the spring unit, which is fluidically connected to a port on the valve unit. A "fluid chamber" is understood to be, in particular, a chamber into which fluid can flow in and out and / or in which the unit is located. This ensures that the restoring force of the spring unit is not negated by a negative pressure in the fluid chamber.
[0022] Advantageously, the spring unit is part of a component that includes a plunger and is made of a single material or two different materials. This allows for simple manufacturing. In particular, the component can be manufactured by injection molding or two-component injection molding.
[0023] In particular, the component may contain an elastomer or consist of an elastomer.
[0024] Furthermore, it is proposed that the valve unit has a plunger attached to the seal, and that the actuator's spring bender has a first end and a second end which is located closer to the plunger than the first end, and that the actuator's SMA wire has a first end and a second end which is located closer to the plunger than the first end of the SMA wire, and that, measured in a principal extension direction of the SMA wire, the second end of the spring bender is located further away from the first end of the SMA wire than the plunger. This allows for a compact design in the principal extension direction.
[0025] The valve assembly is preferably a 2 / 2-NO valve or a 3 / 3-NO valve. A "2 / 2-NO valve" is specifically understood to mean a valve that has a permeable connection in its unactuated state.
[0026] "3 / 3-NO valve" shall be understood in particular to mean a valve which has three ports and three switching positions and which, in an unactuated state, has a single permeable connection from one of the ports to 202405046
[0027] 5
[0028] a second of the connections. This allows for an efficient design.
[0029] Furthermore, it is proposed that the spring unit be arranged in a fluid channel which, in at least one operating state, leads from a first port of the valve unit to a second port of the valve unit. This allows for additional installation space to be saved for the spring unit.
[0030] Further advantages become apparent from the following description of the drawings. The drawings illustrate exemplary embodiments of the invention. The drawings, the description, and the claims contain numerous features in combination. A person skilled in the art will expediently consider the features individually and combine them into meaningful further combinations.
[0031] Fig. 1 shows a section through a valve unit according to the invention,
[0032] Fig. 2 shows a section through an alternative embodiment of a valve unit according to the invention, wherein two actuators are unactuated, Fig. 3 shows a section through the alternative embodiment, wherein both actuators are actuated, and
[0033] Fig. 4 shows a section through the alternative embodiment, in which only one of the actuators is actuated.
[0034] Figure 1 shows a section through a valve unit according to the invention, which comprises an actuator 10, a housing with an outer wall 12, a first chamber 16, and a second chamber 18. The outer wall 12 separates the valve unit from an ambient chamber 14. The actuator 10 is arranged in the second chamber 18. In a first operating state, a connection 20 of the valve unit fluidly connects the first chamber and the second chamber. This first operating state is illustrated in Figure 1. Furthermore, the valve unit has a seal 22, which completely closes the connection 20 in a second operating state. The valve unit also has a spring unit 24 arranged in the first chamber 16, which is located in both the 202405046
[0035] 6
[0036] In both the first and second operating states, a force is exerted on the seal 22. To exert this force, the spring unit 24 is supported against the outer wall 12 of the housing.
[0037] Connection 20 is connected to a port 42 of the valve unit via a fluid channel 68. Port 42 is designed as a consumer port 66, to which, for example, an air cushion can be connected as a consumer. The valve unit is a pneumatic valve unit and can therefore be used with air as the fluid. The fluid channel 68 is formed by the outer housing wall 12 and a component 28 of the valve unit. The component 28 is formed in one piece. Connection 20 is a through-hole 26 in the component 28. Furthermore, a part 40 of the port 42 is formed by a part of the component 28. In addition, the component 28 forms part of an outer wall 32 of the valve unit, which partially delimits the second chamber 18. A circuit board 38 of the valve unit is fastened to the component 28 by a screw 48. Thus, the component 28 forms a support 34 not only for a part 36 of the circuit board but for the entire circuit board 38.An opening 41 of the through-hole into the second space area 18 is formed free of projections extending into the second space area 18 with respect to a surface 43 that surrounds the opening.
