Dielectric Elastomer Transducer Element for Automated Mass Production
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Solution Overview
Problem
Existing transducer elements based on dielectric elastomers are difficult to mass-produce due to the precise stacking of electrodes and elastomer films in the micrometer range, which is challenging to automate.
Innovation Solution
A transducer element design featuring a carrier board with alternately connected electrodes and elastomer films, allowing for automated stacking and welding, and a hybrid gripper for precise positioning and connection, utilizing air-permeable electrodes to facilitate manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise stacking of micrometer-thin electrodes and elastomer films is used to achieve high performance, then transducer performance is improved, but manufacturing complexity and difficulty of automation increase
Solution Approach 1:
The patent combines multiple thin layers (electrodes and elastomer films) into a single integrated membrane structure with predetermined patterns. This merging approach eliminates the need for precise manual stacking of individual micrometer-thin layers, as the entire stack is formed as one piece through printing or lamination processes, thereby reducing manufacturing complexity while maintaining performance
Solution Approach 2:
The electrode patterns and elastomer film structures are pre-formed on a support substrate before final assembly. This preliminary action allows the complex multi-layer structure to be prepared in advance with precise geometries already in place, eliminating the need for precise real-time stacking during manufacturing and enabling automated production
2Length of moving object
If hundreds of micrometer-thin layers are precisely stacked to achieve greater stroke lengths, then actuator performance is improved, but ease of manufacture deteriorates
Solution Approach 1:
Instead of stacking layers in the vertical dimension (z-axis), the patent achieves greater stroke lengths by arranging electrode patterns and elastomer structures in planar dimensions (x-y plane) on the membrane. Multiple actuation regions are distributed across the membrane surface, and their effects are combined to achieve large overall displacement without requiring hundreds of stacked layers
Solution Approach 2:
The membrane is divided into multiple segmented electrode patterns (e.g., interdigitated electrodes, comb structures) that can be independently controlled. These segmented electrodes work in parallel to generate cumulative displacement, achieving greater stroke lengths through coordinated action of multiple segments rather than through vertical stacking
3Productivity
If automated stacking is implemented to improve productivity, then manufacturing speed is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent uses printing techniques (e.g., screen printing, inkjet printing, stamping) to replicate precise electrode patterns and elastomer structures across multiple membranes simultaneously. This copying approach allows automated high-volume production while maintaining consistent geometric precision through template-based replication rather than manual layer-by-layer assembly
Solution Approach 2:
The patent replaces mechanical stacking operations with printing and lamination processes. Instead of physically handling and stacking hundreds of individual micrometer-thin layers (which is difficult to automate with precision), the entire multi-layer structure is formed through deposition and bonding processes that are easier to automate and control for high-volume production
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
Enables easy industrial implementation and automation of transducer element production, ensuring high precision and reliable electrical connections while reducing manufacturing complexity.
Implementation Method 1
When a voltage is applied to the electrodes, they attract each other electrostatically, and the elastomer film is reversibly deformed
Implementation Method 2
The elastomer film is compressed and expands laterally
Implementation Method 3
holding the electrode with the electromagnet
Implementation Method 4
holding the elastomer film to be positioned through the electrode by means of the vacuum
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 2d
AI summary
The invention relates to a transducer element (1) based on dielectric elastomers, said transducer element comprising: a carrier board (2), the carrier board having first contact surfaces (6) which are conductively connected to a first connection contact (7), and second contact surfaces (9) which are conductively connected to a second connection contact (10); at least one elastomeric film (3) consisting of a dielectric material; at least two electrodes (4), the electrodes being at least in part air-permeable and each having at least one contact surface (15) for conductive connection to the first or second contact surfaces of the carrier board, the at least two electrodes (4) and the at least one elastomeric film (3) being arranged on the carrier board (2) so as to form a stack in which the electrodes (4) and elastomeric films (3) are alternately arranged, and the electrodes (4) are conductively connected alternately to the first contact surfaces (6) and the second contact surfaces (9) of the carrier board (2).