U.S. patent application number 12/510641 was filed with the patent office on 2010-04-15 for actuator and method for manufacturing planar electrode support for actuator.
Invention is credited to Katsuhiko ASAI, Nozomu MATSUKAWA, Masaki YAMAMOTO, Kazuo YOKOYAMA.
Application Number | 20100089524 12/510641 |
Document ID | / |
Family ID | 34835933 |
Filed Date | 2010-04-15 |
United States Patent
Application |
20100089524 |
Kind Code |
A1 |
YOKOYAMA; Kazuo ; et
al. |
April 15, 2010 |
ACTUATOR AND METHOD FOR MANUFACTURING PLANAR ELECTRODE SUPPORT FOR
ACTUATOR
Abstract
An actuator as a drive source of robots and the like is usable
for housekeeping assistance, job assistance, and nursing help. The
drive source itself is small, light, flexible, and safe. A
manufacturing method for a planar electrode support therefor is
also described. The actuator has an electrolyte layer in contact
with a conductive polymer layer disposed in between a first
electrode having the conductive polymer layer attached thereto and
opposite second electrode, for deforming the conductive polymer
layer by application of electric fields to the electrodes. The
first electrode has low rigidity in a longitudinal direction of the
conductive polymer layer to facilitate expansion and contraction
thereof.
Inventors: |
YOKOYAMA; Kazuo; (Osaka,
JP) ; ASAI; Katsuhiko; (Nara, JP) ; MATSUKAWA;
Nozomu; (Nara, JP) ; YAMAMOTO; Masaki; (Nara,
JP) |
Correspondence
Address: |
WENDEROTH, LIND & PONACK L.L.P.
1030 15th Street, N.W., Suite 400 East
Washington
DC
20005-1503
US
|
Family ID: |
34835933 |
Appl. No.: |
12/510641 |
Filed: |
July 28, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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|
10588260 |
Aug 3, 2006 |
7586242 |
|
|
PCT/JP2005/001591 |
Feb 3, 2005 |
|
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12510641 |
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Current U.S.
Class: |
156/221 ;
216/13 |
Current CPC
Class: |
Y10S 310/80 20130101;
Y10T 156/1043 20150115; H02N 11/006 20130101; B25J 9/1095
20130101 |
Class at
Publication: |
156/221 ;
216/13 |
International
Class: |
B32B 37/02 20060101
B32B037/02; B44C 1/22 20060101 B44C001/22 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 5, 2004 |
JP |
2004-028838 |
Claims
1-15. (canceled)
16. A manufacturing method for a planar electrode support for a
flat-plate low-profile actuator, in which the flat-plate
low-profile actuator has an electrolyte layer in contact with a
conductive polymer layer disposed in between an electrode having
the planar conductive polymer layer attached thereto and an
opposite electrode for deforming the conductive polymer layer to be
swelled and shrunken by application of electric fields to between
both electrodes, and the planar electrode support is composed of
the conductive polymer layer and the electrodes, comprising:
patterning a planar electrode as the electrode through etching or
punching to have at least one bent portion along a longitudinal
direction that is an expansion and contraction direction of the
conductive polymer layer so that rigidity in the longitudinal
direction is low while rigidity in a width direction almost
orthogonal to the longitudinal direction is high; and in a state
that the patterned planar electrode is in contact with another flat
plate, forming the conductive polymer layer on the electrode by
electrolytic polymerization or casting method, and then removing
the flat plate to manufacture the planar electrode support.
17. The manufacturing method for a planar electrode support for a
flat-plate low-profile actuator as defined in claim 16, wherein the
conductive polymer layer is further formed, by electrolytic
polymerization or casting, on a surface with the flat plate being
removed to manufacture the planar electrode support.
18. The manufacturing method for a planar electrode support for a
flat-plate low-profile actuator as defined in claim 16, wherein in
a state that the planar electrode to make the electrode is linked
to a cutoff portion, which will not remain as the electrode,
through a cutoff portion link portion, the conductive polymer layer
is formed on the electrode by electrolytic polymerization or
casting and then the cutoff portion is removed by cutting at the
cutoff portion link portion to manufacture the planar electrode
support.
19. The manufacturing method for a planar electrode support for a
flat-plate low-profile actuator as defined in claim 16, wherein the
planar electrode to make the electrode is a magnetic substance, and
the electrode made of the magnetic substance is brought into
contact with the another flat plate through attraction by magnetic
force.
Description
TECHNICAL FIELD
[0001] The present invention relates to a flat-plate low-profile
actuator that is applicable to household robots and the like, is
deformed by electrical impulses, and has flexibility and light
weight, and to a manufacturing method for a planar electrode
support for the flat-plate low-profile actuator.
BACKGROUND ART
[0002] Several conventional drive sources are used for joint drive
mechanisms of industrial robots including electromagnetic motors,
hydraulic actuators, and pneumatic actuators. The joint drive
mechanisms using these drive sources, which include those using
electromagnetic motors and reduction mechanisms mainly made from
metals and those using metal hydraulic/pneumatic cylinders, are
themselves made of hard and heavy materials and are managed and
used in specific locations within factories.
[0003] Drive sources of apparatuses such as robots which are
expected to operate near the presence of human beings for
housekeeping assistance, job assistance, and nursing help for
elderly and physically-challenged persons in homes, offices, and
hospitals, are required to be small, light, flexible, safe.
[0004] Examples of such actuators include a rubber pneumatic
actuator having high flexibility among the pneumatic actuators,
though this actuator requires auxiliary equipment such as
compressors and control valves for driving, which limits weight
reduction of the entire system.
[0005] Accordingly, an artificial muscle actuator using various
kinds of polymer materials which have light weight and high
flexibility has been proposed, and its practical application is
much desired.
[0006] A polymer actuator operated by electric impulses is
described in the keynote speech in Non Patent Document 1 (S G. Wax,
R. R. Sands, Smart Structures And Materials 1999: Electroactive
Polymer Actuators and Devices, Proc. SPIE, Vol. 3669, pp. 2-10,
1999). A conference concerning research in this field is held
annually, and active research efforts are being made. The research
is about polymer actuators, which are made of polymer gels, metal
composite ion polymers, organic conductive polymers, carbon
dispersion conductive polymers, dielectric elastomers, and the like
which are driven by electric impulses. Among these, the conductive
polymers such as the organic conductive polymers and the carbon
dispersion conductive polymers can be driven at relatively low
voltage and generate stress having a capacity larger than living
body muscles, and have characteristics such as light weight and
flexibility.
[0007] As an example of the conductive polymers, Patent Document 1
(Japanese Unexamined Patent Publication No. H11-169394) discloses
an actuator manufactured by forming metal electrodes on a
polyaniline film article that is an organic conductive polymer and
sandwiching the metal electrode between solid electrolyte molding
objects. While the organic conductive polymers themselves have
conductivity and so a voltage can be applied by using these as
electrodes, the metal electrodes are formed for the purpose of
avoiding voltage drop caused by resistance of the conductive
polymers. By applying a voltage to between these electrodes, anions
in the solid electrolyte molding objects move from the cathode to
the anode, as a result of which the polyanilines in the anodes are
doped with anions and swell. Contrary to this, the polyanilines in
the cathode are subject to the reverse action, that is, the anions
are separated from the polyanilines and the polyanilines shrink. As
a result, the actuator composed of the conductive polymer and the
polyaniline film article is curved. This is a phenomenon of the
thin film article being deflected to provide a large displacement,
though the deflection rigidity is too low to produce large
forces.
[0008] An example of the actuator in which a conductive polymer is
not deformed by deflection but deformed by expansion and
contraction in its longitudinal direction, and in which an organic
conductive polymer is attached to a metallic coil spring as an
electrode is disclosed in Non Patent Document 2 (Gordon G. Wallace
etc., Smart Structures And Materials 2002: Electroactive Polymer
Actuators and Devices, Proc. SPIE, Vol. 4695, pp. 8-16, 2002.). The
organic conductive polymer is a cylinder shape, resulting in a
small effective cross-sectional area for generating generative
force in a bundle. Further in this example, a cylinder-shaped
conductive polymer with a coil spring is structured to be housed in
a cylinder-shaped container in order to seal an electric field
liquid, which further decreases the effective cross-sectional area.
Moreover, a force action portion is structured so as to be combined
with a movable pin and a spring, which complicates
manufacturing.
[0009] Moreover, Patent Document 2 (Japanese Unexamined Patent
Publication No. H07-83159) and Patent Document 3 (Japanese
Unexamined Patent Publication No. H06-133922) each disclose an
actuator having an electrode formed into a cylinder shape which
performs flexing actions by electric impulses. In both cases, the
actuator is formed into a cylinder shape or a coiled shape with a
large thickness, which causes the actuator to have poor
responsivity, to operate only at low speed, and which makes its
manufacturing difficult.
[0010] The term "conductive polymers" is herein used to broadly
refer to conductive polymers including an organic conductive
polymer in which the polymer itself has conductivity and a
conductive polymer doped with conductive materials such as carbon
particles.
DISCLOSURE OF INVENTION
Issues to be Solved by the Invention
[0011] Several objectives of the present invention are to provide a
flat-plate low-profile actuator and a manufacturing method for a
planar electrode support for the flat-plate low-profile actuator
using a conductive polymer, which is capable of generating large
force and operating at high speed, and which is easy to manufacture
and excellent in reliability, for solving the above identified
issues.
Means for Solving the Issues
[0012] In order to accomplish these objectives, the present
invention is structured as shown below.
[0013] According to the present invention, there is provided a
flat-plate low-profile actuator, comprising:
[0014] a planar conductive polymer layer;
[0015] an electrode in contact with the conductive polymer
layer;
[0016] an opposite electrode opposite to the electrode; and
[0017] an electrolyte layer in contact with the conductive polymer
layer, disposed in between the electrode and the opposite
electrode, [0018] the electrode being a planar electrode patterned
to have at least one bent portion along a longitudinal direction
that is an expansion and contraction direction of the conductive
polymer layer so that rigidity in the longitudinal direction is low
while rigidity in a width direction almost orthogonal to the
longitudinal direction is high, the conductive polymer layer being
deformed to be swelled and shrunken by application of electric
fields to between both the electrodes.
