Piezoelectric Actuator Elastic Resin Buffer Layer
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Solution Overview
Problem
Piezoelectric actuators used in liquid transporting apparatuses face high stress concentration during the joining process, leading to damage such as breaking and cracking, particularly at the edge portions of the deformation receiving area, due to the brittleness of ceramics materials and the need for thin, low-voltage deformation.
Innovation Solution
A method involving the formation of elastic resin layers on both surfaces of the stacked body before joining to a substrate, which relieves stress concentration and prevents damage by acting as a buffer during handling and mounting, using a ceramics material for the inactive layer that does not require piezoelectric properties and forming through holes for electrode deposition to ensure insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the piezoelectric sheet is made thin to reduce power consumption, then power consumption is reduced, but the sheet becomes more susceptible to breaking and cracking due to stress concentration
Solution Approach 1:
A resin layer is formed on the surface of the piezoelectric sheet before the joining process to provide cushioning protection. This resin layer absorbs and distributes stress during pressing operations, preventing stress concentration at the surface of the thin piezoelectric sheet, thereby reducing the risk of breaking and cracking while maintaining the thin design for low power consumption.
Solution Approach 2:
The resin layer acts as an intermediary between the pressing tool and the piezoelectric sheet during the joining process. It mediates the stress transmission, distributing the applied pressure uniformly across the surface rather than concentrating it at specific points, thus protecting the thin piezoelectric sheet from damage.
2Power
If the piezoelectric sheet is made thin to enable deformation at low voltage, then deformation efficiency is improved, but the brittleness of ceramics material increases the frequency of damage occurrence
Solution Approach 1:
The resin layer is applied beforehand to cushion the thin piezoelectric sheet during handling and joining operations. This cushioning effect compensates for the reduced mechanical strength inherent in thin ceramic sheets, allowing them to maintain high deformation efficiency while being protected from stress-induced damage during manufacturing.
Solution Approach 2:
The invention changes the physical state and mechanical properties at the surface of the piezoelectric sheet by adding a resin coating. This modifies the surface characteristics to provide stress distribution and protection, enabling the use of thinner sheets for better deformation efficiency without sacrificing overall structural integrity.
3Ease of manufacture
If the stacked body is pressed against the channel unit during joining, then joining is achieved, but stress concentration at the edge portions causes breaking and cracking
Solution Approach 1:
The resin layer serves as an intermediary layer between the pressing operation and the piezoelectric sheet during the joining process. It distributes the pressing stress uniformly across the surface, preventing stress concentration at edge portions and eliminating the root cause of breaking and cracking while still enabling effective joining to the channel unit.
Solution Approach 2:
By forming the resin layer before the joining process, the piezoelectric sheet is pre-protected against stress concentration during pressing. This beforehand cushioning allows the joining operation to proceed effectively while preventing damage to the brittle ceramic material at vulnerable edge portions.
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
The method significantly reduces damage to the piezoelectric actuator by distributing stress and enhancing durability, while preventing electrical conduction and discharge issues by covering the ceramics layer with resin, thus improving the overall reliability and longevity of the actuator.
Implementation Method 1
A piezoelectric actuator which drives an object by using a deformation (piezoelectric distortion) of a piezoelectric material layer when an electric field acts
Implementation Method 2
forming elastic layers having a lower coefficient of elasticity than that of the piezoelectric material layer on both surfaces respectively of the stacked body after the sintering
Implementation Method 3
forming a stacked body which includes the piezoelectric material layer, the ceramics layer, and the first electrode arranged between the piezoelectric material layer and the ceramics layer and sintering the stacked body
Data Source
AI summary
A method for manufacturing piezoelectric actuator which includes a piezoelectric layer formed of a piezoelectric ceramics material and having a drive area, a first electrode and a second electrode arranged on both surfaces of the piezoelectric material layer respectively each at portion corresponding to the drive area, and a ceramics layer formed of a ceramics material and stacked to face the surface of the piezoelectric material layer on which the first electrode is arranged, the method including: forming a stacked body which includes the piezoelectric material layer, the ceramics layer, and the first electrode, and sintering the stacked body; forming the second electrode on the other surface, of the piezoelectric material layer after the sintering, not facing the ceramics layer; and forming elastic layers having a lower coefficient of elasticity than that of the piezoelectric material layer on both surfaces respectively of the stacked body after the sintering.