Method of manufacturing electroactive polymer transducers for sensory feedback applications

• US 9,425,383 B2
• Filed: 08/09/2011
• Issued: 08/23/2016
• Est. Priority Date: 06/29/2007
• Status: Active Grant

• Current Assignee: Parker Intangibles LLC (Parker-Hannifin Corporation)
• Original Assignee: Parker-Hannifin Corporation
• Inventors: Lipton, Michael G., Polyakov, Ilya, Zarrabi, Alireza, Hui, Otto, Biggs, Silmon James, Kridl, Thomas A., Russell, Gordon, Heim, Jonathan R., Hitchcock, Roger, Weaber, Chris A.
• Primary Examiner(s): Tugbang, A. Dexter
• Application Number:
  US13/205,888
• Publication Number:
  US 20110285247A1
• Time in Patent Office: 1,841 Days
• Field of Search: 29/253.5, 295/84, 298/30, 298/31, 298/42, 298/46, 295/94, 310/328, 310/339, 310/800, 318/116
• US Class Current: 1/1
• CPC Class Codes: G01R 33/28 Details of apparatus provided for in groups G01R33/44 - G01R33/64
• CPC Class Codes: G06F 3/016 Input arrangements with force or tactile feedback as computer generated output to the user
• CPC Class Codes: H01H 13/84 characterised by ergonomic functions, e.g. for miniature keyboards; characterised by operational sensory functions, e.g. sound feedback legends H01H13/83
• CPC Class Codes: H01H 2003/008 with a haptic or a tactile feedback controlled by electrical means, e.g. a motor or magnetofriction
• CPC Class Codes: H01H 2203/008 Wires
• CPC Class Codes: H01H 2217/018 Indication of switch sites
• CPC Class Codes: H10N 30/03 Assembling devices that include piezoelectric or electrostrictive parts
• CPC Class Codes: H10N 30/2041 Beam type
• CPC Class Codes: H10N 30/206 using only longitudinal or thickness displacement, e.g. d33 or d31 type devices
• CPC Class Codes: H10N 30/30 with mechanical input and electrical output, e.g. functioning as generators or sensors
• CPC Class Codes: H10N 30/302 Sensors
• CPC Class Codes: H10N 30/308 Membrane type
• CPC Class Codes: H10N 30/85 Piezoelectric or electrostrictive active materials
• CPC Class Codes: Y10S 310/80 Piezoelectric polymers, e.g. PVDF
• CPC Class Codes: Y10T 29/42 Piezoelectric device making
• CPC Class Codes: Y10T 29/49005 Acoustic transducer
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49121 Beam lead frame or beam lead device
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/49128 : Assembling formed circuit to base
• CPC Class Codes: Y10T 29/4913 : Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49147 : Assembling terminal to base
• CPC Class Codes: Y10T 29/49155 : Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49165 : by forming conductive walled aperture in base

Abstract

A method for fabricating electroactive polymer transducers, the includes providing an electroactive polymer film comprising an elastomeric dielectric polymer, forming an array of electrodes on the film, and sandwiching the electrode array between a top and bottom array of frame components to form an array of electroactive polymer transducers.

Claims

1. A method for fabricating electroactive polymer transducers, the method comprising:

providing an electroactive polymer film comprising an elastomeric dielectric polymer having an elastic modulus of less than about 100 MPa;

forming an array of electrodes on the electroactive polymer film;

sandwiching the electrode array between a top and bottom array of frame components to form an array of electroactive polymer transducers; and

applying an array of negative spring rate biasing mechanisms onto the array of electroactive polymer transducers,

wherein the array of negative spring rate biasing mechanisms are configured to impose a negative spring rate bias on the electroactive polymer film, and

wherein the negative spring rate biasing mechanisms comprise a central hub mechanically coupled to an output disc and two opposing leaf spring flexures extending between the central hub and a frame side of an electroactive polymer transducer.

2. The method of claim 1, further comprising singulating the array of electroactive polymer transducers.

3. The method of claim 2, further comprising incorporating at least one singulated electroactive polymer transducer into a user interface device.

4. The method of claim 1, further comprising incorporating the transducer array into an array of user interface devices.

5. The method of claim 1, wherein each of the transducers are fabricated with web-based manufacturing techniques.

6. The method of claim 1, further comprising sealing at least one electroactive polymer transducer of the array of electroactive polymer transducers.

7. The method of claim 1, wherein sealing the at least one electroactive polymer transducer comprises hermetically sealing the at least one electroactive polymer transducer.

8. The method of claim 1, further comprising applying at least one disc segment onto the array of electroactive polymer transducers.

9. The method of claim 1, further comprising applying at least one output member onto the array of electroactive polymer transducers.

10. The method of claim 9, further comprising mechanically coupling the at least one output member to at least one user contact surface.

11. The method of claim 9, further comprising magnetically coupling the at least one output member to at least one user contact surface.

12. The method of claim 1, wherein forming the array of electrodes on the film comprises applying a high voltage electrode pattern comprising high voltage lines and a ground side electrode pattern comprising ground lines.

13. The method of claim 12, wherein the high voltage lines comprise a pair of high voltage lines and the ground lines comprise a pair of ground lines corresponding to the pair of high voltage lines.

14. The method of claim 1, further comprising incorporating the array of electroactive polymer transducers into a user interface array.

15. The method of claim 14, wherein the user interface array is a keyboard.

16. The method of claim 1, further comprising applying at least one mechanical force sensor onto the array of electroactive polymer transducers.

17. The method of claim 1, further comprising pre-straining the electroactive polymer film by stretching the electroactive polymer film and holding the electroactive polymer film in a pre-strained condition.

18. The method of claim 1, wherein the array of negative spring rate biasing mechanisms are configured to impose the negative spring rate bias on a output component secured to the electroactive polymer film.

19. A method for fabricating electroactive polymer transducers, the method comprising:

providing an electroactive polymer film comprising an elastomeric dielectric polymer having an elastic modulus of less than about 100 MPa, wherein the electroactive polymer film is a first electroactive polymer film;

forming an array of electrodes on the electroactive polymer film;

sandwiching the electrode array between a top and bottom array of frame components to form an array of electroactive polymer transducers;

applying at least one first magnetic unit to the first electroactive polymer film;

providing a second electroactive polymer film;

and applying at least one second magnetic unit to the second electroactive polymer film, and wherein the at least one first magnetic unit and the at least one second magnetic unit are oppositely polarized or similarly polarized.