[0038] The spring unit 24 is part of a component 62, which includes a plunger 50 and is made of a single elastomer. The component 62 is formed in one piece. The spring unit 24 has a dome shape with a recess 58 and further recesses. The spring unit is thickened in a central region. This central region forms the seal 22. The plunger 50 is located on one side of the seal, facing away from the outer housing wall 12. A fluid chamber 60 is located between the outer housing wall and the spring unit 24, and this chamber is fluidly connected to the port 42 via the recess 58 and the further recesses.
[0039] A housing part 71, together with component 28, encloses the second space area 18 in which the actuator 10 is arranged. The housing part 202405046
[0040] 7
[0041] 71 has a fluid drain opening 72, which fluidly connects the second chamber 18 to the surrounding chamber 14. A spring bender 45 of the actuator 10 is partially positioned between the circuit board and the component 28 and is fastened to the component 28 by the screw 48. An SMA wire 56 of the actuator is attached at its first end to the spring bender 45, which consists of a metal sheet, by a component of the actuator. The SMA wire is also attached at its second end to the circuit board by another component. In the first operating state, the actuator is not actuated, and the spring bender 45 presses the plunger 50 against the outer wall 12 of the housing, so that the seal 22 is spaced from the through-hole 26 and the connection 20 is open.
[0042] An imaginary plane 44 has only plane extension directions that are perpendicular to an axial direction 46 of the plunger 50. In other words, the axial direction 46 is perpendicular to the plane 44. The axial direction 46 is also an axial direction of the screw 48. Alternatively, the screw 48 can be replaced by another fastening element, such as, in particular, a rivet, a hot-stitch dome, or a snap hook, whereby the axial direction 46 can also be an axial direction of this other fastening element. The plane 44 is projecting in Figure 1, i.e., a straight line. The plane 44 intersects the circuit board 38 and the spring bender 45. A first half-space 52 and a second half-space 54 are bounded by the plane 44. The half-spaces 52 and 54 are distinct from each other. The spring unit 24 is arranged in the half-space 52 and the SMA wire 56 is arranged in the half-space 54.
[0043] In an unactuated state, the actuator 10 extends further towards the consumer terminal 66 with respect to a main extension direction 64 of the SMA wire 56 than the spring unit 24. Of the parts of the actuator, the SMA wire and the component that attaches the SMA wire to the spring bender extend furthest towards the consumer terminal 66.
[0044] The described valve unit is a 2 / 2 NO valve, i.e., a normally open (NO) vent valve, meaning it is open in the unactuated state, so that the 202405046
[0045] 8
[0046] Connection 20 is permeable in the unactuated state and fluid from a consumer connected to the consumer connection 66 can escape through the connection and through the fluid drain opening 72 into the ambient area 14.
[0047] Component 62 can be made of silicone, for example, or
[0048] The plunger can consist of ethylene propylene diene monomer rubber or be a two-component part. For example, the plunger can consist of a main component, such as a thermoplastic or metal. The plunger can, for example, be an extrusion. The seal 22 and the spring element 24 can be produced by injection-molding a sealing surface made of elastomer onto spring steel.
[0049] Starting from the operating state shown in Figure 1, if current flows through the SMA wire 56 by means of the circuit board, the spring bender, and the components that attach the SMA wire to the spring bender and the circuit board, the wire shortens and deflects the spring bender 45 from its position in the first operating state due to the attachment of the SMA wire to the spring bender. Because the spring element 24 exerts a force on the plunger 50, the plunger 50 then moves away from the outer wall of the housing 12 in the opposite direction 46 until the seal 22 contacts the component 28 and, due to the inherent tension of the spring element 24, remains in contact with the component 28 in such a way that the through-hole 26 is closed. Thus, fluid flow from the first chamber 16 via the connection 20 through the fluid drain opening 72 is no longer possible.If the current flow through the SMA wire 56 is interrupted again, a tensile force exerted on the SMA wire by the spring bender 45 causes the SMA wire to lengthen, so that the spring bender returns to the position it occupied in the first operating state. During this return, the spring bender pushes the plunger 50 in the axial direction 46, so that the seal 22 is removed from the through-hole 26 and the connection 20 is thereby opened.