[0019] According to the present invention, there is provided a
flat-plate low-profile actuator, comprising:
[0020] a planar conductive polymer layer;
[0021] an electrode in contact with the conductive polymer
layer;
[0022] an opposite electrode opposite to the electrode; and
[0023] an electrolyte layer in contact with the conductive polymer
layer, disposed in between the electrode and the opposite
electrode, [0024] the electrode being a planar electrode patterned
to have at least one bent portion along an output direction of
drive force associated with expansion and contraction of the
conductive polymer layer so that rigidity in the output direction
is low while rigidity in a direction almost orthogonal to the
output direction is high, the conductive polymer layer being
deformed to be swelled and shrunken by application of electric
fields to between both the electrodes so that the drive force is
outputted in the output direction.
[0025] According to the present invention, there is provided a
manufacturing method for a planar electrode support for a
flat-plate low-profile actuator, in which the flat-plate
low-profile actuator has an electrolyte layer in contact with a
conductive polymer layer disposed in between an electrode having
the planar conductive polymer layer attached thereto and an
opposite electrode for deforming the conductive polymer layer to be
swelled and shrunken by application of electric fields to between
both electrodes, and the planar electrode support is composed of
the conductive polymer layer and the electrodes, comprising: [0026]
patterning a planar electrode as the electrode through etching or
punching to have at least one bent portion along a longitudinal
direction that is an expansion and contraction direction of the
conductive polymer layer so that rigidity in the longitudinal
direction is low while rigidity in a width direction almost
orthogonal to the longitudinal direction is high; and
[0027] in a state that the patterned planar electrode is in contact
with another flat plate, forming the conductive polymer layer on
the electrode by electrolytic polymerization or casting method, and
then removing the flat plate to manufacture the planar electrode
support.
EFFECTS OF THE INVENTION
[0028] According to the present invention, it becomes possible to
provide the flat-plate low-profile actuator having the electrolyte
layer in contact with the conductive polymer layer and disposed in
between the electrode having the planar conductive polymer layer
attached thereto and the opposite electrode for deforming the
conductive polymer layer to be swelled and shrunken by application
of electric fields to between both electrodes, in which the
electrode having the conductive polymer layer attached thereto can
be the planar electrode also serving as the support, which is
patterned (pattern-formed) so that rigidity in the longitudinal
direction that is an expansion and contraction direction of the
conductive polymer layer (i.e., an output direction of drive force
of the actuator) is low while rigidity in the width direction
almost orthogonal to the longitudinal direction is high.
Consequently, it becomes possible to realize an actuator as a drive
source of apparatuses such as the robots, which are expected to
operate near the presence of human beings for housekeeping
assistance, job assistance, and nursing help for elderly and
physically-challenged persons in homes, offices, and hospitals, and
in which the drive source is small, light, flexible, and safe. It
becomes also possible to provide a manufacturing method for, as
such an actuator, a flat-plate low-profile actuator, as well as a
planar electrode support of the flat-plate low-profile actuator,
which is capable of generating large force and operating at high
speed and which is easy to manufacture and excellent in
reliability.
BRIEF DESCRIPTION OF DRAWINGS
[0029] These and other aspects and features of the present
invention will become clear from the following description taken in
conjunction with the preferred embodiments thereof with reference
to the accompanying drawings, in which:
[0030] FIG. 1A is a plane view showing an actuator in one
configuration in a first embodiment of the present invention;
[0031] FIG. 1B is a cross sectional view showing the actuator in
the one configuration in the first embodiment of the present
invention;
[0032] FIG. 1C is a plane view showing an actuator in another
configuration in the first embodiment of the present invention;
[0033] FIG. 1D is a cross sectional view showing the actuator in
the another configuration in the first embodiment of the present
invention;
[0034] FIG. 2A is a cross sectional view explaining the operation
principle of the actuator of the present invention;
[0035] FIG. 2B is a cross sectional view explaining the operation
principle of the actuator of the present invention;
[0036] FIG. 2C is a cross sectional view explaining the operation
principle of the actuator of the present invention;
[0037] FIG. 2D is a cross sectional view explaining the operation
principle of the actuator of the present invention;
[0038] FIG. 3A is a plane view showing expansion and contraction
operation of the actuator in the first embodiment of the present
invention;
[0039] FIG. 3B is a plane view showing expansion and contraction
operation of an actuator in a schematic configuration in the first
embodiment of the present invention;
[0040] FIG. 3C is a plane view showing expansion and contraction
operation of an actuator in another configuration in the first
embodiment of the present invention;
[0041] FIG. 3D is a plane view showing expansion and contraction
operation of the actuator in the configuration in FIG. 3C in the
first embodiment of the present invention;
[0042] FIG. 3E is a plane view showing expansion and contraction
operation of an actuator in another configuration in the first
embodiment of the present invention;
[0043] FIG. 3F is a plane view showing expansion and contraction
operation of an actuator in another configuration in the first
embodiment of the present invention;
[0044] FIG. 3G is a plane view showing expansion and contraction
operation of an actuator in another configuration in the first
embodiment of the present invention;
[0045] FIG. 3H is a plane view showing expansion and contraction
operation of an actuator in another configuration in the first
embodiment of the present invention;
[0046] FIG. 4 is a view showing a table of comparison of rigidity
between an electrode having a pattern form in patterning according
to the first embodiment of the present invention and electrodes
having other forms;
[0047] FIG. 5A is a plane view showing a reference example for
explaining the result of analysis and calculation of a deformed
state of the actuator in the first embodiment of the present
invention;
[0048] FIG. 5B is a plane view showing the result of analysis and
calculation of a deformed state of the actuator in the first
embodiment of the present invention;
[0049] FIG. 5C is a plane view showing a result of analysis and
calculation of the deformed state of an actuator having an
electrode form in (c) of FIG. 4 for explaining the result of
analysis and calculation of a deformed state of the actuator in the
first embodiment of the present invention;
[0050] FIG. 5D is a plane view showing the result of analysis and
calculation of a deformed state of an actuator having an electrode
form of (d) of FIG. 4 for explaining the result of analysis and
calculation of a deformed state of the actuator in the first
embodiment of the present invention;
[0051] FIG. 5E is a graph showing the relationship between a
thickness of a conductive polymer layer and a displacement amount
of the actuator of FIG. 5B in the first embodiment of the present
invention when a length of the actuator is 8 mm and a film
thickness of the electrode of the actuator is changed (5 .mu.m, 10
.mu.m, 20 .mu.m);
[0052] FIG. 5F is a graph showing the relationship between a
thickness of a conductive polymer layer and a growth rate of a
displacement amount (displacement growth rate) of the actuator of
FIG. 5B in the first embodiment of the present invention when a
length of the actuator is 8 mm and a film thickness of the
electrode of the actuator is changed (5 .mu.m, 10 .mu.m, 20
.mu.m);
[0053] FIG. 5G is a graph showing the result of FIG. 5F by taking
the displacement growth rate as a vertical axis and a ratio of
(thickness of conductive polymer layer/film thickness of electrode)
as a horizontal axis;
[0054] FIG. 6 is a plane view showing an electrode on a flat
surface as an experimental model of the first embodiment of the
present invention;
[0055] FIG. 7A is a plane view showing an actuator in a second
embodiment of the present invention;
[0056] FIG. 7B is a cross sectional view showing the actuator in
the second embodiment of the present invention;
[0057] FIG. 8A is a plane view showing an actuator in another
configuration in the second embodiment of the present
invention;
[0058] FIG. 8B is a cross sectional view showing the actuator in
the another configuration in the second embodiment of the present
invention;
[0059] FIG. 9A is a plane view showing an actuator in still another
configuration in the second embodiment of the present
invention;
[0060] FIG. 9B is a cross sectional view showing an actuator in yet
another configuration in the second embodiment of the present
invention;
[0061] FIG. 10A is a plane view showing an actuator in a third
embodiment of the present invention;
[0062] FIG. 10B is a cross sectional view showing the actuator in
the third embodiment of the present invention;
[0063] FIG. 11A is a plane view showing an actuator in another
configuration in the third embodiment of the present invention;
[0064] FIG. 11B is a cross sectional view showing the actuator in
the another configuration in the third embodiment of the present
invention;
[0065] FIG. 12A is a plane view showing a planar electrode being
supported in the state of being in close contact with another flat
plate in a manufacturing method for a planar electrode support
equipped with a conductive polymer in a fourth embodiment of the
present invention;
[0066] FIG. 12B is a cross sectional view showing the planar
electrode being supported in the state of being in close contact
with the another flat plate in the manufacturing method for a
planar electrode support equipped with a conductive polymer in the
fourth embodiment of the present invention;
[0067] FIG. 12C is a plane view showing the state where the
conductive polymer layer is formed so as to cover most parts of the
planar electrode and the flat plate in the manufacturing method for
a planar electrode support equipped with a conductive polymer in
the fourth embodiment of the present invention;
[0068] FIG. 12D is a cross sectional view showing the state where
the conductive polymer layer is formed so as to cover most parts of
the planar electrode and the flat plate in the manufacturing method
for a planar electrode support equipped with a conductive polymer
in the fourth embodiment of the present invention;
[0069] FIG. 12E is a plane view showing the state where the flat
plate is removed from the electrode and the conductive polymer
layer in the manufacturing method for a planar electrode support
equipped with a conductive polymer in the fourth embodiment of the
present invention;
[0070] FIG. 12F is a cross sectional view showing the state where
the flat plate is removed from the electrode and the conductive
polymer layer in the manufacturing method for a planar electrode
support equipped with a conductive polymer in the fourth embodiment
of the present invention;
[0071] FIG. 12G is a cross sectional view showing the state where a
conductive polymer layer is formed also on the back surface of the
conductive polymer layer in the manufacturing method for a planar
electrode support equipped with a conductive polymer in the fourth
embodiment of the present invention;
[0072] FIG. 12H is a plane view showing the state where cutoff
portions on both sides are respectively cut off from the planar
electrode in the manufacturing method for a planar electrode
support equipped with a conductive polymer in the fourth embodiment
of the present invention;
[0073] FIG. 12I is a cross sectional view showing the state where
cutoff portions on both sides are respectively cut off from the
planar electrode in the manufacturing method for a planar electrode
support equipped with a conductive polymer in the fourth embodiment
of the present invention;
[0074] FIG. 13A is a plane view showing the state where a
conductive polymer layer is formed on a substrate and an electrode
sandwiched by a regulating jig for use in the manufacturing method
in the fourth embodiment of the present invention;
[0075] FIG. 13B is a cross sectional view showing the state where
the conductive polymer layer is formed on the substrate and the
electrode sandwiched by the regulating jig for use in the
manufacturing method in the fourth embodiment of the present
invention;
[0076] FIG. 13C is a plane view showing the state where a
conductive polymer layer is formed on the substrate and the
electrode sandwiched by a regulating jig with a magnet embedded in
a base for use in a manufacturing method in a modified example of
the fourth embodiment of the present invention;
[0077] FIG. 13D is a cross sectional view showing the state where
the conductive polymer layer is formed on the substrate and the
electrode sandwiched by the regulating jig of FIG. 13C;
[0078] FIG. 13E is a partially enlarged view showing a failure
which may occur in the case of using the regulating jigs of FIG.
