METHOD FOR PRODUCING A PIEZOELECTRIC STACK ACTUATOR, AND PIEZOELECTRIC STACK ACTUATOR
20220059751 · 2022-02-24
Assignee
Inventors
Cpc classification
H10N30/057
ELECTRICITY
H10N30/503
ELECTRICITY
H10N30/871
ELECTRICITY
International classification
Abstract
A method for producing a piezoelectric stack actuator and a piezoelectric stack actuator are disclosed. To increase service life of a piezoelectric stack actuator made up of individual actuators, includes providing at least two actuators the method and designed and configured to generate a deflection along an axis (A) when electrically activated; and coupling the at least two actuators to form the stack actuator such that deflections of the actuators generated when the actuators are electrically activated are overlaid along a stacking axis (S) and there is a force-coupling of the actuators over at least one coupling area (K) that is smaller than a projection area (P) of the actuator onto a plane (E) perpendicular to the stacking axis.
Claims
1-7. (canceled)
8. A method for producing a piezoelectric stack actuator, the method comprising: a. Step A: providing at least two actuators which are configured and designed to generate a deflection along an axis (A) when electrically activated, wherein step A includes sub-steps of: Sub-step A1: providing piezoceramic layers and electric contacts to make up the at least two actuators as multi-layer actuators, and Sub-step A4: enveloping the piezoceramic layers and the electric contacts with a ceramic insulating material; and b. Step B: a coupling of the at least two actuators to form the stack actuator such that deflections of the actuators generated when the actuators are electrically activated will be overlaid along a stacking axis (S) and there will be a force-coupling of the actuators over at least one coupling area (K) that is smaller than a projection area (P) of the actuator onto a plane (E) perpendicular to the stacking axis (S).
9. Method according to claim 8, wherein step A comprises at least one or more of the following sub-steps: a. Sub-step A2: stacking the piezoceramic layers along the axis (A); b. Sub-step A3: connecting the electric contacts with electrodes of corresponding polarities; c. Sub-step A4-1: enveloping the piezoceramic layers and the electric contacts with a monolithically sintered ceramic insulating material; and/or d. Sub-step A5: forming at least one coupling area (K) for force-coupling the actuator with an adjacent actuator, according to at least one of the following sub-steps: i. Sub-step A5-1: forming at least one coupling area (K) at an envelope of the actuator; ii. Sub-step A5-2: forming at least one coupling area (K) at an additional element to be arranged between two actuators to be coupled; iii. Sub-step A5-3: forming the coupling area (K) at one or both axial end(s) of the actuator or the additional element, respectively; and/or iv. Sub-step A5-7: forming the coupling area (K) such that with respect to the projection area (P) of the actuator, the following area ratio applies: 0.7*P K<P.
10. The method according to claim 8, wherein step B comprises at least one or more of the following sub-steps: a. Sub-step B2: arranging an additional element between two adjacent actuators; b. Sub-step B3: connecting the at least two actuators such that two adjacent actuators each are directly actively connected or indirectly actively connected via an additional element; c. Sub-step B4: decoupling two actuators outside the at least one coupling area (K); and/or d. Sub-step B5: connecting electrodes of the actuators with same polarities to each other by a connecting section.
11. A piezoelectric stack actuator, comprising: at least two actuators which are made up of piezoceramic layers and electric contacts, each being multi-layer actuators configured and designed to generate a deflection along an axis (A) when electrically activated; and an envelope, the piezoceramic layers and the electric contacts being enveloped with a ceramic insulation material and the at least two actuators being stacked along a stacking axis (S) such that deflections of the actuators generated when the actuators are electrically activated will be overlaid along the stacking axis (S), wherein the at least two actuators are coupled such that a coupling area (K) over which a force-coupling of an actuator to an adjacent actuator will be effected is smaller than a projection area (P) of the actuator onto a plane perpendicular to the axis (A).
