Soft Composite Actuator Bladder Bonding for High-Throughput Manufacturing
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Solution Overview
Problem
There is a need for low-cost, simple, and high-throughput methods for manufacturing soft robotic actuators, as well as new designs for efficient soft robotic actuation devices.
Innovation Solution
The development of soft composite actuators made by bonding two or more material layers to form bladders that can be actuated by pressurized fluid, without the need for molding, using mechanical, thermal, and/or chemical bonding methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molding is used to manufacture soft robotic actuators, then manufacturing precision can be achieved, but production throughput is reduced and costs increase due to batch processing
Solution Approach 1:
The patent replaces traditional mechanical molding processes with a direct bonding approach where pre-cut elastomeric layers are bonded together using thermal, ultrasonic, or adhesive bonding methods. This substitution eliminates the need for complex mold assemblies and batch processing cycles, enabling continuous production and significantly improving throughput while maintaining manufacturing precision through controlled bonding parameters.
Solution Approach 2:
The invention changes the manufacturing parameters from batch-oriented molding cycles to continuous bonding processes. By controlling bonding temperature, pressure, and time parameters during the layer bonding process, the system achieves both high production throughput and precise actuator geometry without requiring traditional molding equipment, thus resolving the contradiction between productivity and ease of manufacture.
2Adaptability or versatility
If complex molding processes are used to create soft robotic actuators, then design flexibility can be achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent divides the actuator design into separate elastomeric layers that can be independently designed, cut, and bonded. Each layer can be fabricated using simple cutting tools or dies, and the final actuator geometry is achieved through the assembly of these segmented layers. This segmentation allows for easy design modifications by simply changing the layer patterns without requiring complex molding tooling, thus maintaining design flexibility while reducing manufacturing process complexity.
Solution Approach 2:
The invention performs preliminary actions by pre-cutting and preparing elastomeric layers before bonding. The layers are prepared in advance with precise geometries using simple cutting methods, and then assembled through bonding. This preliminary preparation allows for design flexibility to be achieved through straightforward layer design rather than complex molding processes, reducing overall manufacturing complexity while maintaining adaptability.
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 allows for the easy and efficient production of soft composite actuators that can be actuated in a predetermined manner, offering a cost-effective and flexible solution for soft robotics applications.
Implementation Method 1
one of the material layers is made of a thermoplastic elastomer material which can be thermally bonded (or high frequency welded or ultrasonically welded) together with other layers to define the actuator's bladder
Implementation Method 2
The soft composite actuator may be actuated when the bladder therein is pressurized by infusing fluids into the bladder
Data Source
Figure 1A
Figure 1B~1C
Figure 2A~2B
AI summary
A soft composite actuator is described, including a first elastomeric layer; a strain limiting layer; and a first radially constraining layer, wherein the first elastomeric layer is disposed between the first radially constraining layer and the strain limiting layer; and the elastomeric layer, the strain limiting layer, and the radially constraining layer are bonded together to form at least one bladder for holding pressurized fluid. Methods of using and making of the soft composite actuator are described.