13A and FIG. 13B;
[0079] FIG. 13F is a cross sectional view showing the state where
the magnet attracts the electrode to the side of the magnet by use
of the regulating jigs of FIG. 13D;
[0080] FIG. 14A is a side view showing a joint drive mechanism in a
non drive state in a fifth embodiment of the present invention in
which the actuator in the embodiment of the present invention being
applied to an actuator of a joint drive mechanism; and
[0081] FIG. 14B is a side view showing the joint drive mechanism in
a drive state in the fifth embodiment of the present invention in
which the actuator in the embodiment of the present invention being
applied to the actuator of the joint drive mechanism.
BEST MODE FOR CARRYING OUT THE INVENTION
[0082] Hereinbelow, the embodiments of the present invention will
be described in detail with reference to the drawings.
[0083] Before the embodiments of the present invention will be
described in detail, various aspects of the present invention will
be describes below.
[0084] According to a first aspect of the present invention, there
is provided a flat-plate low-profile actuator, comprising:
[0085] a planar conductive polymer layer;
[0086] an electrode in contact with the conductive polymer
layer;
[0087] an opposite electrode opposite to the electrode; and
[0088] an electrolyte layer in contact with the conductive polymer
layer, disposed in between the electrode and the opposite
electrode, [0089] the electrode being a planar electrode patterned
to have at least one bent portion along a longitudinal direction
that is an expansion and contraction direction of the conductive
polymer layer so that rigidity in the longitudinal direction is low
while rigidity in a width direction almost orthogonal to the
longitudinal direction is high, the conductive polymer layer being
deformed to be swelled and shrunken by application of electric
fields to between both the electrodes.
[0090] According to a second aspect of the present invention, there
is provided the flat-plate low-profile actuator as defined in the
first aspect, wherein the electrode is a zigzag-shaped planar
electrode having a plurality of bent portions along the
longitudinal direction that is the expansion and contraction
direction of the conductive polymer layer.
[0091] According to a third aspect of the present invention, there
is provided the flat-plate low-profile actuator as defined in the
first or second aspect, wherein the electrode is a planar electrode
comprising: a plurality of band-like portions along the width
direction almost orthogonal to the longitudinal direction that is
the expansion and contraction direction of the conductive polymer
layer; and link portions along the longitudinal direction for
linking the adjacent band-like portions.
[0092] According to a fourth aspect of the present invention, there
is provided the flat-plate low-profile actuator as defined in any
one of the first to third aspects, further comprising planar
extension portions disposed on both sides of the electrode in the
longitudinal direction that is the expansion and contraction
direction of the conductive polymer layer, the planar extension
portions being used as force action portions.
[0093] According to a fifth aspect of the present invention, there
is provided the flat-plate low-profile actuator as defined in the
fourth aspect, wherein the conductive polymer layer is placed on
both front and back surfaces of the electrode, and a hole is
provided on the force action portion that is the extension portion
of the electrode so as to link the front and back conductive
polymer layers for reinforcement.
[0094] According to a sixth aspect of the present invention, there
is provided the flat-plate low-profile actuator as defined in any
one of the first to fifth aspects, wherein the electrode and the
opposite electrode placed on the conductive polymer layer are
stacked in such a way as to be alternately disposed.
[0095] According to a seventh aspect of the present invention,
there is provided the flat-plate low-profile actuator as defined in
any one of the first to sixth aspects, wherein the electrode is a
thin plate made of: metal including gold, platinum, nickel,
titanium, and stainless steel; alloy thereof; or carbon, or any one
of these thin plates coated with these material groups or subjected
to surface treatment such as chemical oxidation.
[0096] According to an eighth aspect of the present invention,
there is provided a flat-plate low-profile actuator as defined in
any one of the first to seventh aspects, wherein the conductive
polymer layer is composed of a pi-conjugated polymer with a
substrate of polyaniline, polypyrrole, or polythiophene; any one of
organic conductive polymers which are derivatives thereof; or a
carbon dispersion conductive polymer such as carbon fine particles,
carbon nanotubes, and carbon fibers.
[0097] According to a ninth aspect of the present invention, there
is provided the flat-plate low-profile actuator as defined in any
one of the first to eighth aspects, wherein the electrolyte layer
is a polymer gel or a polymer containing an ionic liquid.
[0098] According to a 10th aspect of the present invention, there
is provided the flat-plate low-profile actuator as defined in the
first or second aspect, wherein a ratio of a thickness of the
conductive polymer layer to a thickness of the electrode is not
more than 3.
[0099] According to an 11th aspect of the present invention, there
is provided a flat-plate low-profile actuator, comprising:
[0100] a planar conductive polymer layer;
[0101] an electrode in contact with the conductive polymer
layer;
[0102] an opposite electrode opposite to the electrode; and
[0103] an electrolyte layer in contact with the conductive polymer
layer, disposed in between the electrode and the opposite
electrode, [0104] the electrode being a planar electrode patterned
to have at least one bent portion along an output direction of
drive force associated with expansion and contraction of the
conductive polymer layer so that rigidity in the output direction
is low while rigidity in a direction almost orthogonal to the
output direction is high, the conductive polymer layer being
deformed to be swelled and shrunken by application of electric
fields to between both the electrodes so that the drive force is
outputted in the output direction.
[0105] According to a 12th aspect of the present invention, there
is provided a manufacturing method for a planar electrode support
for a flat-plate low-profile actuator, in which the flat-plate
low-profile actuator has an electrolyte layer disposed in between
an electrode having a planar conductive polymer layer attached
thereto and an opposite electrode in the state of being in contact
with the conductive polymer layer, for deforming the conductive
polymer layer to be swelled and shrunken by application of electric
fields to between both electrodes, and the planar electrode support
is composed of the conductive polymer layer and the electrodes,
comprising: [0106] patterning a planar electrode as the electrode
through etching or stamping to have at least one bent portion along
a longitudinal direction that is an expansion and contraction
direction of the conductive polymer layer so that rigidity in the
longitudinal direction is low while rigidity in a width direction
almost orthogonal to the longitudinal direction is high; and
[0107] in a state that the patterned planar electrode is in contact
with another flat plate, forming the conductive polymer layer on
the electrode by electrolytic polymerization or casting and then
removing the flat plate to manufacture the planar electrode
support.
[0108] According to a 13th aspect of the present invention, there
is provided the manufacturing method for a planar electrode support
for a flat-plate low-profile actuator as defined in the 12th
aspect, wherein the conductive polymer layer is further formed, by
electrolytic polymerization or casting, on a surface with the flat
plate being removed to manufacture the planar electrode
support.
[0109] According to a 14th aspect of the present invention, there
is provided the manufacturing method for a planar electrode support
for a flat-plate low-profile actuator as defined in the 12th
aspect, wherein in a state that the planar electrode to make the
electrode is linked to a cutoff portion, which will not remain as
the electrode, through a cutoff portion link portion, the
conductive polymer layer is formed on the electrode by electrolytic
polymerization or casting and then the cutoff portion is removed by
cutting at the cutoff portion link portion to manufacture the
planar electrode support.
[0110] According to a 15th aspect of the present invention, there
is provided the manufacturing method for a planar electrode support
for a flat-plate low-profile actuator as defined in the 12th
aspect, wherein the planar electrode to make the electrode is a
magnetic substance, and the electrode made of the magnetic
substance is brought into contact with the another flat plate
through attraction by magnetic force.
[0111] Hereinbelow, the embodiments of the present invention will
be described in detail with reference to the drawings.
First Embodiment
[0112] FIG. 1A and FIG. 1B are a plane view and a cross sectional
view showing a flat-plate low-profile actuator in one configuration
in a first embodiment of the present invention, in which a
conductive polymer layer 3 and an opposite electrode 2 are disposed
on either one side in a thickness direction of an electrode 1,
e.g., on the lower side. This one configuration is an example of
the present invention composed of minimum component members.
[0113] FIG. 1C and FIG. 1D are a plane view and a cross sectional
view showing a flat-plate low-profile actuator in another
configuration in the first embodiment of the present invention. The
configuration in FIG. 1C and FIG. 1D is such that with respect to
the electrode 1 in the former configuration in FIG. 1A and FIG. 1B,
the conductive polymer layer 3 and the opposite electrode 2 are
disposed symmetrically in upper and lower positions along the
thickness direction. By applying in-phase voltage to two electrodes
2 opposite to the electrode 1, the actuator can be deformed to be
expanded and contracted in an expansion and contraction direction
5. In this structure, since the structure is symmetric in the
thickness direction, unnecessary bending deformation due to
rigidity imbalance will not occur, and so it becomes possible to
effectively expand and contract the actuator in a longitudinal
direction of the actuator, in other words, the expansion and
contraction direction 5 (i.e., an output direction of drive force
of the actuator), which makes the configuration more
preferable.
[0114] The actuator shown in FIG. 1A and FIG. 1B is composed of a
rectangular parallelepiped planar conductive polymer layer 3, an
electrode 1 set in such a way as to be embedded on the upper
surface of the conductive polymer layer 3 in FIG. 1A and made of
metal such as stainless steels or the like and, a rectangular
plate-like opposite electrode 2 disposed away from the electrode 1
so as to be opposed to the electrode 1 and made of metal such as
stainless steels or the like, and an electrolyte layer 4 in between
the conductive polymer layer 3 in contact with the electrode 1 and
the opposite electrode 2.
