Woven Active Fiber Composite

• US 20100227521A1
• Filed: 03/04/2009
• Published: 09/09/2010
• Est. Priority Date: 03/04/2009
• Status: Active Grant

• Current Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Original Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Inventors: Whinnery, Joseph Patrick Wendell
• Granted Patent: US 8,922,100 B2
• Time in Patent Office: Days
• US Class Current: 442/189
• CPC Class Codes: D03D 1/0088 Fabrics having an electronic function
• CPC Class Codes: D03D 15/267 Glass
• CPC Class Codes: D03D 15/43 with differing diameters
• CPC Class Codes: D03D 15/50 characterised by the properties of the yarns or threads
• CPC Class Codes: D03D 15/593 Stiff materials, e.g. cane or slat
• CPC Class Codes: D10B 2101/06 Glass
• CPC Class Codes: D10B 2101/08 Ceramic
• CPC Class Codes: D10B 2101/20 Metallic fibres
• CPC Class Codes: D10B 2401/16 antistatic; conductive
• CPC Class Codes: H10N 30/06 Forming electrodes or interconnections, e.g. leads or terminals
• CPC Class Codes: H10N 30/092 Forming composite materials
• CPC Class Codes: H10N 30/1061 based on piezoelectric or electrostrictive fibres
• CPC Class Codes: H10N 30/87 Electrodes or interconnections, e.g. leads or terminals
• CPC Class Codes: Y10S 310/80 Piezoelectric polymers, e.g. PVDF
• CPC Class Codes: Y10T 442/3065 Including strand which is of specific structural definition
• CPC Class Codes: Y10T 442/3179 Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
• CPC Class Codes: Y10T 442/322 Warp differs from weft
• CPC Class Codes: Y10T 442/3228 Materials differ
• CPC Class Codes: Y10T 442/3236 Including inorganic strand material
• CPC Class Codes: Y10T 442/3382 Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/339 : Metal or metal-coated strand
• CPC Class Codes: Y10T 442/3976 : Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]

Abstract

A woven active fiber composite is disclosed. The woven active fiber composite includes actuating fibers interwoven with conductive wire electrodes. A method of making the woven active fiber composite is also disclosed.

Claims

1. A woven active fiber composite, comprising:

a plurality of actuating fibers;

a plurality of conductive wire electrodes configured to transfer electrical energy to and from the actuating fibers; and

wherein the plurality of conductive wire electrodes are interwoven with the plurality of actuating fibers.

2. The woven active fiber composite according to claim 1, wherein the plurality of actuating fibers are made of a piezoelectric material.

3. The woven active fiber composite according to claim 2, wherein the piezoelectric material is PZT.

4. The woven active fiber composite according to claim 1, wherein a diameter of the plurality of actuating fibers is in a range between 50 and 150 micrometers.

5. The woven active fiber composite according to claim 1, wherein a diameter of the plurality of conductive wire electrodes is in a range between 5 and 25 micrometers.

6. The woven active fiber composite according to claim 1, wherein the plurality of conductive wire electrodes comprises a first electrode set and a second electrode set.

7. The woven active fiber composite according to claim 6, wherein the first electrode set consists of positive electrodes and wherein the second electrode set consists of negative electrodes.

8. The woven active fiber composite according to claim 6, wherein the first electrode set is interdigitated with the second electrode set.

9. The woven active fiber composite according to claim 1, wherein the plurality of conductive wire electrodes has a substantially sinusoidal shape.

11. The woven active fiber composite according to claim 9, wherein adjacent actuating fibers are evenly spaced.

10. A woven active fiber composite, comprising:

a plurality of actuating fibers arranged in a generally parallel direction;

a plurality of conductive wire electrodes configured to transfer electrical energy to and from the plurality of actuating fibers; and

wherein a portion of the plurality of conductive wire electrodes is disposed between any two adjacent actuating fibers.

12. The woven active fiber composite according to claim 10, wherein the even spacing of any two adjacent actuating fibers facilitates actuation of the woven active fiber composite in the axial direction.

13. The woven active fiber composite according to claim 12, wherein the spacing between any two adjacent actuating fibers may change during actuation of the woven active fiber composite in the axial direction.

14. A woven active fiber composite, comprising:

a plurality of actuating fibers arranged in a generally parallel direction;

a plurality of conductive wire electrodes configured to transfer electrical energy to and from the plurality of actuating fibers; and

wherein substantially any two adjacent actuating fibers are spaced apart.

15. The woven active fiber composite according to claim 14, wherein the spacing between adjacent actuating fibers is at least as large as an average diameter of the plurality of conductive wire electrodes.

16. The woven active fiber composite according to claim 15, wherein the spacing between adjacent actuating fibers is larger than the average diameter of the plurality of conductive wire electrodes.

