Shape Memory Actuator Smart Connector

1. Field of the Invention

The present invention relates to a shape memory actuator smart connector having specific physical and mechanical properties and, more particularly, to a connector for connecting a shape memory actuator to a moveable member.

2. Description of the Prior Art

Shape memory elements have been used to open and close vent dampers as shown and described in U.S. Pat. No. 4,284,235 entitled "Vent Control Arrangement for Combustion Apparatus" issued on Aug. 18, 1981. In the arrangement disclosed in this patent, a helix made of a shape memory material is used to open a damper plate. The damper plate is normally in a closed position and opened by heating the helix to the deformation temperature so that it deforms to rotate the damper plate to a fully opened position. A lever mounted on the helix, on reaching the fully open position, closes a limit switch that activates a solenoid actuated gas valve to light the burner. The helix remains energized until the heat requirement is satisfied. The holding circuit is then opened. As the helix cools down, it will rotate the damper to the closed position.

In a device of the type shown in U.S. patent application Ser. No. 276,698 entitled "Personal Environmental Module" filed on Nov. 28, 1988, and assigned to the same assignee, dampers are used to control the air flow rate of cool air and room air into the module to meet the personal requirements of the individual working in the work station. In this type of device motor controllers were used to control the position of the damper plates and thus the temperature and air flow rate of the air passing through the dampers. Accurate control of the position of the damper plate is critical to the success of the module. The electric motors have a limited life, are noisy and expensive and also require periodic maintenance.

In the present invention, a shape memory actuator having two shape memory elements is used to control the position of a damper plate in both opening and closing the damper. Using two shape memory elements makes it possible to positively locate a damper plate in a duct at different positions and thereby control the air flow rate through the duct to satisfy conditions of temperature and pressure. The shape memory elements can be directly incrementally heated to move the damper plate in the duct to positions intermediate, full open and full closed. It should be noted that while the following description is with respect to the control damper plate in an air flow duct, the invention is related to a connector for connecting the shape memory actuator to a control member. The shape memory actuator can be used to position any fluid control member, whether liquid or gas, where the control member is moved in one direction to an open position and another direction to a closed position.

The two shape memory elements, each have a predetermined shape memory austenite or upper phase transition temperature and a predetermined martensite or lower phase transition temperature, one of the shape memory elements being connected to move the damper plate toward an open position when the temperature of the shape memory element is raised to the austenite or upper phase transition temperature and the other actuator being connected to move the damper plate toward the closed position when the temperature of the second shape memory element is raised to the austenite or upper phase transition temperature. The shape memory elements can be heated directly or indirectly to move the damper plate to meet the required air flow rate conditions.

One of the principal features of the invention is the ability to hold a damper plate in a position between full open and full closed without a holding current in the shape memory elements.

One of the features of the invention is the provision of a holding device which may be in the form of a visco elastic mechanism, brake mechanism or a magnetic stepping mechanism to hold the damper plate in a particular position in a duct.

Another feature of the invention is the use of Shape Memory Alloy Rotating Terminal (SMART) connectors for connecting the shape memory elements to the damper plate and to fixed or stationary mounting pins. These connectors have good electrical conductivity, a low mass and low thermal conductivity to avoid heat sinking at the ends of the shape memory elements, act as electric couplers and provide for rotary motion of the connector at the point of connection.

A principal advantage of the invention is the provision of a shape memory actuator that is simple in structure and operation in comparison to motor controlled systems as well as being noiseless in operation.

Another advantage of the invention is the elimination of drive motors, gears, and the like presently used as damper controllers.

Other principal features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings.

FIG. 1 is a perspective view of a fluidic damper using the shape memory actuator according to the invention to control the position of the damper plate in the duct.

FIG. 2 is a top view of the fluidic damper of FIG. 1 showing the position of the shape memory actuator.

FIG. 3 is a view of the shape memory actuator showing the damper plate in the partially open position.

FIG. 4A is a view similar to FIG. 3 showing the damper in the closed position.

FIG. 4B is a view similar to FIG. 3 showing the damper in the full open position.

FIG. 5 is a schematic diagram of an electrical circuit for the shape memory actuator.