12. Piezoelectric stack actuator according to claim 11, wherein each one of the actuators has at least one or more of the following features: a. the piezoceramic layers are stacked along an axis (A); b. the electric contacts are connected with electrodes of corresponding polarities; c. the piezoceramic layers and the electric contacts are enveloped with a monolithically sintered ceramic insulating material; d. the actuator has, in a plane perpendicular to the stacking axis S, an essentially or approximately circular cross-sectional shape; e. the actuator has, in a plane perpendicular to the stacking axis S, a full cross-section or a hollow cross-section; f. for actuators with a circular cross-section, a ratio of a diameter to a height is D/H ≥1; and/or g. for actuators with a rectangular cross-section, a ratio of a edge length to a height is L/H≥1.
13. Piezoelectric stack actuator according to claim 11, wherein the coupling area (K) has at least one or more of the following features: a. the at least one coupling area (K) is at the envelope of the actuator; b. the at least one coupling area (K) is formed at an additional element arranged between two actuators to be coupled;. c. the at least one coupling area (K) is formed at one or both axial end(s) of the actuator or the additional element, respectively; and/or d. the at least one coupling area (K) is configured and designed such that with respect to the projection area (P) of the actuator, an area ratio applies of: 0.1*P<K<P.
14. Piezoelectric stack actuator according to claim 11, wherein the stack actuator has at least one or more of the following features: a. at least one additional element is arranged between two adjacent actuators; b. at least two adjacent actuators are directly actively connected or indirectly actively connected via an additional element; c. at least two adjacent actuators are decoupled from each other, except for the at least one coupling area (K); and/or d. electrodes of actuators with same polarities are connected to each other by a connecting section.
15. Method according to claim 9, wherein step A comprises at least one or more of the following sub-steps: a. Sub-step A2: stacking the piezoceramic layers along the axis (A), such that two adjacent piezoceramic layers face each other with the insertion of one electric contact each, the contact being an electrode layer or a contact plate, with poles of same polarities; b. Sub-step A3: connecting the electric contacts with electrodes of corresponding polarities, such that electrodes of different polarities are arranged spaced apart at a periphery of the actuator, and located on diametrically opposed sides of the actuator; c. Sub-step A4-1: enveloping the piezoceramic layers and the electric contacts with a monolithically sintered ceramic insulating material, wherein the envelope with the insulating material is air-tight and/or moisture-tight; and/or d. Sub-step A5: forming at least one coupling area (K) for force-coupling the actuator with an adjacent actuator, according to at least one of the following sub-steps: i. Sub-step A5-1:forming at least one coupling area (K) at an envelope of the actuator, while maintaining the insulating function of the envelope; ii. Sub-step A5-2: forming at least one coupling area (K) at an additional element arranged between two actuators to be coupled, wherein the additional element is embodied as an electrode; iii. Sub-step A5-3: forming the coupling area (K) at one or both axial end(s) of the actuator or the additional element, respectively, such that the coupling area (K) forms one of the or both axial ends of the actuator or the additional element, respectively; and/or iv. Sub-step A5-7: forming the coupling area (K) such that with respect to the projection area (P) of the actuator, the following area ratio is selected to be at least one of: 0.7*P≤K<P, 0.8*P≤K≤0.99*P, 0.9*P≤K≤0.95*P.
16. The method according to claim 9, wherein step B comprises at least one of the following sub-steps: a. Sub-step B2: arranging an additional element embodied as an electrode between two adjacent actuators; b. Sub-step B3: connecting the at least two actuators such that two adjacent actuators each are directly actively connected or indirectly actively connected via an additional element while forming a firmly bonded connection between the adjacent actuators or between each one of the adjacent actuators and the additional element arranged there between by an adhesive, wherein the adhesive glues the at least one coupling area (K) completely; c. Sub-step B4: decoupling two actuators outside the at least one coupling area (K), in an edge region in the coupling plane, by removing piezoceramic material and/or adhesive and/or by applying release agents; and/or d. Sub-step B5: connecting electrodes of the actuators with same polarities to each other by a connecting section by applying the connecting section onto the electrodes.
