Piezoelectric Actuator Sheet Metal Structure

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Solution Overview

Problem

Existing piezoelectric actuators for haptic feedback in touch interfaces are costly and unsuitable for mass production due to expensive machining processes and labor-intensive manufacturing methods, making them impractical for high-volume sectors like the automotive industry.

Innovation Solution

A piezoelectric actuator with a metallic structure made from bent sheet metal, featuring electric welding and plastic overmolding to reduce material costs and simplify production, including a cable passage with a baffle to prevent cable damage and eliminate the need for a protective sheath, using a flexible polyester thermoplastic elastomer overmolding for durability and ease of assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional machining processes are used to create metallic structures from blocks, then structural integrity is ensured, but manufacturing cost increases and production rate decreases

Engineering Contradiction:

Improveproduction rateVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent changes the manufacturing parameters from traditional block machining to sheet metal forming processes. The metallic structure is created by bending and shaping metal sheets instead of removing material from blocks, which significantly reduces manufacturing time and cost while maintaining structural integrity through controlled forming parameters.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces complex mechanical machining operations with simpler sheet metal forming and joining processes. The metallic structure is assembled from formed sheets using welding or other joining methods, substituting the traditional subtractive manufacturing approach with a formative and assembly-based approach that enables higher production rates.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual welding and sheathing processes are used, then cable stress resistance is improved, but labor cost increases and production efficiency decreases

Engineering Contradiction:

Improvecable stress resistanceVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-forming the metallic structure with integrated cable routing features and pre-positioning cable protection elements before final assembly. The sheathing and cable routing are designed into the structure in advance, eliminating the need for tedious manual sheathing operations during final assembly while maintaining cable stress resistance.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If complex machining and assembly processes are used, then actuator performance is ensured, but manufacturing cost increases

Engineering Contradiction:

Improveactuator performanceVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies segmentation by dividing the metallic structure into modular sheet components that can be independently formed and then assembled. This segmentation allows each component to be optimized for its specific function while simplifying the overall manufacturing process, as standardized sheet components can be produced more efficiently than monolithic machined parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements universality by designing the metallic structure to serve multiple functions through its sheet-based construction. The same formed sheets provide both structural support and cable routing features, while also serving as mounting surfaces. This multi-functionality reduces the total number of components and manufacturing steps compared to traditional designs requiring separate elements for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution significantly reduces production costs and increases manufacturing efficiency by eliminating machining and manual welding, while ensuring structural integrity and vibration control, making the actuators more suitable for high-volume production.

Implementation Method 1

a piezoactive element (3) intended to produce vibrations

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

a metallic structure (5) intended to amplify the vibrations produced by the piezoactive element (3)

Methodology Applied

Scientific EffectVibration amplification: Vibration

Data Source

PatentEP2936575B1Piezoelectric actuator and associated fabrication process

Publication Date: 2020.11.04 DAV

Figure 1~3
Figure 4~7

AI summary

The present invention relates to a piezoelectric actuator (1) comprising: a piezoactive element (3) intended to produce vibrations; and an oblong metal structure (5) having a large axis (7) and a small axis (9) extending perpendicularly one relative to the other and encircling the piezoactive element (3) that is arranged along the large axis (7) of the metal structure (5), said metal structure (5) being configured to prestress the piezoactive element (3) and to amplify, along the small axis (9) of the metal structure (5), the vibrations produced by the piezoactive element (3), wherein the oblong metal structure (5) is obtained by bending at least one precut metal sheet (11).