Actuator Contact Separation in Thickness Direction
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Solution Overview
Problem
Existing actuators face challenges in accurately positioning contacts and preventing short circuits due to the close spacing between adjacent contacts and traces, which requires precise alignment and increases the risk of electrical shorts.
Innovation Solution
The actuator design incorporates first and second flexible substrates with contacts separated in the thickness direction, allowing for non-precise spacing between contacts and reducing the risk of short circuits by connecting them to different flexible substrates, thereby eliminating the need for precise alignment during adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If contacts are lined up in the same plane on the substrate, then the device structure is simple, but the dimension of space between adjacent contacts becomes short requiring accurate positioning and increasing short circuit risk
Solution Approach 1:
The patent applies dimensionality change by separating contacts in the thickness direction (vertical dimension) rather than arranging them in the same plane. The first contact is positioned at a first position in the thickness direction and the second contact is positioned at a second position different from the first position, thereby transforming a two-dimensional planar arrangement into a three-dimensional stacked arrangement. This resolves the contradiction by increasing the effective spacing between contacts without requiring higher positioning precision in the planar direction.
2Device complexity
If contacts are lined up in the same plane on the substrate, then the device structure is simple, but the dimension of space between adjacent traces becomes short increasing short circuit risk
Solution Approach 1:
The patent uses dimensionality change to separate contacts vertically in the thickness direction, which indirectly increases the spacing between traces connected to different contacts. By positioning contacts at different heights (first position and second position in thickness direction), the traces connecting to these contacts can be routed with greater separation, reducing the risk of short circuits between adjacent traces while maintaining a relatively simple overall device structure.
Solution Approach 2:
The patent introduces an insulating film as an intermediary between the first contact and the second contact. This insulating film is positioned between the contacts in the thickness direction and prevents electrical conduction between them. The insulating film acts as a mediator that allows the contacts to be positioned close to each other in the thickness direction while maintaining electrical isolation, thereby preventing short circuits without requiring large spacing.
3Manufacturing precision
If contacts are separated in the thickness direction, then the dimension of space between adjacent contacts can be increased without accurate positioning, but the device structure becomes more complex
Solution Approach 1:
The patent implements positioning tolerance improvement by moving the contact arrangement into the third dimension (thickness direction). The first contact and second contact are positioned at different heights, which allows for larger positioning tolerances in the planar direction since the vertical separation provides the necessary electrical isolation. This trades increased vertical structure complexity for improved manufacturing tolerances.
Solution Approach 2:
The insulating film serves as a mediator that enables the first contact and second contact to be positioned at different heights in the thickness direction while maintaining electrical isolation. This intermediary layer simplifies the positioning requirements by providing a fixed reference plane and automatic electrical insulation, reducing the need for high-precision positioning algorithms or complex alignment mechanisms.
4Reliability
If contacts are separated in the thickness direction and connected to different flexible substrates, then short circuit prevention is improved, but the adhesion process requires more complex positioning
Solution Approach 1:
The insulating film acts as an intermediary that simplifies the adhesion process by providing a clear electrical boundary between the first contact and second contact. When flexible substrates are adhered to contacts at different heights, the insulating film ensures that even if positioning is not perfectly precise, electrical short circuits cannot occur between contacts on different substrates. This mediator element makes the adhesion process more robust to positioning variations.
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 design allows for flexible spacing between contacts without risking short circuits, simplifying the adhesion process and reducing the likelihood of electrical failures, while also preventing short circuits between flexible substrates and contacts.
Implementation Method 1
a first piezoelectric element located on one surface of the substrate; a second piezoelectric element located on the one surface of the substrate
Data Source
AI summary
There is provided a device including: an actuator, a first flexible substrate and a second flexible substrate. The actuator includes a substrate; a first piezoelectric element and a second piezoelectric element that are formed on one surface of the substrate; a first contact connected to the first piezoelectric element; a second contact separated in a thickness direction of the substrate from the first contact and connected to the second piezoelectric element. The first flexible substrate is connected to the first contact; and the second flexible substrate is connected to the second contact.