Stacked Actuating Electrode Structure for Layer Isolation
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Solution Overview
Problem
Existing techniques for electrically induced mechanical movement in devices, such as Eccentric Rotating Mass (ERM) vibration motors, linear resonant actuators (LRA), and piezoelectric actuators, face issues with high power consumption, low durability, short lifespan, complex designs, and poor scalability, especially on flexible surfaces, leading to inadequate electrical isolation between layers.
Innovation Solution
A stacked structure comprising flat active element (FAE) layers with indented lines and insulator layers for electrical isolation, combined with elastic nodules and conductive adhesives for secure connections, and a hermetically or semi-sealed pouch for robustness and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrostatic actuators are used, then electrical isolation between layers is insufficient, but adding more isolation layers increases device complexity
Solution Approach 1:
The electrode is segmented by introducing indented lines that divide the continuous electrode into isolated regions. These indented lines create physical gaps in the conductive material, effectively segmenting the electrode structure to prevent electrical breakdown and improve isolation between stacked layers without adding separate isolation components.
Solution Approach 2:
An insulator layer is introduced as an intermediary material that fills the indented lines of the electrode structure. This insulator layer acts as a mediator between adjacent electrode layers, providing electrical isolation while maintaining the structural integrity and compactness of the stacked actuator design.
2Reliability
If indented lines and insulator layers are added to improve electrical isolation, then manufacturing complexity increases, but manufacturing cost must remain acceptable
Solution Approach 1:
The indented lines and insulator layer formation processes are merged into a single manufacturing step. The insulator material is applied in a way that automatically fills the indented regions during deposition, combining the patterning and insulation steps into one operation, thereby reducing manufacturing complexity while maintaining effective electrical isolation.
3Reliability
If stacked structures are used to improve durability and reduce lateral displacement, then device complexity increases, but scalability is needed
Solution Approach 1:
The solution transitions from addressing lateral displacement in the horizontal plane to controlling it through vertical stacking. By building multiple electrode layers in the vertical dimension with proper isolation, the structure gains improved mechanical stability and reduced lateral displacement without requiring complex lateral constraint mechanisms.
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 provides effective electrical isolation, improved durability, and scalability, while maintaining robustness and cost-effectiveness, preventing sparks between layers and enabling efficient mechanical movement with reduced lateral displacement.
Implementation Method 1
an insulator layer formed on the electrode covering the active region and partially covering the connection region, wherein the insulator layer fills the indented line of the electrode
Implementation Method 2
an elastic layer formed on the active region of the first conductive surface or on an exposed surface of the second substrate, the elastic layer comprising a plurality of elastic nodules spanning the compression space and contacting the second substrate, the plurality of elastic nodules configured to be compressed by relative movement of the first conductive surface and the second conductive surfaces toward each other in response to a voltage difference between the first conductive surface and the second conductive surfaces or in response to an external force
Implementation Method 3
a conductive adhesive contacting the connecting region of the first conductive surface and the connecting region of the second conductive surface; and a conductive element coupled to the conductive adhesive, for electrically connecting the two FAE layers
Data Source
AI summary
An active element (AE) layer includes: a substrate including an active body area and a protruding arm; an electrode, formed on the substrate and including an active region for sensing or actuation formed on the active body area of the substrate and a connection region formed on the protruding arm of the substrate, wherein the electrode includes a first indented line around the periphery of the active region, extending into the connection region and reaching two respective edges of the connection region, wherein the first indented line totally penetrates the electrode to make the respective edges electrically isolated; and an insulator layer formed on the electrode covering the active region and partially covering the connection region, wherein the insulator layer fills the indented line of the electrode.