SMA Bimorph Actuator Structure With Integrated Dielectric Isolation
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Solution Overview
Problem
Existing shape memory alloy (SMA) actuators require multiple materials and complex manufacturing processes, which can lead to inefficiencies and increased resource consumption.
Innovation Solution
The use of a compact SMA actuator design with a limited number of materials, incorporating dielectric injection molding to isolate electrical contacts and simplify manufacturing, such as through heat staking, adhesive bonding, and detab processes to reduce complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple materials and complex manufacturing processes are used in SMA actuators, then functional requirements can be met, but manufacturing complexity and resource consumption increase
Solution Approach 1:
The patent combines multiple functional components into a single integrated base structure that includes electrical contacts, insulators, and mounting features. This merging reduces the number of separate parts and manufacturing steps while maintaining all necessary functions, directly addressing the contradiction between meeting functional requirements and reducing manufacturing complexity
Solution Approach 2:
The base structure is designed to perform multiple functions simultaneously: providing electrical contacts for SMA wire connection, offering insulating properties through integrated dielectric materials, enabling mechanical mounting of the carriage, and facilitating heat transfer during manufacturing processes. This multi-functionality reduces the overall device complexity while ensuring all functional requirements are met
2Reliability
If traditional manufacturing processes are used for SMA actuators, then component functionality is achieved, but production time and resource utilization increase
Solution Approach 1:
The patent incorporates insulating features and electrical contact structures into the base during its initial formation process rather than adding them as separate subsequent steps. This preliminary action ensures component functionality is built-in from the start while reducing the total number of manufacturing steps, thereby improving production efficiency
Solution Approach 2:
The manufacturing process utilizes controlled temperature parameters during the formation of the base structure to simultaneously achieve material bonding, insulator curing, and electrical contact establishment. By optimizing these parameter changes, the patent maintains component functionality while reducing overall production time and improving resource utilization
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 simplified design achieves high actuation height with a reduced footprint and fewer manufacturing steps, enhancing efficiency and resource utilization.
Implementation Method 1
The at least one SMA wire can be configured to actuate the free end of the base responsive to receiving an electrical current
Implementation Method 2
Shape memory alloy ("SMA") systems can include an actuator or structure that can be used in conjunction with various components
Implementation Method 3
The insulator can electrically isolate the first set of electrical contacts at the fixed end of the base
Implementation Method 4
disposing an insulator at the fixed end of the base via an injection molding process
Implementation Method 5
The heat staking process can include applying heat to a protrusion extending from the carriage through a recess formed in the fixed end of the base
Data Source
AI summary
The present embodiments relate to a shape memory alloy (SMA) actuator with a reduced number of materials for manufacturing the actuator. In some instances, elements of the SMA actuator can comprise a dielectric material disposed on the actuator via an injection molding process. In other instances, the SMA actuator can dispose SMA wires above a base of the SMA actuator without the use of any dielectric material. In a first example, an SMA actuator can include a carriage and a base. The base can include a fixed end fixed to the carriage, a free end, a beam connecting the fixed end and the free end, and at least one SMA wire. The SMA actuator can also include an insulator comprising a dielectric material electrically isolating a set of electrical contacts at the fixed end.