FIG. 6 is a view of the shape memory actuator showing the shape memory elements connected to a visco elastic drag assembly for positively positioning the damper plate in a duct.

FIG. 7 is a view of the shape memory elements connected to a damper plate through a shape memory controlled brake mechanism for maintaining the position of the damper plate in a duct.

FIG. 8 is a view similar to FIG. 7 showing the shape memory elements connected to a damper plate through a spring controlled brake mechanism for controlling the position of the damper plate in a duct.

FIG. 9 is a view of the shape memory elements connected to a damper plate through a magnetic stepping mechanism for positively locating the position of the damper plate in the duct.

FIG. 10 is a view of the top of an air flow duct using a rotary magnetic stepping mechanism for controlling the position of the damper plate.

FIG. 11 is a perspective view of a Shape Memory Alloy Rotating Terminal (SMART) connector shown mounted on the first turn of a shape memory coil.

FIG. 11a is a side plan view of the connector shown in FIG. 11.

FIG. 12 is a view of the SMART connector shown in FIG. 11a mounted on each end of a coil spring type shape memory element.

FIG. 13 is a view of the shape memory element of FIG. 12 rotated 90.degree. to show the connection to the pin of the damper plate lever and stationary pin.

FIG. 14 is a perspective view of a non-conductive connector for a coil spring type shape memory element.

FIG. 15 is a view, similar to FIG. 14, showing a non-conductive connector having a portion of the thread broken away to provide for connection of the coil type element to the connector.

FIG. 16 is a view showing another form of mounting for the coil type element to the non-conductive terminator.

FIG. 17 is a perspective view of a modified shape memory alloy rotating terminal (SMART) connector shown mounted on the first turn of a shape memory coil.

FIG. 18 is a perspective view of another form of the modified connector shown in FIG. 17.

FIG. 19 is a view of the modified connectors shown in FIGS. 17 and 18 mounted on respective ends of a coil-spring type shape memory element and connected to the pin for the damper plate lever and stationary pin.

FIG. 20 is a view of the shape memory element of FIG. 19 rotated 90.degree. to show the connection of the coil shaped memory element to the damper pin and the stationary pin.

Before the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details as set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Referring to FIGS. 1, 2, and 3 of the drawings, a shape memory actuator 10 according to the invention is shown for controlling the position of a damper plate 12 in a duct 14. The damper plate 12 is secured to a rod 16 by means of a set screw 28. One end of the rod is mounted for rotary motion in a bearing 18 and the other end in a bearing block 20. One end of the rod 16 is connected to the shape memory actuator 10. The other end of the rod extends outwardly from the bearing block 20 and is secured in the block 20 by a retaining ring 22 and a set screw 24.

In accordance with the invention, the shape memory actuator 10 includes a first means in the form of a shape memory element 30 for opening the damper plate 12 and a second means in the form of a shape memory element 32 for closing the damper plate 12. The shape memory elements 30 and 32, as shown in FIGS. 1, 2, and 3, are in the form of coil springs, however, it should be noted that the shape memory elements can be provided in various forms or configurations. The element 30 is connected at one end to a pivot pin 44 mounted on the end of a lever 36 which is secured to the rod by a screw 38. The other end of the shape memory element 30 is connected to a fixed pivot pin 40. The element 32 is connected to pivot pin 44 and to a fixed pivot pin 42.

The shape memory elements 30 and 32 are made of the same shape memory alloy so that they have essentially the same hysteresis and phase characteristics. Shape memory alloys, as described herein, are of the type described in U.S. Pat. No. 4,881,981, issued on Nov. 21, 1989, entitled "A Method For Producing A Shape Memory Alloy Member Having Specific Physical and Mechanical Properties" which is assigned to the same assignee and is incorporated herein by reference. In that application, a method is described for providing specific physical and mechanical properties for shape memory alloy materials. These properties relate to the transformation temperatures of the various shape memory phases, the resulting hysteresis between such phases, and the relationship between the start and finish temperatures of the respective phases. Although the same alloy is described herein, it is within the contemplation of the invention to use different shape memory alloys as well as alloys having different characteristics for each of the shape memory elements.