[0115] The actuator shown in FIG. 1C and FIG. 1D is composed of a
rectangular parallelepiped plate-like conductive polymer layer 3C,
an electrode 1 set in such a way as to be embedded in a center
portion in a thickness direction of the conductive polymer layer 3C
in FIG. 1D and made of metal such as stainless steels or the like,
rectangular plate-like opposite electrodes 2 disposed in upper and
lower positions away from the electrode 1 so as to be opposed to
the electrode 1, and made of metal such as stainless steels or the
like, and electrolyte layers 4 in between respective portions of
the conductive polymer layer 3C which are in contact with the
electrode 1 in upper and lower positions and the respective
opposite electrodes 2. As described before, the former actuator
(FIG. 1A and FIG. 1B) has the opposite electrode 2 disposed on only
one side of the electrode 1, whereas the latter actuator (FIG. 1C
and FIG. 1D) is different from the former in that it has the
opposite electrodes 2 disposed on both the upper and lower sides of
the electrode 1.
[0116] It is preferable, as one example, to structure a flat-plate
low-profile actuator having the conductive polymer layer with a
thickness of 80 .mu.m or less and the electrode with a thickness of
5 to 50 .mu.m. If the thickness of the electrode is less than 5
.mu.m, it becomes difficult to fulfill the function as a support,
whereas if it is over 50 .mu.m, then rigidity becomes too large and
deformation becomes difficult to achieve, thereby making this
thickness undesirable. If the thickness of the conductive polymer
layer is over 80 .mu.m, then it becomes difficult for ion species
which come and go from the front and back sides of the conductive
polymer layer to spread to the center of the film, and this
decreases generated deformation and reduces operation speed,
thereby making this thickness undesirable. Further, as one more
preferable example, it is preferable to structure a flat-plate
low-profile actuator having a conductive polymer layer with a
thickness of 30 .mu.m or less and an electrode with a thickness of
5 to 10 .mu.m.
[0117] The electrodes 1 having the conductive polymer layers 3, 3C
attached thereto in FIG. 1A to FIG. 1D are patterned
(pattern-formed) so that rigidity in the expansion and contraction
direction 5 of the conductive polymer layers 3, 3C (longitudinal
direction of the actuator in FIG. 1A) is low to make a planar
electrode. The pattern form in patterning of the electrodes 1 in
FIG. 1A to FIG. 1D is such that a number of elongated rectangular
width-direction strip-like patterns 1a are disposed so as to extend
along a width direction (width direction of the actuator) almost
orthogonal to the longitudinal direction 5 at constant intervals in
the longitudinal direction 5, and the width-direction strip-like
patterns (one example of the band portions) 1a, which extend in the
longitudinal direction, are in a rectangular short strip shape, and
are adjacent to each other, are respectively linked to link
portions 1b at width-direction end portions opposed to each other
and are bent at the respective width-direction end portions of the
actuator. Thus, when the end portions of the adjacent
width-direction strip-like patterns 1a are linked through the link
portions 1b, the link portions 1b are disposed alternately in the
longitudinal direction so that the electrode 1 constitutes a rough
zigzag shape. The rough zigzag shape herein refers to an elongated
shape which has at least one notch or space in the width direction
and which disposed in succession in the longitudinal direction 5.
If the rough zigzag shape is an uniform pattern, then operation
control of the actuator is facilitated. In the spaces formed by the
adjacent width-direction strip-like patterns 1a and the link
portions 1b, a part of the conductive polymer layers 3, 3C is
entrapped, and in FIG. 1A, the electrode 1 is embedded in the
conductive polymer layer 3 from the top surface to about half the
depth of the conductive polymer layer 3 so that in FIG. 1A, the
upper surfaces of the conductive polymer layer 3 and the electrode
1 are almost the same. In FIG. 1D, the electrode 1 is embedded in a
first conductive polymer layer 3b from the top surface to about
half the thickness of the first conductive polymer layer 3b, as in
FIG. 1A, so that the top surfaces of the first conductive polymer
layer 3b and the electrode 1 are almost the same. A thin
rectangular parallelepiped plate-like second conductive polymer
layer 3a is disposed on the top surface, as a result of which the
electrode 1 is made to be disposed in a middle portion of the
conductive polymer layer 3C, composed of the first conductive
polymer layer 3b and the second conductive polymer layer 3a. In
terms of functionality, the conductive polymer layer 3C corresponds
to the conductive polymer layer 3 in FIG. 1A.
[0118] Moreover, on both the ends of the longitudinal direction 5
(in other words, an arrow 5 may be an output direction of drive
force of the actuator) of each electrode 1 in FIG. 1A to FIG. 1D,
rectangular plate-like extension portions 1c of the electrode 1
provided and each of the extension portions 1c functions as a force
action portion. On the pattern formation side of each force action
section 1c of the electrode 1, the side being opposite to the edges
of the force action section, three holes 1d for reinforcing the
link between the electrode 1 and the conductive polymer layer 3 are
disposed in alignment along the width direction in FIG. 1A.
Further, a pin hole 1g for inserting a link pin 7 into the force
action portion is formed in the vicinity of the center of each of
the extension portions 1c, so that a hook 6 for clipping the
extension portion 1c and the extension portion 1c are linked
through the pin 7 inserted into the pin hole 1g, by which a load 8
acting onto each extension portion 1c is supported. Between the
electrode 1 and the opposite electrode 2, a power source 9 capable
of applying variable voltages to them is connected via a switch 10.
By turning the switch 10 on, a voltage is applied to both the
electrodes 1 and 2 so as to expand and contract the conductive
polymer layer 3 in the longitudinal direction 5.
[0119] In the case where the conductive polymer layer is an organic
conductive polymer, this expansion and contraction action is
generated by the conductive polymer layer 3 being doped with or
separated from the ion species contained in the electrolyte layer
4. The expansion and contraction action is caused by changes in
bulk of the conductive polymer layer 3 according to coming and
going of the ion species as the ion species have a certain level of
bulk, changes in conformation of the conductive polymer chain
structure of the conductive polymer layer 3 associated with
oxidation reduction action, and further attributed to electrostatic
repulsion by charges of the same kind injected by voltage
application. In the case where the conductive polymer layer is a
carbon dispersion conductive polymer, the expansion and contraction
action does not accompany the oxidation reduction action, but the
deformation is considered to be achieved by the coming and going of
the ion species and the electrostatic repulsion by charges of the
same kind.
[0120] For easy understanding of the operation principle, including
causes of the deformation mechanism, swell and shrinkage
deformation accompanied by the conductive polymer layer 3 (since
the conductive polymer layer 3C operates in the same way,
description is herein given by representatively using the
conductive polymer layer 3) being doped with or separated from
anions 11 (negative ions) is shown in cross sectional views in FIG.
2A, FIG. 2B, FIG. 2C, and FIG. 2D. In some kinds of organic
conductive polymer materials, the primary deformation mechanism is
attributed to doping and separation of the anions 11. FIG. 2A shows
a switch-off state in which a voltage is not applied to the
electrode. FIG. 2B shows the state in which a positive voltage is
applied to the side of the conductive polymer layer 3. The anions
11 uniformly present in the electrolyte layer 4 when no voltage is
applied are pulled to the conductive polymer layer side on the side
of the positive electrode (see arrows of the anions 11 in FIG. 2A
and FIG. 2B), and go into the inside of the conductive polymer
layer 3 from the electrolyte layer 4. Along with the oxidation
process, the volume of the conductive polymer layer 3 swells and so
the conductive polymer layer 3 expands in the longitudinal
direction 5 along the inside of the lamination surface of the
conductive polymer layer 3. It is to be noted that FIG. 2B shows
the state in which the left end of the actuator in the longitudinal
direction 5 is secured while the right end extends from a reference
position R on the right end in the switch-off state. FIG. 2C shows
a switch-off state in which a voltage is not applied to the
electrode, while FIG. 2D shows the state in which a negative
voltage is applied to the conductive polymer layer 3 contrary to
FIG. 2B. The anions 11 present in the conductive polymer layer 3
are pulled to the opposite electrode 2 (see arrows of the anions 11
in FIG. 2C and FIG. 2D), and go away from the conductive polymer
layer 3 into the electrolyte layer 4. Along with the reduction
process, the volume of the conductive polymer layer 3 shrinks and
the conductive polymer layer 3 contracts in the longitudinal
direction 5 along the inside of the lamination surface of the
conductive polymer layer 3. It is to be noted that FIG. 2D shows
the state in which the left end of the actuator in the longitudinal
direction 5 is secured while the right end shrinks from the
reference position R on the right end in the switch-off state. In
other materials, the expansion and contraction action may be
generated by the coming and going of cations (positive ions) from
and to the conductive polymer layer 3 or by reciprocal coming and
going of anions and cations. However, description has been limited
to the mechanism of expansion and contraction action with reference
to the coming and going of the anions for simplification
purposes.
[0121] With the electrodes 1 being set on the conductive polymer
layers 3, 3C, application voltages can be applied instantaneously
and uniformly to the conductive polymer layers 3, 3C compared to
the case where the electrodes 1 are not set, so that the doping
phenomenon of the ion species occurs at high speed, allowing
high-speed expansion and contraction action of the conductive
polymer layers 3, 3C. Patterning the electrode 1 in such a way that
rigidity in the longitudinal direction 5 is low while rigidity in
the width direction is high as described above makes it possible to
generate large generated distortion without blocking the expansion
and contraction action of the conductive polymer layer 3, 3C. It
has been found that generating the large generated distortion is
not only a function in a passive sense of term, that is, to prevent
blocking of the expansion and contraction action, but the function
also fulfills an effect of actively increasing the generated
distortion through assignment of anisotropy in rigidity by the
patterned electrode 1. This will be described in detail later with
reference to FIG. 5A to FIG. 5D.
[0122] Further, structuring the electrode 1 as a plate-like
electrode having the function as a support makes it easy to handle
the conductive polymer layers 3, 3C which are difficult to handle
as individual thin layers. The function as the support herein
refers to a function of holding and supporting the conductive
polymer layer by setting a part of the rigidity of the planar
electrode having the function to be larger than the rigidity of the
conductive polymer layer. Further, since the electrode 1 is planar,
each component member of the actuator is given a planar structure,
which makes stacking easy. The cross sectional ratio of the
conductive polymer layer 3, 3C involving the expansion and
contraction action of the stacked actuator allows employment of
such a planar lamination structure, advantageously allowing for
easy enhancement of packing density.
