Layered Electroactive Polymer Devices for Reduced Operational Voltage
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Solution Overview
Problem
Existing electroactive polymer devices face challenges with high operating voltages and low breakdown voltages, which limit the force generation and energy density, while thinner polymer layers increase fabrication costs and variability.
Innovation Solution
The method involves forming layered electroactive devices using a manifold extrusion die to layer electrode and electroactive polymer precursor materials, curing them to create a nanovoided polymer material with conductive fillers, and combining these layers to achieve a stacked structure that reduces operational voltage and increases force generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If thinner polymer layers are used, then energy density and force generation improve, but fabrication costs and variability increase
Solution Approach 1:
The device is divided into multiple thin polymer layers stacked together. Each layer is fabricated separately at standard thicknesses using conventional processes, then assembled into a stacked configuration. This segmentation allows each layer to be manufactured within acceptable variability tolerances while achieving the equivalent of a much thinner total thickness, thereby improving energy density without incurring the costs and variability associated with fabricating a single thin layer.
2Use of energy by moving object
If thinner polymer layers are used, then energy density and force generation improve, but manufacturing variability increases
Solution Approach 1:
The total polymer thickness is divided into multiple discrete layers, each fabricated at standard thicknesses where manufacturing processes operate with high precision and low variability. By stacking multiple such layers, the cumulative thickness achieves the desired thin profile while each individual layer maintains consistent quality, thereby reducing overall manufacturing variability compared to attempting to fabricate a single thin layer.
Solution Approach 2:
Multiple individually fabricated polymer layers are combined into a stacked assembly. Each layer is manufactured separately with standard thickness tolerances, but when stacked, they collectively achieve the equivalent of a much thinner total thickness with reduced variability. The stacking process allows for quality control and replacement of individual layers if needed, further reducing the impact of manufacturing variability.
3Ease of manufacture
If conventional fabrication processes are used, then manufacturing simplicity is maintained, but operational voltage remains high
Solution Approach 1:
The device uses multiple thin polymer layers stacked together, where each layer is fabricated using conventional processes at standard thicknesses. The stacked configuration reduces the total thickness and therefore reduces the operational voltage required, while each individual layer can still be manufactured with simple conventional processes, maintaining manufacturing simplicity.
Solution Approach 2:
Instead of reducing the thickness of a single polymer layer (one-dimensional approach that increases complexity and variability), the invention stacks multiple layers in the vertical dimension. This dimensional approach achieves voltage reduction through cumulative thinning while allowing each layer to be fabricated independently using simple conventional processes, thereby maintaining manufacturing simplicity.
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 results in electroactive devices with reduced operational voltage, higher energy density, and improved uniformity, addressing the limitations of existing devices by enhancing force generation and fabrication efficiency.
Implementation Method 1
curing the electrode precursor material to form an electrically conductive material, the electrically conductive material including approximately 20% nanovoids by volume and including a polymer and a conductive filler
Implementation Method 2
curing the deposited electroactive polymer precursor material to form an electroactive polymer element including a cured elastomer material
Implementation Method 3
removing at least a portion of the at least one non-polymeric component from the cured elastomer material to form a nanovoided polymer material
Implementation Method 4
flowing an electrode precursor material into a manifold extrusion die via first and second manifold inlet openings, flowing an electroactive polymer precursor material into the manifold extrusion die via a third manifold inlet opening such that the electroactive polymer precursor material may be layered between alternating layers of the electrode precursor material
Data Source
AI summary
In various embodiments, an electrode precursor material may be flowed into a manifold extrusion die having first and second manifold inlet openings. Further, an electroactive polymer precursor material may be flowed into the manifold extrusion die via a third manifold inlet opening such that the electroactive polymer precursor material is layered between alternating layers of the electrode precursor material from the first and second manifold inlet openings. Moreover, the electrode precursor material and the electroactive polymer precursor material may be extruded through a manifold outlet opening of the manifold extrusion die. Various other methods, systems, apparatuses, and materials are also disclosed.