Buckling Microvalve With Through-Holes for Low-Energy Pressure Control
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Solution Overview
Problem
Existing microvalves are inefficient, energy-intensive, and noisy, particularly when controlling fluid flows in applications requiring high pressure and precision, such as in automotive seat systems and biological cell cultures.
Innovation Solution
A microvalve design featuring a buckling membrane with through-holes, actuated by a ring-shaped piezoelectric drive element, which allows for efficient pressure compensation and reduced actuation energy, enabling silent operation and high deflection with a compact geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional microvalves are used to control fluid flow under high pressure, then fluid control capability is achieved, but energy consumption increases and noise is generated
Solution Approach 1:
The patent employs pressure compensation channels that introduce counter-pressure from the second chamber to balance the high fluid pressure in the first chamber. This counterweight mechanism reduces the net pressure differential that the piezoelectric actuator must overcome, thereby enabling high-pressure fluid control with lower energy consumption. The compensation channels effectively create a pressure counterbalance that reduces the actuation force requirement.
Solution Approach 2:
The patent replaces conventional high-power electromagnetic or pneumatic actuation mechanisms with a low-power piezoelectric stack actuator. The piezoelectric element converts electrical energy directly to mechanical displacement with high efficiency, eliminating the energy losses associated with traditional motor-driven or pressure-driven valve actuation systems. This mechanical substitution enables precise control with minimal energy input.
2Reliability
If conventional microvalves operate under high pressure, then fluid control is achieved, but noise is generated
Solution Approach 1:
The pressure compensation mechanism reduces pressure differentials across the valve seat by introducing counter-pressure from the second chamber. By balancing the pressures, the system minimizes turbulent flow and pressure shocks that generate noise, while maintaining the ability to control high-pressure fluid flow. The compensation channels act as pressure-smoothing pathways that eliminate sudden pressure changes.
3Reliability
If a buckling membrane with through-holes is used, then pressure compensation efficiency is improved, but membrane structural complexity increases
Solution Approach 1:
The membrane incorporates through-holes that create a porous structure, enabling pressure compensation by allowing fluid communication between the first and second chambers. The porous configuration provides multiple flow pathways for pressure equalization while maintaining the membrane's deflectable nature. This porous material approach achieves effective pressure compensation without requiring complex external compensation mechanisms.
Solution Approach 2:
The membrane is segmented into multiple functional regions: a central deflectable portion for valve actuation and peripheral through-holes for pressure compensation. This segmentation allows the membrane to simultaneously perform both valve control and pressure balancing functions, reducing the need for separate compensation components and simplifying the overall device architecture.
4Use of energy by moving object
If a ring-shaped piezoelectric drive element is used, then actuation energy is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The piezoelectric stack actuator is designed to work in conjunction with the buckling membrane's dynamic response. The actuator provides controlled displacement that triggers the membrane's buckling transition, leveraging the membrane's inherent mechanical instability to achieve large deflections with minimal actuation force. This dynamic coupling reduces the energy requirement compared to directly actuating a rigid valve element.
Solution Approach 2:
The system utilizes the piezoelectric material's property of changing dimensions in response to applied voltage. By carefully selecting the piezoelectric element's geometry (ring-shaped) and material properties, the design achieves sufficient displacement with reduced voltage requirements. The parameter optimization of the piezoelectric element allows lower energy input while maintaining positioning accuracy through the membrane's mechanical amplification of the actuator's motion.
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 microvalve achieves efficient fluid control with reduced energy consumption and minimal noise, capable of operating under high pressures and pressures, and can be configured into complex valve assemblies like 3/2, 5/2, and 3/3 way valves for diverse applications.
Implementation Method 1
a ring-shaped piezoelectric drive element operable to deflect the membrane
Implementation Method 2
a deflectable membrane which separates the cavity into a first chamber and a second chamber
Data Source
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AI summary
The present disclosure relates to a microvalve and a microvalve array comprising one or more such microvalves designed according to the present disclosure. A microvalve comprises a base body with a cavity and at least one first opening and at least one second opening, each opening extending into the cavity, a deflectable membrane, which separates the cavity into a first chamber and a second chamber, an actuating element, which is supported by the base body and which contacts the deflectable membrane and is operable to deflect the membrane to move between at least two positions, wherein the deflectable membrane comprises at least one through-hole extending between the first chamber and the second chamber.