SMA Bimorph Actuator Structure With Molded Electrical 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 dielectric material in the SMA actuator, integrated via injection molding, to electrically isolate electrical contacts and simplify the manufacturing process, reducing the number of materials and processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple materials and complex manufacturing processes are used in existing SMA actuators, then electrical isolation and structural integrity can be achieved, but manufacturing complexity and resource consumption increase
Solution Approach 1:
The patent combines the insulator and beam into a single integrated component manufactured through injection molding. This merging eliminates the need for separate electrical isolation components and simplifies the manufacturing process while maintaining both electrical isolation and structural integrity functions.
Solution Approach 2:
The insulator component is designed to perform multiple functions simultaneously: providing electrical isolation between contacts, serving as a structural beam to support the SMA wire, and facilitating the injection molding manufacturing process. This multi-functionality reduces the number of separate components needed.
2Reliability
If multiple materials are used in existing SMA actuators, then functional requirements are met, but resource consumption and manufacturing steps increase
Solution Approach 1:
The patent uses a single material (polymer resin) for both the insulator and beam components, achieving functional differentiation through geometric design rather than material differentiation. This homogeneous material approach reduces resource consumption while meeting all functional requirements through clever structural design.
Solution Approach 2:
By merging the insulator and beam into one component made from the same material, the patent eliminates the need for multiple materials and associated material joining processes, thereby reducing resource consumption and manufacturing complexity.
3Reliability
If traditional manufacturing processes are used for SMA actuators, then component integrity is maintained, but processing time and production efficiency decrease
Solution Approach 1:
The injection molding process allows electrical contacts, insulators, and beams to be formed and positioned in their final configurations during the initial manufacturing step. This preliminary action eliminates the need for subsequent assembly operations, maintaining component integrity while dramatically improving manufacturing efficiency.
Solution Approach 2:
The integration of multiple components into a single injection-molded part eliminates multiple manufacturing and assembly steps, thereby improving productivity while maintaining the integrity of each component through the molding process itself.
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
This approach results in a compact SMA actuator with high z-stroke movement and reduced manufacturing complexity, suitable for applications such as autofocus actuators and optical image stabilization systems.
Implementation Method 1
an insulator comprising a dielectric material disposed at the fixed end of the base via an injection molding process. The insulator can electrically isolate the first set of electrical contacts at the fixed end of the base
Implementation Method 2
Each of the at least one SMA wire can be electrically connected to the fixed end at a first set of electrical contacts, and electrically connected to the free end at a second set of electrical contacts. The at least one SMA wire can be configured to actuate the free end of the base responsive to receiving an electrical current
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.