A method of manufacturing an electrode assembly includes positioning a layer stack comprising an electrode positioned between an electrode insulator and a support polymer in a vacuum bag, removing air from the vacuum bag thereby vacuum coupling the electrode to the electrode insulator, and removing the layer stack from the vacuum bag, where upon removal of the layer stack from the vacuum bag, the electrode remains vacuum coupled to the electrode insulator and the electrode insulator is in direct contact with the electrode, thereby forming an electrode assembly.

A variable mold includes a plurality of hydraulic pin systems. Each pin system includes a valve in fluid communication with a supply of pressurized fluid, a tubing in fluid communication with the valve, and a pin coupled to the tubing. The pin is configured to extend from the tubing in response to the supply of the fluid through the valve to the tubing. A longitudinal axis of each pin is mutually parallel and arranged in a two-dimensional array. The variable mold includes a controller operably coupled to the valves that can control the displacement of each pin. The variable mold may include a pin displacement detector configured to detect a displacement of each pin. The pin displacement detector is operably coupled to the controller. The controller can close each valve in response to the pin displacement detector detecting that the pin corresponding to the valve extends a predetermined distance.

High strain hydraulically amplified self-healing electrostatic transducers having increased maximum theoretical and practical strains are disclosed. In particular, the actuators include electrode configurations having a zipping front created by the attraction of the electrodes that is configured orthogonally to a strain axis along which the actuators. This configuration produces increased strains. In turn, various form factors for the actuator configuration are presented including an artificial circular muscle and a strain amplifying pulley system. Other actuator configurations are contemplated that include independent and opposed electrode pairs to create cyclic activation, hybrid electrode configurations, and use of strain limiting layers for controlled deflection of the actuator.

A method of manufacturing an electrode assembly includes positioning a layer stack comprising an electrode positioned between an electrode insulator and a support polymer in a vacuum bag, removing air from the vacuum bag thereby vacuum coupling the electrode to the electrode insulator, and removing the layer stack from the vacuum bag, where upon removal of the layer stack from the vacuum bag, the electrode remains vacuum coupled to the electrode insulator and the electrode insulator is in direct contact with the electrode, thereby forming an electrode assembly.

An artificial muscle including a housing having an electrode region and an expandable fluid region, the housing defining an upper housing portion and a lower housing portion, a strain sensor integrated into at least one of the upper housing portion and the lower housing portion of the housing, a dielectric fluid housed within the housing, and an electrode pair positioned in the electrode region of the housing. The electrode pair includes a first electrode and a second electrode, wherein the electrode pair is configured to actuate between a non-actuated state and an actuated state such that actuation from the non-actuated state to the actuated state directs the dielectric fluid into the expandable fluid region, expanding the expandable fluid region to deform the strain sensor.

An artificial muscle system includes an artificial muscle and a power supply. The artificial muscle includes an electrode pair including a first electrode and a second electrode, an electrical insulator membrane fixed to the second electrode, a housing including an electrode region and an expandable fluid region, the electrode pair positioned in the electrode region of the housing, and a dielectric fluid housed within the housing. The power supply includes a positive terminal and a negative terminal. The positive terminal is electrically coupled to the second electrode. The negative terminal is electrically coupled to the first electrode. The electrode pair is actuatable between a non-actuated state and an actuated state such that actuation from the non-actuated state to the actuated state directs the dielectric fluid into the expandable fluid region.

A method of manufacturing an electrode assembly includes positioning a layer stack comprising an electrode positioned between an electrode insulator and a support polymer in a vacuum bag, removing air from the vacuum bag thereby vacuum coupling the electrode to the electrode insulator, and removing the layer stack from the vacuum bag, where upon removal of the layer stack from the vacuum bag, the electrode remains vacuum coupled to the electrode insulator and the electrode insulator is in direct contact with the electrode, thereby forming an electrode assembly.

An artificial muscle that includes a housing having an electrode region and an expandable fluid region and an electrode pair positioned in the electrode region, the electrode pair having a first electrode fixed to a first surface of the housing and a second electrode fixed to a second surface of the housing. The first and second electrodes each have two or more tab portions and two or more bridge portions. Each of the two or more bridge portions interconnects adjacent tab portions and at least one of the first and second electrodes includes a central opening positioned between the two or more tab portions and encircling the expandable fluid region. A dielectric fluid is housed within the housing and the electrode pair is actuatable between a non-actuated and an actuated state such that actuation from the non-actuated to actuated state directs the dielectric fluid into the expandable fluid region.

An artificial muscle stack that includes a plurality of artificial muscle layers. Each artificial muscle layer includes one or more artificial muscles having a housing with an electrode region and an expandable fluid region, a dielectric fluid housed within the housing, and an electrode pair having a first and second electrode positioned in the electrode region. The first and second electrodes each include two or more tab portions and two or more bridge portions. The two or more bridge portions interconnects adjacent tab portions. At least one of the first and second electrode includes a central opening positioned between the tab portions and encircling the expandable fluid region. The plurality of artificial muscle layers are arranged such that the expandable fluid region of the artificial muscles of each artificial muscle layer overlaps at least one tab portion of one or more artificial muscles of an adjacent artificial muscle layer.

An artificial muscle device includes a plurality of intermuscular boards and a plurality of artificial muscles disposed between the intermuscular boards in an alternating pattern and communicatively coupled to a controller. Each of the one or more artificial muscles includes a housing comprising an electrode region and an expandable fluid region, a dielectric fluid housed within the housing, and an electrode pair positioned in the electrode region of the housing, the electrode pair including a first electrode and a second electrode. The electrode pair is actuatable between a non-actuated state and an actuated state such that actuation from the non-actuated state to the actuated state directs the dielectric fluid into the expandable fluid region, expanding the expandable fluid region, thereby applying pressure to the intermuscular boards.