[0123] A specific structure for patterning the electrode 1 so as to
provide low rigidity in the longitudinal direction may be obtained
by disposing a number of elongated patterns 1a in the width
direction orthogonal to the longitudinal direction 5 and linking
these patterns 1a through the link portions 1b in a zigzag shape or
in a bent state as described above. Though the in-phase rigidity of
flat plates is extremely high, such patterning allows easy
implementation of low rigidity in the longitudinal direction 5.
Such a structure concurrently provides high rigidity in the width
direction orthogonal to the longitudinal direction 5, and assigns
anisotropy in rigidity between the longitudinal direction and the
direction orthogonal thereto.
[0124] In the first embodiment, providing the extension portion 1c
of the electrode 1 on both the ends of the longitudinal direction
and using the extension portion 1c as a force action portion makes
it possible to form the force action portion, which is an essential
element of the actuator, in concurrence with patterning, which
yields an actuator having the force action portion in the electrode
1 itself. This brings about the advantage that an additional member
is not necessary as the force action portion. Further, since the
electrode 1 is a member directly linked to the conductive polymer
layer 3, 3C which produce the expansion and contraction action, it
becomes possible to secure sufficient strength against the load
exerted over the force action portion.
[0125] Providing the holes 1d on the extension portions of the
electrodes 1 and filling the holes 1d with the conductive polymers
of the conductive polymer layers 3, 3C make it possible to generate
anchor effect, and the anchor effect allows for increasing the
strength of the hole portions. While there may be cases where the
bond strength in the interface between the electrode 1 and the
conductive polymer layers 3, 3C is not necessarily strong depending
on the combination of materials, setting such holes 1d to be filled
with the conductive polymers allows the bond strength in the
interface between the electrodes 1 and the conductive polymer
layers 3, 3C to be reinforced.
[0126] FIG. 3A to FIG. 3H are plane views showing the expansion and
contraction operation of the actuator in the first embodiment. For
simplification, only the conductive polymer layer 3 and the
electrode 1 with the conductive polymer layer 3 attached thereto
are schematically shown, since the conductive polymer layer 3C
operates in the same way, description is given by representatively
using the conductive polymer layer 3 in FIG. 3A to FIG. 3H. A few
other configurations adoptable for the actuator of the present
invention will be shown together. FIG. 3A and FIG. 3B show the case
where the form of the electrode 1 is identical to the pattern form
shown in FIG. 1A to FIG. 1D. FIG. 3A shows an initial state, and
FIG. 3B shows the state in which only the left end of the actuator
in the longitudinal direction 5 is secured while the right end of
the conductive polymer layer 3 expands by .delta..sub.1 from a
reference position R in the initial state in FIG. 3A. More
particularly, it is shown that the respective elongated patterns 1a
of the electrode 1 deform in the width direction orthogonal to the
longitudinal direction 5 along the longitudinal direction 5
according to the expansion.
[0127] Similarly, as another configuration of the present
invention, FIG. 3C and FIG. 3D show the states before and after
deformation in the case where the pattern form is constituted by an
elongated pattern 1a of one cycle out of a number of elongated
patterns 1a of the electrode 1. More particularly, it is shown the
state in which the left end of the actuator in the longitudinal
direction 5 is secured while the right end of the conductive
polymer layer expands by .delta..sub.2 from the reference position
R in the initial state in FIG. 3C.
[0128] Generally, a large deformation of the actuator can be
achieved by setting the expansion and contraction direction 5 of
the actuator as the longitudinal direction of the actuator, the
length of the expansion and contraction portion thereby being
longer. As shown in this example, it is also possible to set the
width direction orthogonal to the expansion and contraction
direction 5 as the longitudinal direction. The present invention is
not intended to limit the expansion and contraction direction 5 of
the actuator to the longitudinal direction of the actuator.
[0129] Further, as still another configuration of the present
invention, FIG. 3E and FIG. 3F show a minimum available unit of the
pattern form in patterning of the actuator in the present
invention. More particularly, FIG. 3E shows the case where the
pattern form is constituted of an elongated pattern 1a of a half
cycle out of a number of elongated patterns 1a of the electrode 1,
and FIG. 3F shows the case where the pattern form is constituted of
an elongated pattern 1a of a quarter cycle out of a number of
elongated patterns 1a of the electrode 1.
[0130] Further, as another configuration of the present invention,
the arrangement relationship between the electrode 1 and the
conductive polymer layer 3 in the width direction may be arranged
such that the width of the electrode 1 is larger than the width of
the conductive polymer layer 3 as shown in FIG. 3G, and the
arrangement relationship may also be reversed as shown in FIG. 3H.
Each case is within the scope of the present invention.
[0131] FIG. 4 is a table showing the result of a calculation to
obtain how the rigidity in the longitudinal direction can be
lowered by the pattern forms in patterning of the electrode 1 of
the actuator in the first embodiment of the present invention.
Assumed values for the calculation are set as follows: the material
is stainless steel SUS304; the longitudinal elastic modulus is
0.072.times.10.sup.12N/m.sup.2; and the plate thickness is 10
.mu.m. In the case of a flat plate (solid state or block
configuration) electrode shown in the column (a) in the table, when
the upper end of the flat plate with a thickness of 14 mm.times. a
length of 8 mm was constrained and a distributed load having a
total load of 1 mN was applied onto the lower end of the flat
plate, the displacement in the middle of the lower end was 0.308
.mu.m. In the case of the pattern form with a total width 14
mm.times. a length of 8 mm obtained in patterning the electrode 1
in the first embodiment of the present invention in column (b)
shown in the table, when a concentrated load of the same 1 mN was
applied to the pattern form in patterning with a line width of 0.1
mm and a pitch of 1 mm and, the displacement in the lower end
portion was calculated at 50.56 mm, and assuming that a rigidity
ratio of the former flat plate is 1, a rigidity ratio of the latter
electrode 1 to the former flat plate is 6.1.times.10.sup.-6. Thus,
patterning of the electrode 1 in the first embodiment of the
present invention makes it possible to reduce the rigidity to
1/100,000 or lower as compared with that in the flat plate.
[0132] The column (c) in the table shows, for comparison, the
result of calculation in the case where the link portions 1b for
linking the elongated patterns 1a of the electrode 1 are not
disposed in the bent state but are disposed in the center portion
of the width of the elongated patterns 1a and are disposed in
succession in the longitudinal direction. The displacement in the
middle portion of the lower end when a concentrated load of the
same 1 mN is applied onto the lower end was calculated at 38.6
.mu.m. The rigidity ratio was 7.9.times.10.sup.-3, and the rigidity
was reduced to at best nearly 1/100. Thus, for achieving a large
rigidity reduction effect, it is necessary to dispose the link
portions 1b in the bent state with respect to the elongated
patterns 1a of the electrode 1. Further, the column (d) in the
table shows the result of calculation in the case where the
electrode is patterned in a waveform, and the result indicates that
such a form can achieve considerable reduction in rigidity.
[0133] FIG. 5B to FIG. 5D are views in which conductive polymer
layers are attached to the electrodes with the pattern forms in
patterning of (b) to (d) shown in FIG. 4, and deformations
associated with constriction of the conductive polymer layers in
in-plane directions are simulation-calculated by finite element
method. Under the conditions that the material of the conductive
polymer layers is polypyrrole, the longitudinal elastic modulus is
0.003.times.10.sup.12N/m.sup.2, Poisson's ratio is 0.3, and the
conductive polymer layers are to contract in the in-plane direction
of the polypyrrole in an isotropic way, deformations in the pattern
forms in respective electrode patternings were relatively compared.
The total size was set at 14 mm wide.times.8 mm long as was the
case with FIG. 4, and the thickness of the polypyrrole conductive
polymer layers was set at 20 .mu.m.
[0134] FIG. 5A shows the case in which an electrode is not present
and only a conductive polymer layer sheet is present. With the
displacement in the center portion on the lower end in this case
being 1, relative displacements at the same location were compared.
It is to be noted that the results of calculation show the relative
displacements, together with the forms before and after the
deformations, as well as contour lines showing displacements of
respective parts from a constraint point (center on the upper end)
in gray scale.
[0135] FIG. 5B shows the case in which the conductive polymer layer
3 is attached to the electrode 1 with the pattern form in
patterning in the first embodiment of the present invention in the
column (b) in FIG. 4. The relative displacement in this case was
calculated at 1.16, indicating that not only the displacement of
the electrode was less inhibited by reduction in rigidity in the
longitudinal direction 5 of the actuator, but also such the
anisotropy in rigidity of the electrode 1 has an effect of
increasing the generated displacement. It is to be noted that in
FIG. 5B, the state before deformation is shown by a chain line
while the shrunken state after deformation is shown by a solid
line.
[0136] Such a generated displacement increase effect in the
longitudinal direction of the actuator in the present invention may
be construed in such a way that high rigidity in the width
direction orthogonal to the longitudinal direction constrains the
displacement in this direction, and distortion components unable to
escape will turn out to join the displacement in the longitudinal
direction of the actuator.
[0137] It is to be noted that while it is not strictly affirmed
that the conditions used as the assumptions for calculation such as
the contraction being generated in the sheet-plane of the
conductive polymer layer in an isotropic way and the Poisson's
ratio being constant are correct, the assumption for calculation
that the elastic characteristics of the conductive polymer layer
are maintained is considered to be an accurate approximation.
[0138] FIG. 5C shows the case in which the conductive polymer layer
sheet is attached to the electrode 1 in the column (c) in FIG. 4
having the link portions 1b of the elongated patterns 1a of the
electrode 1 being disposed at the middle portions in succession in
the longitudinal direction. In this case, the calculation result
indicated that the generated displacement increase effect was not
realized and that the displacement was reduced to 62% of the
displacement gained in the case of the conductive polymer layer
sheet only.
[0139] FIG. 5D shows the case of the electrode in the column (d) in
FIG. 4, which is patterned in a waveform. In this case, the
displacement increase effect, though smaller than that in the case
of FIG. 5B, was realized. However, while deformation in the case of
FIG. 5B is generated evenly in each part on the entire area, the
deformation in the case of D is uneven and resultant unnecessary
distortion and internal stress as an actuator are considered to
impose an unfavorable influence on the reliability of the actuator.
Moreover, in the case of FIG. 5B, a distance from the electrode to
the plane surface of the conductive polymer layer sheet is even on
the entire area range and is short, which makes it possible to
apply homogeneous electric fields to the conductive polymer layer
and to perform uniform and high-speed doping of the conductive
polymer layer with ion species, which contributes to deformation.