Referring to FIG. 4A, it should be noted that the shape memory element 30 has been heated to a temperature at or above the austenite phase transition temperature, and the element has assumed the tight coil spring memory shape. As the element 30 assumes the tight coil spring shape the damper 12 is closed and the element 32 is stretched mechanically transforming element 32 from a austenite phase A to a martensite phase, M. When the shape memory element 30 cools after being transformed to the austenite or upper phase A, the element 30 will remain in the austenite phase until the element 32 is heated to open the damper. As the element 32 is heated above its austenite phase transition temperature, it assumes the tight coil memory shape, FIG. 4B. The cooled element 30 will be stretched to mechanically transform the element 30 from the austenite phase to the martensite phase.

Certain thermo-mechanically processed shape-memory alloys transform from the austenite phase to the martensite phase by first transforming to a rhombohedral phase and then transforming to the martensite phase.

It is important in the transformation of the elements 30 and 32 from the austenite to the martensite phase, that the transformation is mechanically induced by stretching and not thermally induced by cooling. The life of the SMA spring is reduced if the element is initially thermally induced to the martensite phase and then reoriented when mechanically stretched by the other element. This is prevented by selecting an SMA alloy that is compatible with the expected environmental conditions.

It should be noted that in the operation of the damper control two elements, 30 and 32, are used. When one element is heated to open or close the damper, the second element will be stretched by the contracting motion of the first element. In either case, once the damper is opened or closed, the heated element is allowed to cool down no farther than the start of the unstressed martensite phase.

It is also possible to partially open or close the damper. In this regard, one of the elements 30 or 32 can be incrementally heated up to obtain partial austenite transformation. The second of the elements will be stretched, to partially induce martensite transformation. If it is desired to open the damper farther, the same element can be heated again to obtain the desired increase in the opening. If it is desired to move the damper in the opposite direction, the second element can be heated to obtain partial or complete austenite transformation to move the damper in the opposite direction. It should be noted that both of the elements may not be simultaneously heated to the austenite phase. In partial transformation, both phases may co-exist in the same element.

The shape memory elements 30 and 32 are energized by means of an electrical controller circuit 35 as shown in FIG. 5. The shape memory elements 30 and 32 are connected across a power source 37 and in series with solid state switches (triacs) 39 and 41. Each switch 39, 41 being controlled by controller 43. When the controller responds to a signal to increase or decrease the air flow through the duct 14, one of the switches 39 or 41 is activated to close the circuit for one of the shape memory elements 30, 32. The energized shape memory element will move to its memory shape moving the damper plate in the opening or closing direction. When the damper plate reaches the desired position, the controller will turn off the switch. Once the switch is turned off, a time delay is initiated by the controller preventing the energization of the other switch until the previously energized element has cooled down to a temperature that permits the mechanical induction of the martensite phase.

In operation, the first shape memory element 30 is energized to close the damper plate 12. As seen in FIG. 4A, the first element 30 will contract and the second shape memory element 32 will be stretched by the contraction of the first element 30. The damper is opened by heating element 32. As seen in FIG. 4B, the element 32 contracts and the element 30 is stretched by the contracting motion of element 32.

If the damper is to be partially opened as shown in FIG. 3, the element 30 is heated long enough to move the damper plate 12 incrementally to the desired setting and then de-energized.

A balance of forces is achieved between the stress imposed on the heated element as it contracts and is transformed to the austenite phase while the other element is stretched mechanically inducing the martensite phase in the other element.

When the element 30 is de-energized, the element 30 may have sufficient spring force to move the damper plate 12 slightly in the opposite direction. Means are therefore provided for holding the damper plate 12 in the position to which it was moved by the energized element.

In this regard and referring to FIGS. 6 through 10, a number of shape memory actuators are shown which include means for holding the damper plate 12 in a fixed position with respect to the duct 14. As seen in FIG. 6, the shape memory elements 30, 32 are connected to a drag assembly 44 which is used to hold the damper plate 12 in a particular position. The drag assembly 44 includes a pinion gear 46 mounted on the rod 16 and a rack 48 provided on an elongate member 50 which is connected at each end to the elements 30, 32. A fixed member 52 is located in abutting relation to the member 50. A viscoelastic material 54 is provided between the elongate members 50, 52 to slightly resist sliding motion between the members 50, 52.

