Reinforced Dielectric Elastomer Composite for Thin Roll-to-Roll Films
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Solution Overview
Problem
Current methods face challenges in producing thin, strong dielectric elastomeric films suitable for continuous roll-to-roll processing, particularly for applications requiring voltages below 2000 volts, where achieving thicknesses less than 50 μm is difficult without defects.
Innovation Solution
A dielectric elastomeric composite is developed, comprising a compacted porous membrane, an elastomer material that penetrates the membrane, and an electrically conductive material, with the compacted porous membrane being transversely or machine direction compacted, and optionally both, to achieve a thickness of less than 170 μm, allowing for stacked or wound configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If elastomeric films with thickness less than 50 μm are produced, then the voltage requirement is reduced (below 600 volts), but the manufacturing difficulty increases and handling becomes problematic
Solution Approach 1:
The patent creates a composite structure consisting of a porous membrane layer and a dielectric elastomer layer. The porous membrane provides mechanical strength and dimensional stability, while the thin dielectric elastomer layer (less than 50 μm) provides the necessary dielectric properties. This composite approach allows achieving low voltage operation without sacrificing manufacturability and handling ease, as the porous membrane reinforces the thin elastomer structure.
Solution Approach 2:
The patent employs a porous membrane as the reinforcement layer, which provides high surface area and porosity for elastomer penetration while maintaining mechanical integrity. The porous structure allows the elastomer to penetrate and bond effectively, creating a strong composite material that is both thin and handleable, resolving the contradiction between reduced thickness for low voltage and manufacturing/d handling difficulty.
2Use of energy by moving object
If elastomeric films with thickness less than 50 μm are produced, then the voltage requirement is reduced (below 600 volts), but defects increase
Solution Approach 1:
The composite structure with porous membrane reinforcement provides mechanical support to the thin dielectric elastomer layer, preventing defects such as pinholes, tears, and handling damage. The porous membrane acts as a scaffold that maintains structural integrity, allowing the production of reliable thin-film actuators with thickness less than 50 μm that operate at low voltages without increased defect rates.
3Productivity
If thin elastomeric films are produced for roll-to-roll processing, then productivity increases, but the material strength and integrity decrease
Solution Approach 1:
The patent creates a composite material where a porous membrane provides mechanical strength and reinforcement to thin dielectric elastomer films. This composite structure maintains sufficient strength and integrity for continuous roll-to-roll processing while enabling the production of thin films that would otherwise be too weak for such high-productivity manufacturing methods.
Solution Approach 2:
The porous membrane reinforcement layer provides mechanical strength and dimensional stability to the thin dielectric elastomer, enabling roll-to-roll processing. The porous structure allows for effective elastomer penetration and bonding while maintaining the structural integrity needed for continuous high-speed manufacturing processes.
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 enhances the integrity and lifetime of the composite, reduces the risk of thinning and cracking, and enables increased actuation and sensitivity, while allowing for planar processing and roll-to-roll production.
Implementation Method 1
an elastomer material that at least partially penetrates the compacted porous membrane
Data Source
AI summary
The present disclosure is directed to dielectric elastomeric composites that include a retainable processing membrane, an elastomer material, and an electrically conductive material. The elastomer layer may be partially imbibed into the retainable processing membrane. The retainable processing membrane may be porous. The retainable processing membrane is compacted in the transverse direction, machine direction, or in both directions prior to the application of an elastomer material and an electrically conductive material. The compaction of the retainable processing membrane may form structured folds or folded fibrils in the membrane, giving the retainable processing membrane a low modulus and flexibility. In some embodiments, the dielectric composites are positioned in a stacked configuration. Alternatively, the dielectric elastomeric composites may have a wound configuration. The dielectric composites have a total thickness less than about 170 μm. The dielectric elastomeric composites may be used, for example, in dielectric elastomer actuators, sensors, and in energy harvesting.