In the case of FIG. 5D, on the contrary, a distance from the
electrode to the plane surface of the conductive polymer layer is
uneven, which generates uneven electric fields and uneven doping of
ion species in accordance with the uneven distance, which limits
the operation speed. It is to be noted that in FIG. 5D, the state
before deformation is shown by a chain line while the shrunken
state after deformation is shown by a solid line. Thus, the case of
FIG. 5D, though it is also the first embodiment of the present
invention, is less preferable than the case of FIG. 5B.
[0140] FIG. 5E is a graph view showing the relationship between the
thickness of the conductive polymer layer and a displacement amount
of the actuator of FIG. 5B in the first embodiment of the present
invention when a length of the actuator is 8 mm and a film
thickness of the electrode of the actuator is changed (5 .mu.m, 10
.mu.m, 20 .mu.m). Moreover, FIG. 5F is a graph view showing the
relationship between a thickness of the conductive polymer layer
and a growth rate of a displacement amount (displacement growth
rate) of the actuator of FIG. 5B in the first embodiment of the
present invention when a length of the actuator is 8 mm and a film
thickness of the electrode of the actuator is changed (5 .mu.m,
.mu.m, 20 .mu.m). These graph views show the results of simulation
when assumed values for calculation of the patterned electrode are
set as follows as with the case described before: the material is
stainless steel SUS304; the longitudinal elastic modulus is
0.072.times.10.sup.12N/m.sup.2; Poisson's ratio is 0.3; and the
thickness is 10 .mu.m, whereas assumed values of the conductive
polymer layer are set as follows: the material is polypyrrole; the
longitudinal elastic modulus is 0.003.times.10.sup.12N/m.sup.2;
Poisson's ratio is 0.3; and the thickness is 10 .mu.m, 20 .mu.m, 40
.mu.m, 80 .mu.m, and 160 .mu.m. It was discovered that when the
thickness of the conductive polymer layer was 10 .mu.m which was
the same as the thickness of the electrode, the displacement growth
rate was 30%, and as the thickness increased, the displacement
growth rate decreased.
[0141] FIG. 5G is a graph view showing the result of FIG. 5F by
taking the displacement growth rate as a vertical axis and a ratio
of thickness of the conductive polymer layer to film thickness of
the electrode as a horizontal axis. It was discovered that when
said ratio was 3 or less, noticeable displacement increase effect
was present.
[0142] The displacement increase effect generated in the actuator
longitudinal direction (expansion and contraction direction) in the
first embodiment of the present invention is generated in such away
that high rigidity in the width direction orthogonal to the
longitudinal direction constrains the displacement in this width
direction, and distortion components unable to escape turn out to
join the displacement in the longitudinal direction of the
actuator. The phenomenon of the displacement increase effect
decreasing as thickness increases is attributable to the fact that
as the thickness of the conductive polymer layer becomes larger
than the thickness of the patterned electrode, the distortion
components are absorbed by a volume potion in the thickness
direction so that the components contributing to the displacement
in the longitudinal direction of the actuator decrease. Therefore,
the displacement increase effect found in the structure of the
actuator in the first embodiment of the present invention is a
characteristic developed particularly and distinctively in a
flat-plate low-profile actuator.
[0143] In an actuator which deforms a conductive polymer, the major
deformation principle is coming and going of anions or cations from
and to the conductive polymer layer in an oxidation reduction
reaction. Therefore when excessive voltage is applied, the
electrochemical reaction becomes irreversible, thereby generating
defects which affect its cycle life. It is indicated that the
aforementioned displacement increase effect of the actuator in the
first embodiment of the present invention allows the actuator to
drive at a voltage relatively lower than the actuator which does
not have the displacement increase effect, for obtaining the same
generated displacement. Therefore, the irreversible electrochemical
reaction can be avoided and this particularly is an advantage of
the actuator of the present invention, which makes it possible to
provide an actuator excellent in cycle life and durability.
Similarly, an electrolyte is dissolved by application of an
excessive voltage, and this affects the life of the actuator. This
issue can be solved by driving at a low voltage.
[0144] Further, these apparatuses function by coming and going of
anions and cations from and to the conductive polymer layer through
voltage application, and since this process is a diffusion process,
the speed is controlled by the diffusion process. By structuring
the conductive polymer layer of the actuator in the first
embodiment of the present invention to be flat-plate and
low-profile, the diffusion is performed swiftly and uniformly in
the thickness direction, thereby making it possible to provide an
actuator capable of high-speed function.
Working Example 1
[0145] FIG. 6 shows a prototype electrode 1-1 formed by etching a
stainless foil with a thickness of 10 .mu.m to have a zigzag-shaped
electrode patterning similar to that in FIG. 3A. The dimensions of
an elongated pattern 1a can be 10 .mu.m width and 14 mm long, with
a pitch of 1 mm. Since these zigzag-shaped patterns are extremely
thin lines, they have rigidity low enough for them to be deformed
by their own weights and lose their shape. Therefore for the
purpose of reinforcement, a cutoff portion if is disposed on both
sides along the longitudinal direction, and the link portions 1b of
the elongated patterns 1a and the cutoff portions if are linked by
cutoff portion link portions 1e. As described later, these cutoff
portions if are cut away at cutting positions 21 shown by chain
lines in FIG. 6 after the conductive polymer layer 3 is formed on
the electrode 1-1. The size of a pattern formation portion of the
electrode 1 after the cutting is set at 100 mm long and 14 mm wide
(corresponding to the length of the aforementioned elongated
patterns 1a). On both the end portions of the electrode 1-1,
extension portions 1c functioning as a force action portion are
provided, and pin holes 1g for coupling hooks with pins are
provided. Further, on the end portions of the extension portions 1c
of the electrode 1-1, extraction electrodes 1h are further
provided. It is to be noted that a small hole and a long hole
outside the pin holes 1g disposed on both the ends are holes
disposed for alignment of the pin during manufacturing process.
[0146] While formation of the conductive polymer layer 3 on the
electrode 1-1 can be achieved by electrolytic polymerization or
casting method, herein the electrolytic polymerization method was
employed as a formation method for organic conductive polymer. In
this case, since the conductive polymer layer 3 was grown by
polymerization at locations where the electrode of the patterned
electrode portion is not present, electrolytic polymerization was
conducted while the electrode in FIG. 6 was in contact with another
stainless flat plate electrode, and then the stainless flat plate
electrode was removed. As the conductive polymer layer 3,
polypyrrole with a current density of 1 mA/cm.sup.2 and a film
thickness of 20 .mu.m was synthesized by electrolytic
polymerization in an aqueous solution in which 0.1 mol/liter of
pyrrole monomer and 0.25 mol/liter of paraphenol sulfonic acid that
was to be a supporting electrolyte layer were dissolved, in a
galvanostat mode (constant current control mode) with use of the
electrode as a deposition electrode.
[0147] Next, as the electrolyte layer, a polymer gel sheet
containing ionic fluid containing butyl methyl imide cation
(BMIM.sup.+) hexa fluorophosphate (PF.sub.6) was bonded to the
polypyrrole sheet, and carbon powders were sprayed and applied to
the polymer gel sheet as an opposite electrode.
[0148] When a voltage of .+-.1V was applied to the actuator, strain
of about 3.5% was observed in the longitudinal direction in an
non-load state, and generated stress of about 3 Mpa was observed in
the state that the displacement is constrained. It is to be noted
that as a result of checking generated displacement in an actuator
composed of polypyrrole only with use of the materials system same
as above and without the use of the electrode 1 in the first
embodiment of the present invention, the generated displacement was
about 3%, which confirmed the displacement increase effect achieved
by electrode 1 in the first embodiment of the present
invention.
[0149] In each of the embodiments of the present invention, as the
material of the electrode 1, metal including gold, platinum,
nickel, or titanium; alloy; or carbon, in addition to stainless
steel in the above embodiment may be used. Further, a thin plate
made of any one of these materials may be coated with these
material groups through sputter deposition etc. Further, the
surface thereof may be subjected to surface treatment such as
chemical oxidation. Among these materials, a titanium thin plate or
a surface coated with titanium through sputter deposition which was
subjected to chemical oxidation treatment with alkali solution such
as SCI solution (H.sub.2O.sub.2:NH.sub.3:water=1:1:5) provided
particularly good bond strength with polypyrrole. This chemical
oxide film was good in electrical conductivity with
polypyrrole.
[0150] In each of the embodiments of the present invention, as the
material of the conductive polymer layer 3, a pi-conjugated polymer
with a base substrate of polyaniline, polypyrrole, or
polythiophene; any one of organic conductive polymers which are
derivatives thereof; or a carbon conductive polymer such as carbon
fine particles, carbon nanotubes, or carbon fibers are used, by
which an actuator involving swell and shrinkage deformation as with
the case of the above embodiment may be implemented.
[0151] In each of the embodiments of the present invention, an
example of forming an organic conductive polymer layer by casting
method is obtained by dissolving powders of polyaniline basic
emeraldine (emeraldine base: EB) synthesized by oxidation
polymerization in a solvent and spreading the powders and the
solvent on a substrate to evaporate the solvent so as to obtain a
polyaniline cast film as an organic conductive polymer layer.
[0152] Moreover, an example of forming a carbon dispersion system
conductive polymer layer by a casting method is obtained by mixing
carbon fine particles into a Nafion dispersed solution and
spreading the mixture on a substrate to evaporate the solvent.
[0153] In each of the embodiments of the present invention, using
polymer gel or polymer containing an ionic solution as an
electrolyte layer as described in the above embodiment has
following advantages. The ionic solution has a vapor pressure of 1
mHg or lower at ambient temperatures and is nonvolatile, and
therefore the electrolyte layer will not change by evaporation,
allowing long-term usage in the atmosphere with sufficient
reliability.
[0154] In each of the embodiments of the present invention, as the
electrolyte constituting the electrolyte layer, a fibrous sheet
physically impregnated with an electrolyte solvent or an
electrolyte solvent being held in a polymer gel skeleton may be
considered.
[0155] The ionic solution is used as the electrolyte, and it is
possible to consider a fibrous sheet physically impregnated with
the ionic solution or the ionic solution being held in a polymer
gel skeleton.
[0156] In each of the embodiments of the present invention, as the
opposite electrode, in addition to the carbon powders applied to
the actuator in the above embodiment, a conductive paste or grease
containing nonoxide metal powders of carbon, gold, or the like may
be applied thereto. Moreover, a deposited thin film made of metal
such as gold, platinum, nickel, or titanium, alloy thereof, or
carbon; or the deposited thin film so patterned as to decrease
rigidity in the longitudinal direction of the actuator may be
used.