In operation, one of the elements 30, 32, is energized so that it starts to heat up. As it passes through the austenite start transition temperature, the element will start to move toward its memory shape configuration pulling the elongate member 50 toward the energized element. The de-energized element will stretch and the damper plate 12 will move toward the open or closed position. When the damper plate 12 reaches the desired position, the energized element is de-energized. The stretched element will try to pull the member 50 slightly backward. The visco elastic material will hold the elongate member 50 in a fixed relation with respect to the fixed member 52 so that the damper plate 12 remains in the fixed or desired position.

Referring to FIG. 7, another form of holding means is shown which includes an elongate member 50' having a rack 48 on one surface of the member 50' which is positioned to engage the pinion gear 46. A series of depressions 56 are provided on the opposite surface of the member 50'. A fixed member 52' is positioned next to member 50' and is provided with a bore 58 that houses a stop pin 60. The pin 60 is biased into engagement with the elongate member 50' by means of a spring 62 which bears against a plate 64 provided on the pin 60. The pin is retained within the bore by means of a retaining ring 66 provided in a groove 63 in the open end of the bore 58. The pin 60 is withdrawn from the elongate member 50' by means of a shape memory element 68 which is connected to the end of the pin 60 and to a fixed pin 70.

Whenever the damper plate 12 is to be moved to a new position, one of the elements 30, 32 will be energized and the element 68 will also be energized. When the damper plate 12 reaches the desired position, both the energized element and the element 68 will be de-energized so that the spring 62 will bias the pin 60 into engagement with the corresponding depression 56 to lock the member 50' in a fixed position.

In the embodiment of the invention shown in FIG. 8, the elongate member 50" includes a rack 48 which is positioned to engage the pinion gear 46. A ratchet gear 72 is provided on the bottom of the member 50". The stationary member 52" includes a pin 60, spring 62 and plate 64 as described above. The pin 60 is in the form of a pawl which is biased by means of a spring 62 into engagement with the gear 72. When the element 30 is energized, the elongate member 50" will be moved to the left and the pawl 60 will snap from one gear to the next in the gear 72 and thereby retain the member 50" in position when the element 30 is de-energized.

In FIGS. 9 and 10 step by step holding means are shown in the form of an elongate magnetic assembly 80 (FIG. 9) and a circular magnetic assembly 90 (FIG. 10). As seen in FIG. 9, the elongate member 50'" has a rack 48 positioned to engage the pinion gear 46. The member 50'" is made up of alternate north and south magnetic pole pieces 47 and 49, respectively. A fixed member 52'" is also made up of alternate north and south pole pieces 51 and 53, respectively. When one of the shape memory actuators is heated, the elongate member 50'" will be moved to the right or left with respect to the fixed member 52'". When the shape memory element is de-energized, the member 50'" will move to align the north pole 47 and south pole 49 with the corresponding south pole 53 and north pole 51 on member 52'".

In FIG. 10 a duct 14 is shown of the type shown in FIGS. 1 and 2 in which the step by step holding means is in the form of circular magnetic members 92 and 94 which are used to control the position of the damper plate 12. The member 92 having alternate north and south poles 91, 93, respectively. The member 94 having alternate north and south poles 95, 97, respectively. The member 92 is mounted on the duct 14 and the member 94 is mounted on the end of the rod 16. On energization of one of the elements 30 or 32, the member 94 will rotate to a position wherein the north and south poles of member 94 are opposite the south and north poles of member 92 when the actuator is de-energized.

The elements 30 and 32 can be connected to the fixed pins and moveable members by means of shape memory alloy rotational terminal (SMART) connectors 100 and 200. The shape memory elements 30 and 32 are shown in the form of coils in FIGS. 11-13 and 17-20. This form is used because it provides the least amount of stress in the actuator and provides a secure connection for the shape memory elements. It is important to provide an electrically conductive connector that requires a minimum amount of turns of the coil for mechanical and electrical connection and is of small mass and low thermal conductivity to prevent heat sinking at the ends of the coil. It is important to minimize heat sinking in the connectors so that there is equal strain between each loop when heated and cooled as shown in FIG. 13.