17. The woven active fiber composite according to claim 14, wherein the plurality of conductive wire electrodes is associated with recesses in the plurality of actuating fibers.

18. The woven active fiber composite according to claim 17, wherein the spacing between adjacent actuating fibers is less than the average diameter of the plurality of conductive wire electrodes.

19. A woven active fiber composite, comprising:

an actuating fiber including a curved peripheral portion;

a conductive wire electrode configured to transfer electrical energy to and from the actuating fiber; and

wherein the conductive wire electrode is configured to contact the actuating fiber over the substantial entirety of the curved peripheral portion.

20. The woven active fiber composite according to claim 19, wherein the actuating fiber includes two curved peripheral portions and wherein the two curved peripheral portions comprise a substantial majority of a circumference of the actuating fiber.

21. The woven active fiber composite according to claim 20, wherein the conductive wire electrode is configured to contact the actuating fiber over the substantial entirety of the two curved peripheral portions.

22. The woven active fiber composite according to claim 19, wherein the conductive wire electrode is woven with the actuating fiber in a smooth manner to substantially prevent sharp points in the conductive wire electrode.

23. The woven active fiber composite according to claim 19, wherein the curved peripheral portion has a length that is at least as large as an eighth of a circumference of the actuating fiber.

24. The woven active fiber composite according to claim 19, wherein the curved peripheral portion has a length that is at least as large as a quarter of a circumference of the actuating fiber.

25. The woven active fiber composite according to claim 24, wherein the curved peripheral portion has a length that is approximately one half of a circumference of the actuating fiber.

26. A woven active fiber composite, comprising:

an actuating fiber including a periodically varying diameter;

a first portion of the actuating fiber associated with a first diameter and a second portion of the actuating fiber associated with a second diameter that is less than the first diameter;

a conductive wire electrode configured to transfer electrical energy to and from the actuating fiber; and

wherein the conductive wire electrode is configured to contact the actuating fiber at the second portion.

27. The woven active fiber composite according to claim 26, wherein the first portion is associated with a maximum diameter of the actuating fiber.

28. The woven active fiber composite according to claim 27, wherein the second portion is associated with a minimum diameter of the actuating fiber.

29. The woven active fiber composite according to claim 26, wherein a depth of the second portion with respect to the first portion is larger than a diameter of the conductive wire electrode.

30. The woven active fiber composite according to claim 26, wherein a depth of the second portion with respect to the first portion is less than a diameter of the conductive wire electrode.

31. The woven active fiber composite according to claim 26, wherein a depth of the second portion with respect to the first portion is substantially equal to a diameter of the conductive wire electrode.

32. The woven active fiber composite according to claim 26, wherein the first portion comprises a relatively flat outer surface.

33. The woven active fiber composite according to claim 29, wherein the second portion is a recess in the outer surface of the actuating fiber.

34. A method of attaching conductive wire electrodes with actuating fibers, comprising the steps of:

arranging a plurality of actuating fibers in a generally parallel direction;

weaving a plurality of conductive wire electrodes through the actuating fibers; and

thereby attaching the plurality of conductive wire electrodes with the plurality of actuating fibers.

35. The method according to claim 34, wherein the plurality of actuating fibers is woven with the plurality of conductive wire electrodes using a loom.

36. The method according to claim 34, wherein each conductive wire electrode of the plurality of conductive wire electrodes is woven across the actuating fibers in a direction perpendicular to a length of the plurality of actuating fibers twice.

37. The method according to claim 34, wherein the plurality of actuating fibers includes a plurality of recesses.

38. The method according to claim 37, wherein the plurality of conductive wire electrodes is configured to be woven into the plurality of recesses.

39. A method of making a woven active fiber composite, comprising the steps of:

weaving a plurality of actuating fibers with a plurality of conductive wire electrodes;

sintering the plurality of actuating fibers after they have been woven with the plurality of conductive wire electrodes;

applying an electromagnetic field to the plurality of actuating fibers and the plurality of conductive wire electrodes to pole the plurality of actuating fibers;

attaching at least one conductive strip to ends of the plurality of conductive wire electrodes; and

applying an epoxy matrix to the plurality of actuating fibers, the plurality of conductive wire electrodes and the at least one conductive strip to form a woven active fiber composite.

40. The method according to claim 39, wherein the step of applying an electromagnetic field occurs substantially simultaneously with the step of sintering the plurality of actuating fibers.

41. The method according to claim 39, wherein the plurality of actuating fibers is poled prior to the application of the epoxy matrix.

42. The method according to claim 39, wherein a step of applying a conductive strip to the plurality of conductive wires follows the step of weaving the plurality of actuating fibers with the plurality of conductive wires and wherein the conductive strip is applied prior to the step of sintering.