Elastomer Stack Actuator Production via Delamination and Stacking
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Solution Overview
Problem
Current methods for producing elastomer-based film stack actuators are inefficient, particularly for industrial production, due to difficulties in handling thin elastomer layers and precise positioning of layers and electrodes, leading to challenges in achieving high production rates and quality.
Innovation Solution
A method involving a starting process with delamination, a stacking process with repeated electrode application and lamination, and a finalization process for encapsulation, which includes using cover layers to facilitate efficient processing and parallel production of stack actuators, allowing for the handling of sticky and thin elastomer layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If thin elastomer layers are used to reduce operating voltage and increase energy density, then energy density and response time are improved, but handling difficulty and processing complexity increase due to sticky properties
Solution Approach 1:
A release film is introduced as an intermediary between the sticky elastomer layers during the stacking process. The release film prevents direct adhesion between elastomer surfaces, enabling easy handling and precise positioning of thin elastomer layers without their inherent sticky properties interfering with the manufacturing process.
Solution Approach 2:
The elastomer layers are prepared with release films attached beforehand before the stacking process begins. This preliminary action ensures that the sticky surfaces are protected and positioned correctly in advance, preventing handling difficulties during the actual assembly process.
2Force
If multiple individual actuators are stacked to increase actuator forces and capacitance, then mechanical feedback is improved, but production efficiency decreases due to difficult handling and positioning
Solution Approach 1:
Release films serve as mediators between stacked actuator layers, enabling automated and high-speed stacking processes. The release films allow multiple actuators to be stacked efficiently without manual positioning, thus increasing production rate while maintaining the force multiplication benefit of stacking.
Solution Approach 2:
Multiple individual actuators are combined into a single stack actuator unit through the lamination process. This merging approach achieves the desired high force output while enabling parallel production of multiple stack actuators on the same equipment, improving overall productivity.
3Manufacturing precision
If precise positioning of layers and electrodes is achieved to ensure quality, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The release film acts as a positioning aid that maintains precise alignment between elastomer layers and electrode layers during the stacking process. The film's structure enables accurate positioning without requiring time-consuming manual adjustment, thus achieving high manufacturing precision efficiently.
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 enables efficient production of elastomer-based film stack actuators by ensuring precise handling and positioning of layers, resulting in high-quality actuators with improved mechanical feedback and energy density, suitable for industrial-scale production.
Implementation Method 1
If a voltage is applied to the electrically conductive electrodes, the electric field generated by the voltage causes the dielectric to contract in the direction of the field and at the same time an increase in the actuator surface perpendicular to the direction of the field.
Implementation Method 2
This takes place via the measurable change in electrical capacity under the influence of a mechanical force that causes a deformation of the actuator or sensor.
Implementation Method 3
removing one of the two cover layers from the elastomeric film to produce a delaminated film arrangement
Data Source
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AI summary
The invention relates to a method for producing an elastomer-based film stack actuator, comprising: a starting process having the steps: a1) providing an elastomer film (200) having an elastomer layer (202) and two cover layers (201, 203) in the form of a lamination layer (201) and a liner layer (203), and a2) removing of one of the two cover layers (201, 203) from the elastomer film (200) to produce a delaminated film assembly, b) a stacking process following the starting process, having the steps: b1) applying a layer of electrodes (301, 601) to the elastomer layer (202) of the delaminated film assembly, b2) laminating an additional delaminated elastomer film (401) on the film assembly having electrodes (301, 601), and b3) removing of one of the two cover layers from the laminated film assembly to produce a delaminated film assembly, wherein, in the stacking process b) the steps b1) to b3) are repeated at least once, and wherein the delaminated film assembly produced in the previous step b3) is provided to the repeated step b1) as a delaminated film assembly, c) a finalization process following the stacking process, having the steps: c1) contacting the electrodes (301, 601) of the film assembly produced by the stacking process, c2) separating of stacking actuators of the film assembly produced by the stacking process, and c3) encapsulating the separated stacking actuators.