Piezoelectric Polymer Composite Films via Electric Field Alignment

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Solution Overview

Problem

Current methods for producing piezoelectric polymer composite films face challenges in achieving high flexibility, power efficiency, transparency, and cost-effectiveness, particularly in large-scale production for applications like wearable technologies and sensors.

Innovation Solution

A process involving the alignment of lead zirconate titanate (PZT) particles and electrically conductive nanoparticles, such as graphene nanoplatelets, within a polymer matrix under a uniform electric field, facilitating charge transport and reducing particle quantity while maintaining transparency, is used to produce high-performance piezoelectric polymer composite films suitable for roll-to-roll production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If piezoelectric polymer composite films are produced using conventional methods, then manufacturing simplicity is maintained, but flexibility, power efficiency, and sensitivity are insufficient

Engineering Contradiction:

ImprovesensitivityVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses composite materials by combining piezoelectric particles (such as PZT) with polymer matrices (such as PVDF or PDMS) to create piezoelectric polymer composite films. This composite structure enhances sensitivity and power efficiency while maintaining flexibility, resolving the contradiction between performance improvement and manufacturing simplicity.

Inventive Principle:

Principle #40Composite materials

2Power

If particle quantity is increased to enhance piezoelectric effect, then energy harvesting capability improves, but material costs increase and transparency decreases

Engineering Contradiction:

Improveenergy harvesting capabilityVSAvoidparticle quantity

Core Design Contradiction:

PowerVSQuantity of substance

Solution Approach 1:

The patent changes key parameters including particle size (reducing to nanoscale), particle shape, and spatial distribution within the polymer matrix. By optimizing these parameters, the piezoelectric effect is enhanced with reduced particle quantity, maintaining transparency and reducing material costs while improving energy harvesting capability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by creating regions with optimized particle concentrations and distributions. Rather than uniform high particle quantity throughout, the composite structure has locally optimized zones that maximize piezoelectric effect while maintaining overall transparency and reducing total particle quantity.

Inventive Principle:

Principle #3Local quality

3Productivity

If conventional production methods are used, then production process simplicity is maintained, but large-scale production efficiency and cost-effectiveness are insufficient

Engineering Contradiction:

Improvelarge-scale production efficiencyVSAvoidproduction process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the production process into distinct modules: particle synthesis, polymer matrix preparation, composite film formation, and optional alignment/curing stages. This segmentation enables each module to be optimized independently for large-scale production while maintaining overall process efficiency and cost-effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a universal production framework that can manufacture various piezoelectric composite films with different particle types (PZT, BaTiO3, etc.), polymer matrices (PVDF, PDMS, etc.), and applications (sensors, energy harvesters, actuators) using the same core process methodology, enabling scalable production across multiple product lines.

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

This approach results in flexible, transparent, and high-sensitivity piezoelectric nanogenerators and pressure sensors with enhanced energy harvesting capabilities, compatible with continuous large-scale production, reducing material costs and maintaining transparency for applications like touchscreen interfaces and electronic skin.

Implementation Method 1

aligning the PZT and nanoparticles along nanocolumns in a thickness direction of the liquid polymer precursor matrix by subjecting the PZT and nanoparticles to a uniform electric field

Methodology Applied

Scientific EffectElectric field alignment: Electric Field

Implementation Method 2

piezoelectric materials and their polymer counterparts are attracting a great deal of attention due to their high levels of sensitivity and fast response times even at small deformations

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS11552240B2Machines and processes for producing polymer films and films produced thereby

Publication Date: 2023.01.10 PURDUE RES FOUND

AI summary

A sensor is disclosed which includes a piezoelectric layer, a piezoresistive layer, one or more electrode layers coupled to the piezoelectric layer and to the piezoresistive layer, the piezoelectric layer configured to provide an electrical signal in response to application of a dynamic disturbance, and the piezoresistive layer configured to provide a change in resistivity in response to application of a static disturbance.