Batch‐Sprayed and Stamp‐Transferred Electrodes: A New Paradigm for Scalable Fabrication of Multilayer Dielectric Elastomer Actuators
Abstract
Multilayer dielectric elastomer actuators have a wide range of potential applications, but their development and commercial implementation have been hindered by existing manufacturing processes. Existing processes are low‐throughput, limited in area, and/or can only process a narrow range of elastomers. This study presents a novel fabrication paradigm that overcomes these challenges: instead of sequentially patterning electrodes directly onto successive elastomer layers, electrode stamps are patterned onto a carrier film in an independent batch‐spray process and the electrodes are then stamp‐transferred onto each elastomer layer. By modularizing the production and assembly of electrodes, a laboratory‐scale implementation of the process achieves a throughput of 15 layers h−1, a maximum electrode size of 300×300 mm, and tuning‐free compatibility with a wide range of elastomers. The batch‐spraying paradigm also provides the unique capability to evaluate and modify electrodes before they are assembled into a multilayer; a method of mechanically treating the electrodes is employed to increase the breakdown strength of Elastosil P7670 devices from 15.7 to 33.5 V µm−1. The electrodes are conductive up to a strain of more than 200% and add negligible stiffness to the multilayer structure. The capabilities of this process to produce useful devices are demonstrated with a large‐area loudspeaker and an actuator with 60 active layers.
Document Details
- Document Type
- Pub Defense Publication
- Publication Date
- Aug 21, 2022
- Source ID
- 10.1002/adfm.202205394
Entities
People
- Andy J. Cohen
- Dae‐young Lee
- David R Clarke
- Matthias Kollosche
- Michelle C Yuen
- Robert J Wood
Organizations
- Harvard University
- KAIST
- Meta
- National Science Foundation