[0157] In each of the embodiments of the present invention, it is
naturally understood that a flat plate electrode having a structure
identical to that of the electrode 1 may also be used as the
opposite electrode 2.
Second Embodiment
[0158] FIG. 7A and FIG. 7B are a plane view and a cross sectional
view showing a flat-plate low-profile actuator having a pattern
form in another electrode patterning corresponding to second
embodiment of the present invention. The actuator shown in FIG. 7A
and FIG. 7B is identical to the actuator in FIG. 1 in the respect
that an electrolyte layer 4 in contact with the conductive polymer
layer 3 is present between an electrode 1-2 (corresponding to the
electrode 1) having a conductive polymer layer 3 and a opposite
electrode 2. The electrode 1-2 having the conductive polymer layer
3 is patterned to have low rigidity in an expansion and contraction
direction 5 of the conductive polymer layer 3, and serves as a
planar electrode also functioning as a support. The pattern form in
patterning the electrode 1-2 in FIG. 7A and FIG. 7B is the form in
which mainly in a direction orthogonal to the longitudinal
direction 5, a number of elongated patterns 1a-2 are disposed and
linked through link portions 1b. This point is also similar to FIG.
1A, though a basic pattern formed by elongated patterns 1a-2 is
closed like a closed circuit (in other words, like a square-shaped
frame), and these patterns are linked through the link portions 1b.
This structure has the advantage that if a closed circuit pattern
portion 1a-2 is disconnected, critical continuity failures of the
electrode 1-2 will not occur unlike the case of the pattern in FIG.
1A.
[0159] FIG. 8A and FIG. 8B are a plane view and a cross sectional
view showing an actuator having a pattern form in patterning of an
electrode 1-3 (corresponding to the electrode 1) in another
configuration in the second embodiment of the present invention.
The component members and their operations in the drawings are
identical to those in FIG. 1A and so the description thereof is
omitted. The pattern form in the electrode patterning is
characterized in that the proportion of the link portions 1b to a
number of elongated patterns 1a-3 (corresponding to the elongated
patterns 1a) are further decreased, and closed circuit pattern
portions 1a-3 composed of elongated patterns are increased. As a
result, even if the electrode might be disconnected, the
probability of critical failure can be further reduced.
[0160] FIG. 9A and FIG. 9B are plane views showing an actuator
having a pattern form in patterning of an electrode 1-4
(corresponding to the electrode 1) in still another configuration
in the second embodiment of the present invention. In FIG. 9A, the
width of elongated patterns 1a-4 (corresponding to the elongated
patterns 1a) positioned close to extension portions 1c (force
action portions) of the electrode 1-4 and the width of link
portions 1b-4 (corresponding to the link portions 1b) are made
relatively larger than the width of elongated patterns 1a-5
(corresponding to the elongated patterns 1a) and the width of link
portions 1b-5 (corresponding to the link portions 1b) which are the
portions other than the elongated patterns 1a-4 and the link
portions 1b-4 for increasing rigidity in the expansion and
contraction direction 5. This provides an effect of reinforcing the
strength in the locations close to the extension portions 1c (force
action portions). FIG. 9B shows an actuator in a pattern form in
patterning of an electrode 1-6 (corresponding to the electrode 1)
in yet another configuration in the second embodiment of the
present invention, in which elongated patterns 1a-6 (corresponding
to the elongated patterns 1a) in locations close to extension
portions 1c (force action portions) and link portions 1b-6
(corresponding to the link portions 1b) are disposed in a plurality
of lines as with the case in FIG. 9A, so that rigidity in the
locations in the expansion and contraction direction 5 can be
increased to reinforce the strength in those locations. Thus,
arbitrary distribution of the pattern form in patterning of the
electrode 1-6 makes it possible to impart desirable functions.
Third Embodiment
[0161] FIG. 10A, FIG. 10B, FIG. 11A, and FIG. 11B are plane views
and cross sectional views respectively showing a stacked actuator
in a third embodiment of the present invention and a stacked
actuator in another configuration in the third embodiment.
[0162] In the actuator shown in FIG. 10A and FIG. 10B, a second
conductive polymer layer integrally formed with a conductive
polymer layer 3 on the top surface of the flat-plate low-profile
actuator in the second embodiment in FIG. 7A with an electrode 1-2
being disposed in a center portion of the conductive polymer layer
3 and an electrolyte layer and an opposite electrode 2 being
disposed on the top surface side of the conductive polymer layer 3
constitutes a flat-plate low-profile constitutional unit. The
flat-plate low-profile constitutional units are stacked in a
plurality of layers, e.g., three layers, so that the electrodes
1-2, the conductive polymer layers 3, the electrolyte layers 4, and
the opposite electrodes 2 are disposed in parallel with each other,
and one opposite electrode 2 is commonly used for the opposite
electrode 2 on the lower end of the first-layer actuator and the
opposite electrode 2 on the top end of the second-layer actuator,
while one opposite electrode 2 is commonly used for the opposite
electrode 2 on the lower end of the second-layer actuator and the
opposite electrode 2 on the top end of the third-layer actuator.
Further, a conductive link member 13 is interposed in between each
extension portion 1c of the first-layer actuator and each extension
portion 1c of the second-layer actuator to establish an electric
connection, while a conductive link member 13 is interposed in
between each extension portion 1c of the second-layer actuator and
each extension portion 1c of the third-layer actuator to establish
electric connection. Then, the extension portions 1c of the
first-layer actuator to the extension portions 1c of the
third-layer actuator are hooked by hooks 6, and the hook 6, the
hooked extension portion 1c of the first-layer actuator, upper-side
conductive link member 13, extension portion 1c of the second-layer
actuator, lower-side conductive link member 13, and extension
portion 1c of the third-layer actuator are pierced by a pin 7, and
by linking these members with the pin 7, the load 8 acting upon
each extension portion 1c is supported. It is to be noted that
reference numeral 12 in FIG. 10A is a protruding portion protruding
from the opposite electrode 2 of the third-layer actuator along the
width direction, and one end of a circuit having a switch and a
power source 9 is connected to the protruding portion 12 while the
other end is connected to the conductive link member 13 disposed on
either one of the end portions of the actuator.
[0163] Moreover, FIG. 11A and FIG. 11B show an actuator in another
configuration. More particularly, in the actuator shown in FIG. 11A
and FIG. 11B, a second conductive polymer layer integrally formed
with a conductive polymer layer 3 on the top surface of the
actuator in the second embodiment in FIG. 7A with an electrode 1-2
being disposed in a center portion of the conductive polymer layer
3 and an electrolyte layer 4 and an opposite electrode 2 being
disposed on the top surface side of the conductive polymer layer 3
basically constitutes a constitutional unit. The constitutional
units are stacked in a plurality of layers, e.g., two layers, so
that the electrodes 1-2, the conductive polymer layers 3, the
electrolyte layers 4, and the opposite electrodes 2 are disposed in
parallel with each other, and one opposite electrode 2 is commonly
used for the opposite electrode 2 on the lower end of the
upper-side (second layer in FIG. 11B) actuator and the opposite
electrode 2 on the top end of the lower-side (third layer in FIG.
11B) actuator. Further, in the uppermost (first layer in FIG. 11B)
actuator, the electrolyte layer 4 and the opposite electrode 2 are
not disposed on the upper surface side of the conductive polymer
layer 3, while in the lowermost (fourth layer in FIG. 11B)
actuator, the electrolyte layer and the opposite electrode 2 are
not disposed on the lower surface side of the conductive polymer
layer 3. Further, a conductive link member 13 is interposed in
between each extension portion 1c of the first-layer actuator and
each extension portion 1c of the second-layer actuator to establish
electric connection, a conductive link member 13 is interposed in
between each extension portion 1c of the second-layer actuator and
each extension portion 1c of the third-layer actuator to establish
electric connection, and further a conductive link member 13 is
interposed in between each extension portion 1c of the third-layer
actuator and each extension portion 1c of the fourth-layer actuator
to establish electric connection. Then, the extension portions 1c
of the first-layer actuator to the extension portions 1c of the
fourth-layer actuator are hooked by hooks 6, and the hook 6, the
hooked extension portion 1c of the first-layer actuator, upper-side
conductive link member 13, extension portion 1c of the second-layer
actuator, middle conductive link member 13, extension portion 1c of
the third-layer actuator, lower-side conductive link member 13, and
extension portion 1c of the fourth-layer actuator are pierced by a
pin 7. By linking these members with the pin 7, the load 8 acting
upon each extension portion 1c is supported. It is to be noted that
reference numeral 14 in FIG. 11A is a protruding portion protruding
from the lower-side opposite electrode 2 of the first-layer
actuator along the width direction, and one end of a circuit having
a switch 10 and a power source 9 is connected to the protruding
portion 14 while the other end is connected to the conductive link
member 13 disposed on either one of the end portions of the
actuator.
[0164] In the stacked actuator in the third embodiment and the
stacked actuator in another configuration in the third embodiment,
the electrode 1-2 is planar, and therefore each component member of
the actuator is given a planar structure, which can make stacking
easy. The cross sectional ratio of the conductive polymer layer 3
involving the expansion and contraction action of the stacked
actuator allows employment of such a planar lamination structure,
thereby bringing about advantages of easy enhancement of packing
density. As a result, it becomes possible to increase the cross
sectional area of the conductive polymer layer 3, which is limited
in the case of a single unit, thereby allowing implementation of an
actuator having large generated force necessary in robotics
applications and the like.
[0165] It is to be noted that since coming and going of ion species
from and to the conductive polymer layer 3 is a diffusion process,
there is a trade-off that time necessary for diffusion can be
reduced by decreasing the thickness of the conductive polymer layer
3. Therefore, it is desirable to stack a number of conductive
polymer layers 3 as a way of increasing the cross sectional
area.
Fourth Embodiment
[0166] Description will be given of a manufacturing method for a
planar electrode support for an actuator in a fourth embodiment,
the planar electrode support functioning as a fundamental member to
form the actuators in the first to third embodiments described
before.