17. Piezoelectric stack actuator according to claim 11, wherein each one of the actuators has at least one or more of the following features: a. the piezoceramic layers are stacked along an axis (A) such that two adjacent piezoceramic layers face each other with insertion of one electric contact each, the contact being an electrode layer or a contact plate, with poles of same polarities; b. the electric contacts are connected with electrodes of corresponding polarities, wherein electrodes of different polarities are arranged spaced apart at a periphery of the actuator and are located on diametrically opposed sides of the actuator; c. the piezoceramic layers and the electric contacts are enveloped with a monolithically sintered ceramic insulating material, wherein the envelope with the insulating material is air-tight and/or moisture-tight; d. the actuator has, in a plane perpendicular to the stacking axis S, an essentially or approximately circular cross-sectional shape; e. the actuator has, in a plane perpendicular to the stacking axis S, a full cross-section or a hollow cross-section; f. for actuators with a circular cross-section, a ratio of a diameter to a height is selected to be one or more of D/H≥1, D/H>5, and/or D/H=6.4; and/or g. with actuators with a rectangular cross-section, a ratio of an edge length to a height is selected to be one or more of L/H≥1, L/H>5, and/or L/H=6.4.
18. Piezoelectric stack actuator according to claim 11, wherein the coupling area (K) has at least one or more of the following features: a. the at least one coupling area (K) is at the envelope of the actuator while maintaining the insulating function of the envelope; b. the at least one coupling area (K) is formed at an additional element arranged between two actuators to be coupled, wherein the additional element is embodied as an electrode; c. the at least one coupling area (K) is formed at one or both axial end(s) of the actuator or the additional element, respectively, such that the coupling area (K) forms one of or both axial ends of the actuator or the additional element, respectively; and/or d. the at least one coupling area (K) is configured and designed such that with respect to the projection area (P) of the actuator, the area ratio is selected to be one or more of: 0.1*P<K<P, 0.5*P<K<0.95*P, and/or 0.75*P<K<0.9*P.
19. Piezoelectric stack actuator according to claim 11, wherein the stack actuator has at least one or more of the following features: a. at least one additional element is arranged between two adjacent actuators, wherein the additional element is embodied as an electrode; b. at least two adjacent actuators are directly actively connected or indirectly actively connected via an additional element, by a firmly bonded connection between the adjacent actuators or between each one of the adjacent actuators and the additional element arranged there between, by an adhesive, wherein the adhesive glues the at least one coupling area (K) completely; c. at least two adjacent actuators are decoupled from each other, except for the at least one coupling area (K), in an edge region, in the coupling plane, by removing piezoceramic material and/or adhesive and/or by applying release agents before gluing; and/or d. electrodes of the actuators with same polarities are connected to each other by a connecting section, wherein the connecting section is applied onto the electrodes.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0069] In the drawings:
[0070]
[0071]
[0072]
[0073]
[0074]
[0075]
[0076]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0077] The preferred embodiments of the invention will be described below in detail with reference to the enclosed drawings.
[0078] Each actuator 2 of the stack actuator 1 is made up as a single- or multi-layer actuator of piezoceramic 2a and electric contacts or electrode layers (inner electrodes) 2c, 2e. The piezoceramic layers 2a are stacked along the axis A such that two adjacent piezoceramic layers 2a face each other with the insertion of one electric contact (inner electrode) each in the form of an electrode layer or disk 2c, 2e with poles 2b, 2d of the same polarities.
[0079] The electric contacts (inner electrodes) 2c, 2e are in turn connected to (outer) electrodes (or side electrodes, respectively) 25, 26 of a corresponding polarity which are arranged spaced apart at the periphery at the actuator 2 on diametrically opposed sides of the actuator 2. The arrangement of the (outer) electrodes (or side electrodes, respectively) 25, 26 in direct proximity with respect to each other, however, may also be advantageous. In the present example, an electrode layer 2c is connected as an inner electrode to the positive pole 2b of the piezoceramic layer 2a and connected to the positive outer electrode 25 (in
[0080] The piezoceramic layers 2a and the electric contacts or electrode layers (inner electrodes) 2c, 2e have different sizes and are stacked one upon the other such that the piezoceramic layers 2a extend radially to the axis A beyond the electric contacts or electrode layers (inner electrodes) 2c, 2e. Thereby, the electric contacts or electrode layers (inner electrodes) 2c, 2e are surrounded at their edges by piezoceramic material to create an air- and moisture-tight “insulation” permitting the use of the actuator 2 in a damp environment. The sections of the piezoceramic layers 2a covered and activatable by the electric contacts or electrode layers (inner electrodes) 2c, 2e, or the sections which, with a projection onto a plane oriented perpendicularly to the axis A, are located radially within the electric contacts or electrode layer (inner electrodes) 2c, 2e, form the active region of the actuator (in
[0081] The actuator 2 represented in
[0082] In a preferred embodiment, a monolithically sintered ceramic insulating layer 20 surrounds the actuator 2 at its periphery with the exception of the negative electrode 25 and the positive electrode 26.
