Folded Electrode Stack Structure Without Through-Holes
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Solution Overview
Problem
Existing techniques for electrically induced mechanical movement in devices, such as Eccentric Rotating Mass (ERM) vibration motors, linear resonant actuators (LRA), and piezoelectric actuators, face issues with high power consumption, low durability, complex designs, and poor scalability, especially on flexible surfaces, and are not suitable for large area actuation.
Innovation Solution
A multilayer sensor or actuator structure is created using a single substrate without through holes, featuring conductive patterns, elastic nodules, and an adhesive layer, which is folded to form a stacked structure with air reservoirs and insulating layers, allowing for efficient electrical connections and reduced lateral displacement, and can be manufactured using a roll-to-roll method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional actuators (ERM, LRA, piezoelectric) are used, then electrical induced mechanical movement is achieved, but power consumption is high
Solution Approach 1:
The patent replaces traditional mechanical actuators (ERM motors, LRA coils, piezoelectric elements) with an electrostatic actuation system that uses electric fields to directly deform an elastomeric membrane. This substitution eliminates the need for rotating masses, magnetic fields, or high-voltage piezoelectric materials, thereby reducing power consumption while maintaining actuation functionality.
Solution Approach 2:
The patent changes the operating parameters by using high-voltage low-current electrostatic fields instead of traditional motor driving schemes. The electrostatic actuation uses voltage differences across the elastomeric membrane to create mechanical deformation, operating at different electrical parameters (high voltage, low current) compared to traditional actuators, which reduces overall power consumption.
2Device complexity
If traditional actuators are used, then mechanical movement is produced, but the design becomes complex with external motors and masses
Solution Approach 1:
The patent merges the actuation function directly into the display or sensor structure by using the elastomeric membrane itself as the actuating element. The electrostatic actuation layers are integrated within the same structure, eliminating separate external motors, masses, or piezoelectric elements. This integration simplifies the overall design while enabling large-area actuation across the entire membrane surface.
Solution Approach 2:
The elastomeric membrane serves multiple functions simultaneously: it acts as the structural substrate, the actuating element, and the functional layer for display or sensing. The electrostatic actuation system provides universal actuation capability across the entire membrane area, replacing multiple specialized components with a single multi-functional structure.
3Ease of manufacture
If through holes are used in substrate, then electrical connections between layers are achieved, but lateral displacement occurs and manufacturing becomes difficult
Solution Approach 1:
The patent extracts the electrical connection function from through-hole structures and implements it through edge-based conductive connections. The conductive layers are connected at the edges of the substrate rather than requiring holes through the middle, eliminating the manufacturing complexity and precision issues associated with through-hole alignment while maintaining electrical connectivity between stacked layers.
Solution Approach 2:
The patent transitions from planar through-hole connections to three-dimensional edge-based connections. Instead of connecting layers through holes in the same plane, the conductive paths extend to the edges where connections are made, utilizing the vertical stacking dimension to achieve electrical connectivity without compromising lateral positioning precision.
4Strength
If adhesive layer completely covers substrate, then layers are firmly bonded, but air reservoirs cannot be formed
Solution Approach 1:
The patent applies adhesive material with local quality variation: the adhesive layer completely covers the substrate in most areas to provide strong bonding, but deliberately leaves uncovered regions (air reservoirs) in specific locations where mechanical compliance and pressure equalization are needed. This localized differentiation of adhesive coverage optimizes both bonding strength and functional performance.
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 solution enables cost-effective manufacturing of scalable, durable, and efficient electrically induced mechanical movement devices with improved suitability for flexible surfaces and large area actuation, while minimizing power consumption and complexity.
Implementation Method 1
an adhesive layer applied on but not completely covering the conductive patterns and substrate. Each fold of the substrate folds the adhesive layer inward for forming the stacked structure by adhering each layer of the plurality of layers.
Implementation Method 2
at least one layer of elastic nodules formed between two layers of the plurality of layers, the layer of elastic nodules comprising a sensing area being used for at least one of actuation or sensing
Implementation Method 3
When the sensing area is compressed, displaced air is transmitted to the air reservoir.
Implementation Method 4
a plurality of conductive patterns printed on the substrate... improved electrical connections between the layers
Data Source
AI summary
A stacked structure is composed of a plurality of layers, and includes: a substrate; a plurality of conductive patterns printed on the substrate; and at least one layer of elastic nodules formed between two layers of the plurality of layers, the layer of elastic nodules including a sensing area being used for at least one of actuation or sensing. The stacked structure is formed by folding the substrate multiple times. The stacked structure further includes: an adhesive layer printed on but not completely covering the conductive patterns and substrate, and forming at least one air reservoir for holding air displaced when the sensing area is compressed. The stacked structure does not include electrically conducting through holes or electrically connecting structures.