[0167] FIG. 12A, FIG. 12B to FIG. 12H, and FIG. 12I are plane views
and cross sectional views showing the planar electrode support
structured to have conductive polymer layer 3 on the electrode 1
and a manufacturing method therefor. Since major component members
in FIG. 12A and FIG. 12B are identical to those of the electrode 1
in the flat-plate low-profile actuator described in FIG. 1A (in
FIG. 12A, the electrode 1 is hatched to distinguish the electrode 1
from space portions), the detailed description is omitted. Herein,
as a component element facilitating manufacturing of a planar
electrode support 90, a planar electrode 1 is formed to have cutoff
portions 1f, which do not remain as part of the electrode 1 in the
final product, on both the sides in the width direction. Respective
link portions 1b for linking a number of elongated patterns 1a
patterned on the electrode 1 to each other are linked to each
opposed cutoff portion if through cutoff portion link portions 1e.
Such patterning is performed by etching or punching. FIG. 12A and
FIG. 12B show the state in which such a planar electrode 1 is
supported in close contact with another flat plate 20.
[0168] Next, FIG. 12C and FIG. 12D show a state where a conductive
polymer layer 3 is formed so as to cover most parts of the planar
electrode 1 in close contact with the flat plate 20 and the flat
plate 20 (in FIG. 12C, the electrode 1 is hatched to distinguish
the electrode 1 from space portions). In the case of forming the
conductive polymer layer 3 through electrolytic polymerization, the
flat plate 20 serves as a flat plate electrode, and electrolytic
deposition of conductive polymer is conducted by using both the
electrode 1 and the flat plate electrode 20 as deposition
electrodes to form the conductive polymer layer 3 in such a way as
to cover most parts of the electrode 1 and the flat plate electrode
20. The conductive polymer layer 3 made of polypyrrole in the
aforementioned working example 1 was formed by this method. As
another formation method for the conductive polymer layer 3, a
casting method may be employed. In this case, the flat plate 20
does not necessarily need to be an electrode, and the conductive
polymer layer 3 can be formed by such methods as printing or
application. One way of forming the conductive polymer layer 3 by a
casting method is dissolving powders of polyaniline basic
emeraldine (emeraldine base: EB) synthesized by oxidation
polymerization in a solvent and spreading the powders and the
solvent on a substrate to evaporate the solvent so as to obtain a
polyaniline cast film as the conductive polymer layer 3.
[0169] Next, after the conductive polymer layer 3 is formed on the
flat plate 20 so as to cover most parts of the electrode 1, the
flat plate 20 is separated and removed from the electrode 1 and the
conductive polymer layer 3. FIG. 12E and FIG. 12F show a state
where the flat plate 20 is removed from the electrode 1 and the
conductive polymer layer 3 in this way. If necessary, a conductive
polymer layer 3d may be formed on the back surface of the
conductive polymer layer 3 as shown in the cross sectional view of
FIG. 12G. Thus, forming the conductive polymer layers 3, 3d on the
both surfaces of the planar electrode support 90 provides the
advantages that the effective area can be increased and a hole 1d
provided on the extension portion 1c that is a force action portion
can be linked through the front and back surfaces to increase
reinforcement effect. Moreover, since the actuator may be
structured to be symmetrical with respect to the planar electrode
support 90 as the center, it becomes possible to provide a planar
electrode support 90 equipped with the conductive polymer layers 3,
3d, which is free from unbalanced swell and shrinkage actions of
the conductive polymer layers 3, 3d, free from unnecessary bending
deformation and allows efficient expansion and contraction
deformation in the expansion and contraction direction 5.
[0170] Finally, at the locations of cutoff lines 21 in FIG. 12E,
the cutoff portions 1f are cut off from both the sides of the
planar electrode 1 so as to obtain the planar electrode support 90
equipped with the conductive polymer layers 3, 3d shown in FIG. 12H
and FIG. 12I. At the stage that the conductive polymer is formed by
electrolytic polymerization or casting method while the patterned
planar electrode 1 is in contact with another flat plate 20, the
interface between the flat plate 20 and their contact portion is
not tightly bonded, and so the flat plate 20 can be easily
separated from the electrode 1 and the conductive polymer layer 3.
The inventors of the present invention have further discovered that
easier separation is possible by using a flat plate having a
sufficiently smooth surface such as stainless steel plates
mirror-finished by buffing for example, or polished glassy carbon
(amorphous carbon) plates as the flat plate 20. Particularly, the
glassy carbon plate is excellent as it is high in surface hardness,
sufficient in chemical stability, and is capable of enduring
repeated use. Employing such a manufacturing method allows
simplified and easy manufacturing of the planar electrode support
for an actuator in the present invention.
[0171] Further, FIG. 13A and FIG. 13B are a plane view and a cross
sectional view showing a state where a regulating jig is used in
the formation of a conductive polymer layer 3 by electrolytic
polymerization, the conductive polymer 3 layer is formed on a
substrate 20, and an electrode 1 sandwiched by the regulating jig.
The regulating jig is composed of a base 31 on which the substrate
20 is placed and a rectangular frame-shaped mask plate 30 placed on
the rectangular plate-like base 31 and having an aperture window
30a corresponding to the region in which the conductive polymer
layer 3 is formed. With use of these, the substrate 20 is placed on
the base 31 and is covered with the mask plate 30, and while the
substrate and the electrode 1 which are in close contact are
interposed in between the base 31 and the mask plate 30, screws 32
are inserted into thru-holes of the mask plate 30 and the pin holes
1g of the electrode 1 on both the end portions and are screwed into
screw holes on the substrate 20 for attachment. When these screwed
substrate 20 and the electrode 1 are dipped in an electrolyte,
portions of the substrate 20 and the electrode 1 other than the
regions which are to constitute the conductive polymer layer 3 are
sandwiched between the base 31 and the mask plate 30, as a result
of which the conductive substrate 20 and electrode 1 are exposed to
the electrolyte only at the location of the aperture window 30a, by
which the conductive polymer layer 3 is synthesized by electrolytic
polymerization only at this location.
[0172] Thus, with respect to the substrate 20 and the electrode 1,
the portions other than the region in which the conductive polymer
layer 3 is formed, are covered with the base 31 and the mask plate
30, so that only the region in which the conductive polymer layer 3
is formed is exposed, allowing the conductive polymer layer 3 in
the region to be formed reliably and easily.
[0173] Further, FIG. 13C and FIG. 13D show a regulating jig with
magnets 33 embedded in a base 31A, 31B as another embodiment of the
regulating jig. FIG. 13E is a partially enlarged view showing a
failure which may occur in the case of using the regulating jig of
FIG. 13A and FIG. 13B, in which contact between the electrode 1 and
the flat plate 20 may be poor enough to generate a gap 34. In the
case where such a gap 34 is generated, local film defects are
likely to be generated when conductive polymer is formed thereon.
To cope with this issue, as shown in FIG. 13F, a thin plate made of
magnetic materials such as magnetic stainless materials or nickel
foils is used as the electrode 1 and the regulating jig with the
magnets 33 embedded therein is used, so that the magnets 33 attract
the electrode 1 toward the magnet side, which provides an effect of
bringing the electrode 1 and the flat plate 20 into close contact
without any gap. Further, in the case of forming the conductive
polymer layer by electrolytic polymerization, synthesis initiation
of the conductive polymer layer occurs with concentrated portions
of magnetic fields in the vicinity of the magnets as a core, which
allows synthesis of an entirely homogeneous conductive polymer
layer. As the magnetic material of the planar electrode, stainless
steel having magnetism such as SUS430, or nickel can be used as a
material noncorrosive in the electrolyte.
Fifth Embodiment
[0174] Examples of applying any one of the actuators in the first
to fourth embodiments of the present invention to joint drive
mechanism actuators 40, 40' are described as a fifth embodiment of
the present invention. FIG. 14A is a side view showing the joint
drive mechanism in the fifth embodiment. The joint drive mechanism
is structured such that a pair of the actuators 40, 40' are linked
across rotatable indirect portions 42 of indirect drive mechanisms
which are connected through links 41, and a pair of these actuators
40, 40' are driven by antiphase voltages applied from a drive power
source 43 to respective electrodes 1 and the like of the actuators
40, 40'. As the need arises, a pair of these actuators 40, 40' are
antagonistically driven by superimposed bias voltages from the
drive power source 43 applied to the respective electrodes 1 and
the like. Consequently, as shown in FIG. 14B for example, the joint
drive mechanism can be driven in such a way that the link 41 is
inclined toward the right upper side as the conductive polymer
layer 3 in the actuator 40 contracts along the longitudinal
direction 5 as shown in FIG. 2D while the conductive polymer layer
3 in the actuator 40' expands along the longitudinal direction 5 as
shown in FIG. 2B. Conversely, when voltages reverse to the above
voltages are applied from the drive power source 43 to the
respective electrodes 1 and the like of a pair of the actuators 40,
40', the joint drive mechanism can be driven in such a way that the
link 41 is inclined toward the right lower side.
[0175] Therefore, it becomes possible to provide a joint drive
mechanism for robots which is deformable and provides excellent
controllability.
[0176] It is to be understood that among the aforementioned various
embodiments, arbitrary embodiments may be properly combined so as
to achieve the effects possessed by each embodiment.
[0177] Although the present invention has been fully described in
connection with the preferred embodiments thereof with reference to
the accompanying drawings, it is to be noted that various changes
and modifications are apparent to those skilled in the art. Such
changes and modifications are to be understood as included within
the scope of the present invention as defined by the appended
claims unless they depart therefrom.
INDUSTRIAL APPLICABILITY
[0178] The actuator in the present invention is a flat-plate
low-profile actuator having an electrolyte layer in contact with a
planar conductive polymer layer disposed in between an electrode
having the conductive polymer layer attached thereto and an
opposite electrode, for deforming the conductive polymer layer to
be swelled and shrunken by application of electric fields to
between both electrodes, in which the electrode having the
conductive polymer layer attached thereto is a planar electrode
also serving as a support, which is patterned so that rigidity in a
longitudinal direction that is an expansion and contraction
direction of the conductive polymer layer is low while rigidity in
a width direction almost orthogonal to the longitudinal direction
is high. The actuator is usable as a drive source of various
apparatuses such as robots which are expected to operate near the
presence of human beings for housekeeping assistance, job
assistance, and nursing help for elderly and physically-challenged
persons in homes, offices, and hospitals, and as a flat-plate
low-profile actuator in which the drive source itself is
small-size, light-weighted, and flexible as well safe.
* * * * *