Method and apparatus for manufacturing multi-layered high deformation piezoelectric actuators and sensors

• US 6,245,172 B1
• Filed: 08/26/1999
• Issued: 06/12/2001
• Est. Priority Date: 08/26/1999
• Status: Expired due to Term

• Current Assignee: Face International Corp.
• Original Assignee: Face International Corp.
• Inventors: Face, Samuel A. Jr.
• Primary Examiner(s): SELLS, JAMES D
• Application Number:
  US09/383,697
• Time in Patent Office: 656 Days
• Field of Search: 156/73.1, 156/89.11, 156/89.12, 156/250, 156/269, 156/290, 156/292, 156/324
• US Class Current: 156/89.11
• CPC Class Codes: B32B 2038/1891 Using a robot for handling the layers
• CPC Class Codes: B32B 38/1866 conforming the layers or laminate to a convex or concave profile
• CPC Class Codes: H10N 30/073 by fusion of metals or by adhesives
• CPC Class Codes: H10N 30/088 by cutting or dicing
• CPC Class Codes: H10N 30/204 using bending displacement, e.g. unimorph, bimorph or multimorph cantilever or membrane benders
• CPC Class Codes: Y10T 156/1084 of continuous or running length bonded web

Abstract

A method for manufacturing high deformation piezoelectric actuators and sensors using a continuous tape manufacturing process is provided. The ceramic layer is dispensed between two metal/adhesive layers to form a composite tape and is tack welded together. Lengths of composite tape are heated and then cut into individual actuators. A special pattern punched in the tapes allows for ease of alignment of the layers of the actuators.

Claims

1. A method of constructing a piezoelectric device, comprising the steps of:

dispensing a first tape onto a moveable track;

said first tape having a plurality of spaced apart pinholes therethrough engageable with a plurality of spaced apart pins on said moveable track;

dispensing a first ceramic onto said first tape;

dispensing a second tape onto said first ceramic;

said second tape having a plurality of spaced apart pinholes therethrough engageable with a plurality of spaced apart pins on said moveable track;

securing said first tape to said second tape to form a composite tape;

increasing a temperature of said composite tape;

decreasing a temperature of said composite tape;

and cutting said composite tape to form at least one piezoelectric device.

2. The method of claim 1;

wherein said step of dispensing said first tape comprises dispensing a tape comprising a metal layer and an adhesive layer;

and wherein said step of dispensing a ceramic onto said first tape comprises dispensing a ceramic onto said adhesive layer of said first tape.

3. The method of claim 1;

wherein said step of dispensing said second tape comprises dispensing a tape comprising a metal layer and an adhesive layer;

and wherein said step of dispensing a second tape onto said ceramic comprises dispensing said adhesive layer of said second tape onto said ceramic.

4. The method of claim 1, further comprising:

dispensing a second ceramic onto said first tape after said step of dispensing said first ceramic onto said first tape;

wherein said step of dispensing said second tape onto said first ceramic further comprises dispensing said second tape onto said second ceramic.

5. The method of claim 1, wherein said step of increasing a temperature of said composite tape comprises the steps of:

placing said composite tape into an autoclave;

and raising a temperature of said autoclave;

and wherein said step of decreasing a temperature of said composite tape comprises the step of decreasing a temperature of said autoclave.

6. The method of claim 1, wherein said step of increasing a temperature of said composite tape comprises the steps of:

placing said composite tape into an autoclave;

and raising a temperature of said autoclave;

and wherein said step of decreasing a temperature of said composite tape comprises the removing said composite tape from said autoclave.

7. The method of claim 1, further comprising the step of:

cutting said composite tape into strips before said step of increasing said temperature of said composite tape.