Soft Deformable Haptic Bubble Displays via Single-Shot Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing haptic feedback systems face challenges in achieving high-density actuator arrays for providing human perceptual resolution, especially in reducing the size of the system while maintaining actuator density and avoiding bonding failures and leakage.
Innovation Solution
The development of soft deformable high-density haptic bubble displays using a single-shot molding technique, where a computer-generated model is used to create a three-dimensional wax mold, allowing for the formation of haptic feedback systems with high-density bubble arrays in a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-step fabrication processes are used to create haptic feedback systems with high-density actuator arrays, then manufacturing complexity increases and bonding failures occur, but achieving high actuator density and fine tactile feedback resolution becomes possible
Solution Approach 1:
The patent combines multiple fabrication steps into a single-shot molding process where actuators and channels are formed simultaneously in one manufacturing operation. This eliminates the need for separate bonding operations between layers, reducing fabrication complexity while maintaining high actuator density of approximately 22 actuators per square centimeter.
Solution Approach 2:
The patent uses a wax mold structure that is 3D printed before the actual molding process. This preliminary wax mold serves as a negative copy that defines the precise geometry of actuators and channels, enabling high manufacturing precision without requiring complex post-fabrication alignment or bonding operations.
2Volume of moving object
If the haptic feedback system size is reduced for untethered wearable integration, then portability improves, but maintaining high actuator density and system reliability becomes more difficult
Solution Approach 1:
The patent employs flexible elastomeric materials for the haptic feedback system structure, allowing the compact design to accommodate high actuator density without compromising reliability. The flexible material properties enable the system to be miniaturized while maintaining structural integrity and preventing bonding failures that would occur in rigid conventional designs.
3Strength
If bonding operations are used to assemble actuator layers, then structural integrity can be achieved, but bonding failures and leakage occur reducing reliability
Solution Approach 1:
The patent merges actuator formation and channel routing into a single-shot molding process, eliminating the need for separate bonding operations to join actuator layers. This integration approach maintains structural integrity through the continuous elastomeric material while preventing bonding failures and leakage issues associated with multiple assembly steps.
Data Source
AI summary
The disclosed computer-implemented method may include creating a computer-generated model for a haptic feedback system including a plurality of actuators arranged in a first layer of the haptic feedback system, and a plurality of channels routed in a second layer of the haptic feedback system, the second layer being below the first layer, printing a three-dimensional wax mold structure of the computer-generated model, and forming the haptic feedback system in a single step using the three-dimensional wax mold structure. Various other methods, systems, and computer-readable media are also disclosed.