Electrostatic Actuator Injection Molding Cost Reduction

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Solution Overview

Problem

Existing low voltage/power valves for fluid handling have high fabrication costs, which is a concern for industrial and aerospace applications where cost efficiency is crucial.

Innovation Solution

The development of electrostatically actuated device components using a multilayered structure comprising a polymer support layer, a conductive layer, and a dielectric layer with controlled surface roughness, fabricated through injection molding to reduce fabrication costs and improve efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional low voltage/power valves are used, then power consumption is reduced, but fabrication cost increases

Engineering Contradiction:

Improvepower consumptionVSAvoidfabrication cost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent combines multiple components (support layer, conductive layer, dielectric layer, and molding compound) into a single integrated structure through injection molding. The multilayered structure is formed as one unified component, eliminating the need for separate assembly steps and reducing fabrication costs while maintaining low voltage operation capabilities

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a composite multilayered structure consisting of different materials (polymer support layer, conductive material, dielectric material) bonded together. This composite approach allows optimization of each layer's properties for low voltage operation while the integrated molding process keeps manufacturing costs low

Inventive Principle:

Principle #40Composite materials

2Use of energy by moving object

If multilayered structure with controlled surface roughness is used, then voltage requirements are reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvevoltage requirementsVSAvoidmanufacturing complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent controls the surface roughness parameter of the dielectric layer to be less than 1000 angstroms, which is critical for reducing voltage requirements. By specifying this parameter range and using injection molding to achieve it, the patent reduces the voltage needed for electrostatic actuation while managing manufacturing complexity through process control

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If injection molding process is used, then fabrication cost is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvefabrication costVSAvoidsurface roughness control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The injection molding process itself is used to create the multilayered structure and bond the layers together. The process parameters (temperature, pressure, injection rate) are controlled to automatically achieve the required surface roughness specification of less than 1000 angstroms, eliminating the need for additional finishing operations and keeping fabrication costs low

Inventive Principle:

Principle #25Self-service

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 reduces the voltage requirements for valve operation and lowers fabrication costs, enhancing the reliability and efficiency of fluid handling systems while maintaining performance.

Implementation Method 1

electrostatically actuated device component

Methodology Applied

Scientific EffectElectrostatic actuation: Electrostatics

Implementation Method 2

a third layer comprising a dielectric material, the third layer disposed over the second layer

Methodology Applied

Scientific EffectDielectric material property: Dielectric

Implementation Method 3

positioning the multilayered structure within an injection mold, and injecting a second polymer into the mold and bonding the first layer to the second polymer

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS8007704B2Insert molded actuator components

Publication Date: 2011.08.30 RESIDEO USA LLC

AI summary

The present invention relates to electrostatically actuated device components and methods of making the same. In an embodiment, the invention includes a method of making an electrostatically actuated device component including providing a multilayered structure comprising a first layer comprising a first polymer, a second layer comprising a conductive material, the second layer disposed over the first layer, a third layer comprising a dielectric material, the third layer disposed over the second layer, positioning the multilayered structure within an injection mold, and injecting a second polymer into the mold and bonding the first layer to the second polymer to produce an electrostatically actuated device component. In an embodiment, the invention includes a method of injection molding a stator component for an electrostatically actuated valve.