[0083] In the present example, a circular coupling area K is formed at the upper side 21 of each actuator 2 of a piezoceramic material. The coupling area K extends in a plane E perpendicular to the axis A concentrically to the axis A of the actuator 2 and is arranged axially offset to the top by a step with respect to an adjacent and surrounding edge region of the actuator 2 to form the upper axial end of the actuator 2.
[0084] As an alternative or in addition to the upper-side coupling area K, at the bottom side of the actuator 2, a corresponding coupling area K can be formed (cf.
[0085] The coupling area K is, according to the invention, smaller than a projection area P of the actuator 2 onto a plane E perpendicular to the axis A. The meaning of this feature will be illustrated with reference to
[0086] Each actuator 2 generates a deflection along its axis A when electrically activated. This direction of deflection corresponds to the axis A along which the piezoceramic layers 2a are stacked one upon the other. When electrically activated, the active region of the actuator 2 (represented in a shaded manner in
[0087] In the present example, with a projection onto a plane E perpendicular to the stacking axis S, the coupling area K is located completely within the projection area P of the actuator 2 and is surrounded by the projection area P across its complete periphery (cf.
[0088] For illustrating the principle of the invention with reference to the figures, among other things, stack actuators 1 which are made up from such actuators 2 will be described below. The number of actuators 2 coupled into a stack actuator 1 is not restricted.
[0089] The piezoelectric stack actuator 1 illustrated in
[0090] In the stack actuator 1 represented in
[0091] The identically designed actuators 2 (cf.
[0092] In the example according to
[0093] The (outer/side) electrodes 25, 26 of the actuators 2 with the same polarities are connected to each other by a connecting section 11, the connecting section 11 being fixed to the corresponding electrode of each actuator 2 at an individual fixing point 12.
[0094] In the coupling plane which includes the coupling area K, the edge regions of the actuators 2 are decoupled from each other outside the coupling area K and freely movable with respect to each other. Consequently, peak loads caused by passive deformations of the piezoceramic layers 2a can be reduced without mutually blocking the coupling of the actuators 2 in the edge regions. Thereby, a crack formation is prevented and the service life of the stack actuator 1 is considerably increased.
[0095] In the present example, each coupling area K is designed as a plane extending perpendicularly to the axis A or S, respectively. The area dimension of the coupling area K is approximately 0.9-times or 90% of the projection area P of the actuator 2 onto the plane perpendicular to the axis A.
[0096] In other words, the advantage of the invention, according to which the coupling area K is reduced compared to the flat extension of the actuator 2 in a plane perpendicular to the axis A, is analogously that the adjacent actuators 2 in the edge regions formed by passive insulation edges are selectively decoupled from each other. In each actuator 2, tensile stresses occur in the so-called passive region in case of expansions since it does not contain any electrodes 2b and therefore does not actively deform. Due to the low height of the actuators 2 and a passive deformation of the edge regions, the tensile stress is below a critical load in each individual actuator 2. When the actuators 2 are glued all-over across their complete cross-sectional areas (extension in a plane perpendicular to the axis A), the coupling of the actuators would block and prevent this deformation. The effect will be increased the more actuators 2 are glued one upon the other. The stresses caused by the deformation would sum up without any countermeasures being taken and exceed the final strength of the passive boundary layer. At the weakest points, a crack formation would result without the features according to the invention.
[0097] A stress relief by the adhesive layers is usually not sufficient since for achieving high actuator stiffness, stiff adhesives and very thin glue gaps are employed. It is nevertheless within the scope of the invention that even soft and damping adhesives may be used.
[0098] Gluing is therefore preferably only performed at the coupling areas K, and not in the edge regions of the actuators 2 which surround the coupling areas K in the coupling planes. The coupling areas K are smaller than the flat extension of the actuators 2 to be coupled in a plane E perpendicular to the stacking axis S, or smaller than the projection areas P of the actuators 2 to be coupled onto a plane E perpendicular to the axis A or S, respectively (cf.
