Modular SMA Valve Assembly for Quiet Compact Fluid Switching
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Solution Overview
Problem
Traditional fluid valves used in automotive seating, such as those for lumbar support and massage functions, are bulky, heavy, and noisy, and their implementation with shape memory alloy (SMA) wires can be complex and difficult to integrate due to large dimensions and assembly challenges.
Innovation Solution
A modular setup for fluid valves using an actuator component with a carrier, plunger, and SMA wire that can be assembled separately and attached to a housing, featuring a resilient member for biasing and electrical actuation to efficiently switch fluid flows, allowing for compact and reliable valve design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional solenoid technology is used for valve actuation, then reliable fluid flow switching is achieved, but the valve becomes bulky and heavy
Solution Approach 1:
The patent replaces the traditional solenoid (electromagnetic) actuation system with a shape memory alloy (SMA) wire actuator. The SMA wire utilizes thermal-mechanical coupling to generate actuation force, eliminating the need for bulky electromagnetic coils and cores. This substitution significantly reduces valve weight while maintaining reliable fluid flow switching through the phase transformation properties of the SMA material.
Solution Approach 2:
The patent changes the actuation mechanism from electromagnetic field-based (solenoid) to thermal-mechanical field-based (SMA wire). By utilizing the temperature-dependent phase transformation parameters of the shape memory alloy, the system achieves compact actuation with reduced weight while maintaining functional reliability for fluid flow control.
2Reliability
If traditional solenoid technology is used for valve actuation, then fluid flow switching is achieved, but significant noise is generated during operation
Solution Approach 1:
The patent replaces the solenoid actuation system with an SMA wire actuator that operates through smooth thermal-mechanical phase transformation. This eliminates the electromagnetic switching noise and mechanical impact noise characteristic of solenoid operation, significantly reducing the noise level while maintaining reliable fluid flow switching capability.
3Weight of moving object
If SMA wire is used for valve actuation, then weight and noise are reduced, but the valve structure becomes complex with many parts
Solution Approach 1:
The patent merges the SMA wire actuator, plunger, and valve body into an integrated modular assembly. The actuator component is pre-assembled with the plunger and sealing elements, then mounted as a single unit to the valve body. This merging approach reduces the number of discrete parts and simplifies the overall structure while maintaining the weight advantages of SMA actuation.
Solution Approach 2:
The patent segments the valve into modular components: a valve body with fluid ports and a separate actuator component containing the SMA wire and plunger. This segmentation allows for simplified assembly and reduces the complexity of the overall structure by enabling independent optimization of each module while reducing total part count through selective integration.
4Reliability
If SMA wire actuator with large housing dimensions is used, then valve functionality is achieved, but integration becomes difficult
Solution Approach 1:
The patent segments the valve system into a compact valve body with integrated fluid ports and a separate actuator component. This segmentation allows the housing dimensions to be minimized while maintaining full valve functionality, as the actuator can be mounted externally on the compact valve body rather than requiring a large internal housing space.
Solution Approach 2:
The patent transitions from a traditional internal actuator configuration to an external mounting arrangement where the actuator component is attached to the exterior of the compact valve body. This dimensional reconfiguration allows for reduced housing volume while maintaining functionality, as the actuation mechanism operates from the external dimension rather than consuming internal housing space.
5Productivity
If modular actuator component design is used, then assembly efficiency is improved, but additional assembly steps are required
Solution Approach 1:
The patent segments the valve into pre-assembled modular components (valve body and actuator component) that can be manufactured and tested independently. This segmentation improves overall assembly efficiency by enabling parallel manufacturing and quality control of modules, reducing the complexity of final assembly despite the additional step of module integration.
Solution Approach 2:
The patent merges multiple sub-components (SMA wire, plunger, sealing elements) into a pre-integrated actuator component assembly. This merging improves assembly efficiency by reducing the number of discrete parts to be handled during final assembly, and the additional assembly step of mounting the pre-assembled component is offset by the simplified integration process and improved quality control.
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 modular design facilitates simple and efficient switching of fluid flows, reduces noise and bulk, and enables compact integration of valves with tight sealing, improving assembly efficiency and reducing complexity.
Implementation Method 1
an actuator employing a shape memory alloy (SMA) wire
Implementation Method 2
The SMA wire is arranged between the carrier and the plunger and is configured to exert an actuation force onto the plunger
Implementation Method 3
an elastic member that is arranged between the carrier and the plunger and is configured to exert a bias force onto the plunger
Implementation Method 4
The elastic member can be implemented by a spring, e.g., a compression spring
Data Source
AI summary
A valve includes a housing with a bottom plate, first and second fluid ports, and an actuator component arranged such that the bottom plate engages the actuator component. The actuator component includes a carrier, a plunger arranged on the carrier and comprising a sealing surface, a shape memory alloy actuator arranged co-linearly with the plunger between the carrier and the plunger to exert an actuation force onto the plunger, and a spring co-linearly arranged with the plunger between the carrier and the plunger to exert a bias force onto the plunger. The sealing surface of the plunger can sealingly engage the first fluid port. The valve further includes a circuit board comprising circuitry to actuate the shape memory alloy actuator. The housing is at least partly arranged between the circuit board and carrier and comprises through holes to receive electrical pins of the actuator component extending towards the circuit board.