[0050] The outer wall of the housing is formed by a housing cover. 202405046
[0051] 9
[0052] Except for its recesses, the component 62 is rotationally symmetrical with respect to an axis of the plunger extending in the axial direction 46. The component 62 is inserted between the housing outer wall and component 28 before assembly. The recesses of the component 62 prevent a vacuum or positive pressure from forming between the housing outer wall and the spring assembly 24. Alternatively, the recesses can be replaced by channels and / or ribs on one side of the spring assembly facing the housing outer wall, and / or by channels and / or ribs in the housing outer wall.
[0053] The plane 44 can also intersect the spring bender where it touches the plunger. The half-spaces 52 and 54 would be modified accordingly.
[0054] The restoring force of component 62, which is achieved here by the spring unit 24, can also be supported by an additional spring, for example a coil spring, which can be positioned between the outer housing wall 12 and the seal 22. Another embodiment of component 62 consists of the plunger, the seal 22, and the aforementioned spring.
[0055] The spring bender 45 has a first end 86 and a second end 87, the latter being a shorter distance from the plunger 50 than the first end. Furthermore, the SMA wire 56 has a first and a second end 88, 89, the latter being a shorter distance from the plunger than the first end 88 of the SMA wire. Measured in a principal extension direction 64 of the SMA wire, the second end 87 of the spring bender is a greater distance from the first end 88 of the SMA wire than the plunger.
[0056] The spring bender can also be shaped to act as an air deflector, directing any fluid escaping from connection 20 away from the SMA wire to minimize uneven cooling caused by fluid flow. 202405046
[0057] 10
[0058] In the described design, component 62 has a small number of components, resulting in low costs for these components and their assembly.
[0059] Figures 2 to 4 show an alternative embodiment of a valve unit. Except for the differences described below, this valve unit is identical in construction and function to the valve unit in Figure 1.
[0060] Components, features, and functions that remain essentially the same are generally numbered with the same reference numerals. However, to distinguish the embodiments, the letter "a" has been added to the reference numerals of the embodiment shown in Figures 2 to 4. The following description is essentially limited to the differences from the embodiment shown in Figure 1, whereby reference is made to the description of the embodiment shown in Figure 1 with regard to components, features, and functions that remain the same.
[0061] The valve unit of Figures 2-4 has a spring bender 45a and an SMA wire 56a, which are attached to a circuit board (not shown) in the same way as the corresponding parts of the first embodiment. Furthermore, the valve unit has another actuator 73a, which is identical in construction to the actuator 10a. Therefore, the actuator 73a also has a spring bender 74a and an SMA wire 75a, which are attached to another circuit board (not shown). The other actuator is arranged in a space 18a. When in operation, the valve unit is connected to a pump or a compressed air reservoir (not shown) via a connection 70a.
[0062] Figure 2 shows a first state during operation of the valve unit, in which both actuators are unactuated. A component 28a, together with a cap 76a and a diaphragm 78a, forms a fluid chamber 77a. The diaphragm is attached to the component 28a and the cap. Another component 79a, together with the component 28a, forms a first opening 80a and a second opening 81a, which leads to the connection 70a. In the first state, a spring 82a of the valve unit, which is supported by the cap 76a, presses the diaphragm 78a into 202405046
[0063] 11
[0064] The component 79a is directed so that openings 80a and 81a are closed. Furthermore, in the first state, the spring bender 75a presses a seal 83a against the cap, thus closing a through-hole 84a in the cap, which connects the second chamber 18a and the fluid chamber. A channel 85a, formed in component 28a and the cap, connects the port 70a and the fluid chamber fluidly. The first state is a state in which a consumer connected to port 42a (not shown), such as an air cushion, is being or has been vented.