It is desirable to have the connectors 100 and 200 made from a material having a thermal conductivity generally less than 60 BTU Ft./.sub.Hr. Ft. 2 .degree..sub.F. preferably 15 BTU Ft./.sub.Hr. Ft. 2.sub..degree.F. and an electrical resistivity less than 200 micro ohm cm. preferably 80 micro ohm. cm. This is accomplished by using SMART connectors 100 or 200 which are stamped from sheet stock, preferably stainless steel in the form of a flat strip of material having a low mass. The connector 100 is provided with a pair of legs 104 at one end and a hook 106 at the other end. A hole 108 is provided in the center of the strip for connecting the connector to an electrical lead 112. The SMART connectors are connected to the last turn of the coil at each end of the shape memory elements 30 and 32. The connectors are mounted on the coil by inserting the projection 101 at the end of the connector into the coil and wrapping the legs 104 around the coil thus providing both a mechanical and electrical connection to the element. The hole 108 provides a connection for the electric leads 112.

Alternate types of SMART connectors 200 and 200a are shown in FIGS. 17-20 which are stamped from a thin strip of noncorrosive and electrically conductive material having low thermal conductivity such as stainless steel to ensure the life of the connectors as well as reduce thermal losses. The electrical resistance of the connectors 200 and 200a should be less than the electrical resistance of the shape memory element. The connectors 200 and 200a each include a "V" shaped body 201 having legs 202 and 203 which intersect at a pocket 210. A clip 212 is formed on leg 202 by a right angle flange 204 provided on the end of leg 202. The outer end 205 of flange 204 is bent downward along a fold line 206 for clamping the connector to one of the coils of the shape memory element 30. A pair of holes 207 are provided in the fold line 206 and are spaced apart a distance less than the mean diameter of the coil. Spacing the holes 207 at a distance less than the mean diameter of the coil will secure the connector to the coil. A spade type lug 208 is stamped in the end of leg 203 for connection to a spade connector 216.

The connectors 200 and 200a are mounted on one of the coils near the end of the element 30 by inserting the end of the coil through holes 207 in the fold line 206. The outer end 205 of flange 204 is folded over the coil and crimped into engagement with flange 204 between the holes 207 to encapsulate the coil. The connectors 200, 200a are mounted on pins 40 and 44 by aligning the pockets 210 with pins 40 and 44, respectively. It should be noted that the coil in the connector is held in axial alignment with the coils in element 30 due to the ability of the connectors 200, 200a to pivot or swivel on the pins 40 and 44.

In FIGS. 14, 15 and 16 a spring shape memory alloy link (SSMAL) connector 120 is shown as an alternate means for connection to the element. The link connector is made out of a material which is electrically and thermally non-conductive so that there is no heat sink formed at the end of the coil. The link connector 120 is in the form of a rod 122 which is threaded either totally or partially with a square thread 124 that is matched to the SMA member turns per inch. The diameter of the rod 122 is measured from the bottom of the thread and is the same or slightly larger than the inside diameter of the coils of the shape memory element 126.

The materials which can be used for this type of link are engineering thermoplastics. Means can be formed on the end of the rod 122 for attaching the connector 120 to a pivot member. Such means is in the form of a hook 127, secured to or molded on the end of rod 122.

Means are provided at the end of the thread 124 for forming a solid, inflexible point of egress 130 for the element 126. Such means is formed at the end of the rod 122 by removing a portion of the thread at the spring end of the rod 122. The portion is removed for one-fourth of one revolution from the normal end of the thread. This provides a solid, inflexible point of egress 130 for the element 126 when wound on the link connector.

Means can be provided on the threads of the link connector for covering the turns of the coil in the spaces between the threads on the connector so that they cannot unwind. Such means is in the form of a non-flowing, high peel strength epoxy 132 applied in the spaces between the threads where the coils of the element have been wound as shown in FIG. 15.

Referring to FIG. 16, a modified form of link connector 120 is shown in which a portion of the thread 124 is removed to form a space 125 to facilitate the application of the epoxy 132 so that the epoxy does not contact the active portion of the coils of the element 126. The active portion of the element 126 begins at the point of egress 130.

Thus, it should be apparent that there has been provided, in accordance with the invention, a shape memory alloy rotational terminal connector that fully satisfies the aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that there are many alternatives, modifications, and variations that will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.