[0099] To realize the subject matter of the invention, different variants of the embodiment are conceivable.
[0100] It is on the one hand possible to leave the adhesive away in the edge region. Technically, this is complicated since the adhesive will flow during curing under pressure and often also at an increased temperature. A defined and reproducible gluing on an unlimited area within a plane is thus hardly possible. Therefore, the coupling area K is preferably arranged offset to the adjacent areas or limited.
[0101] Preferably, a release agent is therefore applied in the region of the insulation edge which delimits the coupling area K by preventing either the contact with the adhesive or at least its adhesion to at least one connecting partner.
[0102] As an alternative, a thin additional element 3 with a smaller cross-section can be introduced between two actuators 2 each, wherein the additional element 3 forms the coupling areas K to the adjacent actuators 2 (
[0103] Working out a small step at the axial front sides of the individual actuators 2 is also possible (
[0104] Instead of the step, a chamfer or any other recess can be also used (
[0105] With high-voltage actuators, a thin plate with a reduced cross-section is glued between the actuator segments by default (
[0106] A solution approach for this type of actuator is the application of a protective layer which does not completely fill the gaps. This is possible on the one hand by applying a very thin layer (e. g. evaporation, spraying, . . . ). Furthermore, the application of a film instead of a liquid is possible.
[0107] A further alternative is to fill the gaps with a resilient material. Subsequently, the stack can be enveloped as usual.
[0108] For both types of actuators 2, the mentioned solution approaches are applicable for arbitrary cross-sections with respect to the shape (round, oval, rectangular, . . . ) and size.
[0109] Here, not only full cross-sections are conceivable, but also hollow cross-sections, for example in the form of hollow cylinders.
[0110] Tests with various actuators 2 showed that the service life with a static tension of individual chip actuators is usually essentially higher than that of glued chip stacks, in some cases even by at least the factor 2.
[0111] By the decoupling of the critical regions of the chips according to the invention, the advantage with respect to the service life in a glued stack is maintained.
[0112] With actuators 2 that have a circular cross-section in a plane perpendicular to the stacking axis S, the ratio of the diameter D to the height H can be specified. In an advantageous development of the above-described embodiments, the ratio is D/H≥1, preferably D/H >5, and particularly preferred D/H=6.4. It can furthermore make sense for D/H to be <50.
[0113] With actuators 2 that have a rectangular cross-section in a plane perpendicular to the stacking axis S, the ratio of the edge length L to the height H can be specified. In an advantageous development relating to actuators 2 with a rectangular cross-section, the ratio is L/H ≥1, preferably L/H >5, and particularly preferred L/H=6.4. It can furthermore make sense for L/H <50.
[0114] With such D/H and L/H ratios it is possible to provide actuators with a high stiffness and simultaneously a high deflection which also have a minimum tendency to crack and consequently a high reliability.
[0115] With actuators 2 with a circular cross-section, there is in general an advantage compared to actuators 2 with a rectangular cross-section in that a more uniform deformation in the transition region between the active and the passive regions takes place since the passive region has a constant radial distance from the stacking axis S, which is not the case in square or rectangular actuator cross-sections.
LIST OF REFERENCE NUMERALS
[0116] 1 stack actuator [0117] 2 actuator [0118] 2a piezoceramic layer [0119] 2b positive pole [0120] 2c contact (plate) or (inner) electrode for positive pole [0121] 2d negative pole [0122] 2e contact (plate) or (inner) electrode for negative pole [0123] 3 additional element [0124] 20 insulation [0125] 21 upper side [0126] 22 bottom side [0127] 23 step/chamfer at the upper side [0128] 24 step/chamfer at the bottom side [0129] 25 (outer/side) electrode positive pole [0130] 26 (outer/side) electrode negative pole [0131] A axis [0132] D diameter of an actuator with a circular cross-section [0133] E plane perpendicular to the stacking axis [0134] H height of an actuator [0135] K coupling area [0136] L edge length of an actuator with a rectangular cross-section [0137] P projection area onto the plane perpendicular to the axis [0138] S stacking axis