[0065] Starting from the first state, the consumer can be filled. First, actuator 10a is actuated, closing connection 20a. Then, actuator 73a is actuated, causing seal 83a to be removed from through-hole 84a, thus connecting the fluid chamber to the second chamber 18a. Because the pressure in the fluid chamber is the same as at connection 70a in the first state, fluid flows from the fluid chamber into the second chamber 18a and out through drain 72a after through-hole 84a is opened. More fluid flows out of the fluid chamber than flows in through channel 85a, causing a pressure drop in the fluid chamber.Due to pressure acting on the port 70a and consequently on the diaphragm 78a in the region of the opening 81a, the diaphragm is pressed into the fluid chamber against a force from the spring 82a. This opens the openings 80a and 81a, and fluidically connects the port 70a to a consumer port 66a via a fluid channel 68a. This is because fluid flowing from the port 70a through the fluid channel 68a flows laterally past a component 62a. In a corresponding operating condition (Figure 3), a spring unit 24a of the component 62a is arranged in the fluid channel 68a.If the consumer is, for example, an air cushion, fluid introduced into the air cushion can be retained in the air cushion by releasing the actuator 73a, which causes the seal 83a to close the through-opening 84a again and a pressure increase in the fluid chamber via the channel 85a until a force from the spring 82a moves the diaphragm 78a towards the component 79a, until the openings 202405046.
[0066] 12
[0067] Connections 80a and 81a are again sealed by the diaphragm. Connection 20a remains sealed by seal 22a (Figure 4), thus placing the valve unit in a state where it can remain closed when actuator 10a is actuated and actuator 73a remains disengaged, and in which the fluid is retained in the air cushion. Pressure within the air cushion helps to press seal 22a against the opening of a through-hole 26a, keeping connection 20a closed. When actuator 10a is returned to a disengaged state, connection 20a opens and the air cushion is vented through connection 20a. Overall, the valve unit is therefore a 3 / 3 normally open (NO) valve, which can be used for advanced massage functions via the air cushion.If the valve unit is installed in a car, the actuators can be inactive when the car is parked, thus deflating the air cushion. Should a defect cause a leak allowing fluid to flow into the air cushion, this poses no problem when parked because connection 20a is open, allowing the fluid to escape and preventing the air cushion from continuously inflating due to the leak.
[0068] The spring bender 45a can be stopped in a state in which the actuator 10a is unactuated, either by the spring bender resting on the component 28a or by resting on the component 62a, which in turn rests on a housing outer wall 12a.
