Multilayer Actuator Manufacturing via Sintered Bar Processing
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Solution Overview
Problem
The production of multilayer actuators with high precision and ease of handling is challenging due to the difficulty in handling individual stacks and the unpredictable dimensional changes of ceramic materials after sintering, which can lead to precision issues in actuating elements like injection valves.
Innovation Solution
A method involving the application of insulation layers and creation of contact holes on a sintered multilayer bar, followed by covering with conductive material, and then separating the bar into individual actuators, which simplifies the process, reduces handling difficulties, and maintains precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If production steps are carried out on individual stacks, then precision can be maintained, but handling difficulty increases and productivity decreases
Solution Approach 1:
Multiple individual stacks are merged into a single multilayer bar for processing. The insulation layers are applied and contact holes are created on the entire bar surface simultaneously, allowing all stacks to be processed together rather than individually, thus improving ease of operation while maintaining precision through consistent processing conditions.
Solution Approach 2:
The multilayer bar is segmented into multiple individual stacks after the common processing steps are completed. The bar is divided along the insulation layer boundaries, allowing each stack to be separated and handled individually only after the difficult processing steps have been performed on the combined structure.
2Productivity
If production steps are carried out on a multilayer bar, then ease of operation and productivity improve, but manufacturing precision may deteriorate due to unpredictable dimensional changes
Solution Approach 1:
Insulation layers are applied to the multilayer bar before sintering, and contact holes are created after sintering but before separation. This preliminary action on the combined bar allows for consistent positioning and processing of all stacks simultaneously, improving productivity while maintaining precision through uniform processing conditions across all segments.
Solution Approach 2:
The processing sequence utilizes parameter changes by applying insulation layers in the green state (before sintering) and creating contact holes after sintering when dimensional stability is achieved. This timing of operations at different stages of the sintering process allows for both high productivity through combined processing and high precision by operating at stable dimensional states.
3Ease of manufacture
If ceramic material is processed in green state, then ease of manufacture improves, but manufacturing precision deteriorates due to unforeseeable dimensional changes after sintering
Solution Approach 1:
Insulation layers are applied in advance to the green state multilayer bar, taking advantage of the ease of manufacture at this stage. The layers are positioned and secured before sintering, ensuring that subsequent dimensional changes do not affect the positioning accuracy, thus resolving the contradiction between ease of manufacture and manufacturing precision.
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 reduces manufacturing costs, improves process robustness, and ensures precise production of multilayer actuators by performing essential steps on a sintered multilayer bar before separation, thereby minimizing the risk of damage and increasing efficiency.
Implementation Method 1
Creation of first contact holes through a first insulation layer of the insulation layers to every second of the electrode layers, in particular by means of laser structuring; c) Creation of second contact holes through a second of the insulation layers towards the remaining of the electrode layers, in particular by means of laser structuring
Data Source
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AI summary
The invention relates to a method for producing a multi-layer actuator designed as a stack (1), which is formed from a plurality of material layers (2), which react to the application of an electrical field, and from a plurality of electrode layers (3, 4). Each material layer (2) is arranged between two of the electrode layers (3, 4). The applying of a respective isolation layer (IS1, IS2) to one (1a, 1b) of two geometrically discontinuous circumference regions (1a, 1b), the producing of first and second contact holes (KL1, KL2) through one first and one second isolation layer (IS1, IS2) of the isolation layers (IS1, IS2) to every second (3) of the electrode layers (3, 4), and the substantially whole-area covering of the respective isolation layers (IS1, IS2) by an electrically conductive material (EL1, EL2), in which the contact holes (KL1, KL2) are filled with the electrically conductive material (EL), occurs on a sintered multi-layer bar (10) which consists of an alternating arrangement of the plurality of material layers (2) and the plurality of electrode layers (3, 4) in a stacking direction (hs) of the multi-layer bar(10). The multi-layer bar (10) is then divided, parallel to the depth (ts) and stacking direction (hs) thereof, into the plurality of multi-layer actuators.