Roll-to-Roll Piezoelectric Manufacturing with Continuous Corona Polling
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Solution Overview
Problem
Existing piezoelectric manufacturing processes are inefficient due to batch polling, which increases production time and costs, limiting the widespread application of piezoelectronics in various fields.
Innovation Solution
A roll-to-roll manufacturing process using corona polling to continuously orient piezoelectric dipoles, allowing for continuous printing and polling of piezoelectric materials on a substrate roll, eliminating the need for batch processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch process polling is used to orient piezoelectric dipoles, then the piezoelectric material achieves proper polarization, but production time increases and throughput decreases
Solution Approach 1:
The patent implements continuous polling by passing the substrate roll through a corona discharge apparatus that continuously applies electric field to orient dipoles as the material moves through the system, eliminating the start-stop nature of batch processing and enabling uninterrupted production flow
Solution Approach 2:
The patent applies the polling electric field during the printing process itself, orienting the piezoelectric dipoles before the material is fully processed and cut into individual devices, thereby preparing the material in advance for subsequent operations without requiring separate batch polling steps
2Manufacturing precision
If batch process polling is used to orient piezoelectric dipoles, then the piezoelectric material achieves proper polarization, but manufacturing cost increases
Solution Approach 1:
The continuous polling process eliminates idle time between batches and maximizes equipment utilization, spreading fixed manufacturing costs over a larger production volume and reducing the cost per unit of piezoelectric material processed
Solution Approach 2:
The patent combines the polling operation with the printing and processing operations into a single integrated continuous process, eliminating the need for separate batch polling equipment and operations, thereby reducing overall manufacturing complexity and cost
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 method significantly reduces manufacturing time and enhances cost efficiency, enabling the widespread use of piezoelectronics in applications such as sensors, actuators, energy harvesting, and flexible electronics.
Implementation Method 1
The polling electric field generator may comprise a corona field generator
Implementation Method 2
Batch process polling is typically implemented by applying a very strong electrical field to the piezo materials in the prescribed direction for a sufficient time period
Implementation Method 3
Piezoelectric transducers are well understood in the art to generate an electrical signal responsive to a mechanical movement or stress
Data Source
AI summary
The disclosure is and includes at least an apparatus, system and method for manufacturing piezoelectrics. The apparatus, system and method may include at least a first roller and an end roller; a continuous printable substrate roll extending at least from the first roller to the end roller as the first and end roller turn; at least one printer for printing piezoelectric material onto the continuous substrate roll to form a plurality of the piezoelectrics; and an electric field generator that polls the piezoelectric material as the continuous substrate roll is rolled from the first roller to the end roller. The polling electric field generator may comprise a corona field generator.