[0069] In both described embodiments, the actuator(s) are arranged at ambient pressure. 202405046
[0070] 13
[0071] Reference symbol list:
[0072] 10 Actuator
[0073] 12 Outer wall of the housing
[0074] 14 Surrounding area
[0075] 16 Room area
[0076] 18 Room area
[0077] 20 connection
[0078] 22 Seal
[0079] 24 spring unit
[0080] 26 through hole
[0081] 28 components
[0082] Part 30
[0083] 32 Exterior wall
[0084] 34 carriers
[0085] Part 36
[0086] 38 circuit boards
[0087] 40 parts
[0088] 41 Mouth
[0089] 42 connection
[0090] 43 area
[0091] Level 44
[0092] 45 spring benders
[0093] 46 Axial direction
[0094] 48 screw
[0095] 50 pestles
[0096] 52 half-space
[0097] 54 half-space
[0098] 56 SMA wire
[0099] 58 Exclusion
[0100] 60 Fluid area
[0101] 62 Component
[0102] 64 Main direction of extension 202405046
[0103] 14
[0104] 66 Consumer connection 68 Fluid channel
[0105] 70 connection
[0106] 71 Housing part
[0107] 72 fluid drain opening 73 actuator
[0108] 74 spring benders
[0109] 75 SMA wire
[0110] 76 cap
[0111] 77 Fluid chamber
[0112] 78 Membran
[0113] 79 Component
[0114] 80 opening
[0115] 81 Opening
[0116] 82 springs
[0117] 83 Seal
[0118] 84 Through hole
[0119] 85 Channel
[0120] 86 End
[0121] 87 End
[0122] 88 End
[0123] 89 End
Claims
202405046 15 Patent claims:
1. Valve unit comprising at least one actuator (10), at least one housing outer wall (12) which separates the valve unit from an ambient area (14) of the valve unit, a first space area (16), at least one second space area (18) in which the actuator (10) is at least partially arranged, at least one connection (20) which fluidly connects the first space area (16) and the second space area (18) in at least one first operating state, at least one seal (22) which at least partially closes the connection (20) in at least one second operating state, and at least one spring unit (24) which exerts a force on the seal (22) at least in the second operating state and which is at least partially arranged in the first space area (16). characterized by the fact that the spring unit (24) is supported on the outer wall of the housing (12).
2. Valve unit according to claim 1, characterized in that the connection (20) is at least a through hole (26) of a one-piece component (28) of the valve unit and the component (28) forms at least a part (30) of an outer wall (32) of the valve unit and / or a support (34) for at least a part (36) of a circuit board (38) of the valve unit and / or at least a part (40) of a connection (42) of the valve unit.
3. Valve unit according to at least one of claims 1 or 2, characterized in that the connection (20) is at least one through hole (26) and an opening (41) of the through hole into the second space area (18) is formed free of projections extending into the second space area (18) with respect to a surface (43) surrounding the opening.
4. Valve unit according to at least one of the preceding claims, characterized in that the spring unit (24) is located in a plane (44) which is intersected by an imaginary plane which intersects a circuit board (38) of the valve unit arranged in the second space area (18) and / or a spring bender (45) of the actuator (10). 202405046 16 and is arranged in a three-dimensional half-space (52) bounded by an axial direction (46) of a screw (48) of the valve unit which fastens the circuit board and / or the spring bender, and / or is perpendicular to an axial direction (46) of a plunger (50) of the valve unit, which differs from a three-dimensional half-space (54) bounded by the plane in which an SMA wire (56) of the actuator (10) is arranged.
5. Valve unit according to at least one of the preceding claims, characterized in that the spring unit (24) has a calotte shape with at least one recess (58) or a calotte shape.
6. Valve unit according to claim 5, characterized by a fluid area (60) which is arranged between the outer wall of the housing (12) and the spring unit (24) and is fluidically connected to a port (42) of the valve unit.
7. Valve unit according to at least one of the preceding claims, characterized in that the spring unit (24) is part of a component (62) which has a plunger (50) and which consists of a single material or of two different materials.
8. Valve unit according to at least one of the preceding claims, characterized in that the valve unit has a plunger (50) attached to the seal (22) and a spring bender (45) of the actuator (10) has a first end (86) and a second end (87) which has a shorter distance to the plunger than the first end, and an SMA wire (56) of the actuator has a first and a second end (88, 89) which has a shorter distance to the plunger than the first end (88) of the SMA wire, and measured in a principal extension direction (64) of the SMA wire, the second end (87) of the spring bender has a greater distance to the first end (88) of the SMA wire than the plunger.
9. Valve unit according to at least one of the preceding claims, 202405046 17 characterized in that the valve unit is a 2 / 2-NO valve or a 3 / 3-NO valve.
10. Valve unit according to claim 9, characterized in that the spring unit (24a) is arranged in a fluid channel (68a) which in at least one operating state leads from a first port (42a) of the valve unit to a second port (70a) of the valve unit.