Dielectric Elastomer Stack Actuator Production Process
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Solution Overview
Problem
Existing methods for manufacturing dielectric elastomer stack actuators are complex and inefficient, requiring pre-crosslinking steps and precise control of viscosity and temperature, which limits the production of multiple thin layers with uniform thickness and surface quality, and necessitates high operating voltages.
Innovation Solution
A method where dielectric layers are applied to a stationary substrate using a grid device, followed by direct application of electrode layers without pre-crosslinking, allowing for subsequent crosslinking and forming a quasi-monolithic actuator with improved anchoring and reduced operational voltage requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-crosslinking steps are performed before electrode layer application, then the dielectric layer achieves sufficient stabilization, but the production process becomes complex and time-consuming
Solution Approach 1:
The patent applies preliminary stabilization treatment to the dielectric layer before electrode deposition, but performs this stabilization in advance during dielectric layer formation rather than requiring a separate pre-crosslinking step before electrode application. This eliminates process complexity while maintaining the necessary stabilization.
Solution Approach 2:
The patent combines the stabilization process with the dielectric layer formation process itself, merging what were previously separate steps (stabilization and electrode application) into an integrated sequence. This reduces the number of discrete process steps and simplifies production.
2Use of energy by moving object
If multiple thin dielectric layers are stacked to reduce operating voltage, then the actuator can operate at lower voltages, but achieving uniform thickness and surface quality across all layers becomes difficult
Solution Approach 1:
The patent replaces manual or mechanical layer-by-layer stacking processes with a dip-coating method where the entire multi-layer structure is formed simultaneously by immersing the substrate in liquid dielectric material. This substitution of the mechanical stacking system with a fluid-based coating process ensures uniform thickness and surface quality across all layers while enabling voltage reduction through multiple thin layers.
Solution Approach 2:
The patent controls the viscosity and other parameters of the liquid dielectric material to achieve consistent layer formation across multiple stacked layers. By maintaining constant viscosity and controlling the dip-coating parameters, uniform thickness is achieved throughout the multi-layer structure, enabling operation at reduced voltages.
3Extent of automation
If spin coating method is used to produce dielectric layers with controlled thickness, then automatic production is achieved, but the experimental setup becomes complicated and requires precise control of viscosity and speed
Solution Approach 1:
Instead of rotating the substrate at high speed as in spin coating, the patent inverts the approach by keeping the substrate stationary and moving the coating head in a dipping motion. This inversion eliminates the need for complex centrifugal control systems while maintaining automatic production capability through controlled linear motion of the coating head.
Solution Approach 2:
The patent extracts the rotational motion from the coating process, removing the centrifugal mechanism entirely. By taking out the rotating substrate and replacing it with a stationary substrate and linearly moving coating head, the system complexity is reduced while automation is maintained through programmed linear motion.
4Use of energy by moving object
If dielectric layers are made thinner to reduce operating voltage, then lower voltages are required, but the number of layers increases requiring more production steps
Solution Approach 1:
The patent replaces the mechanical process of individually stacking multiple thin layers with a dip-coating process that forms all layers simultaneously in a single operation. This substitution maintains the benefit of thin layers for reduced operating voltage while dramatically improving productivity by eliminating the need for repeated individual layer deposition and stacking steps.
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 simplifies the production process, achieves reproducible and homogeneous dielectric elastomer stack actuators with reduced operating voltages, and enhances mechanical stability, enabling the creation of complex structures like artificial muscles.
Implementation Method 1
in a second centrifugal step at an increased speed, the centrifugal acceleration is used to distribute the elastomer on the substrate
Implementation Method 2
When an electrical voltage is applied to the electrodes, an electrostatic field is generated between the electrodes, causing the elastomer material to deform due to the Maxwell voltage
Implementation Method 3
causing the elastomer material to deform due to the Maxwell voltage. During deformation, the material expands perpendicularly to the field direction and is compressed parallel to the field direction
Implementation Method 4
After the dielectric layer has been produced, thermal energy must be supplied to the substrate
Data Source
Figure 1a~1b
Figure 2a~2c
AI summary
A process for producing a multilayer dielectric elastomer stack actuator, consisting of a plurality of dielectric layers of at least one elastomer embedded between a plurality of electrode layers, comprises the steps of i) application of a liquid, non-crosslinked elastomer to form the dielectric layer (40) with a reproducible layer thickness of less than 50 μm by means of a scanning apparatus (2) on a substrate, directly subsequent thereto ii) application of electrically conductive material particles to the surface of the dielectric layer to form an electrode layer (41, 42) by utilizing the surface tension of the elastomer, and the final steps iii) at least partial crosslinking of the dielectric layer with an electrode layer lying on the surface in a floating manner by thermal treatment and/or irradiation, and repetition of steps i) to iii), wherein all steps proceed under ambient conditions and with an inactive substrate holder (1) and substrate held immovably.