U.S. patent number RE45,464 [Application Number 12/855,589] was granted by the patent office on 2015-04-14 for electroactive polymer animated devices.
The grantee listed for this patent is Joseph S. Eckerle, Roy D. Kornbluh, Qibing Pei, Ronald E. Pelrine. Invention is credited to Joseph S. Eckerle, Roy D. Kornbluh, Qibing Pei, Ronald E. Pelrine.
United States Patent |
RE45,464 |
Kornbluh , et al. |
April 14, 2015 |
Electroactive polymer animated devices
Abstract
The present invention relates to animated devices that include
one or more electroactive polymer transducers. When actuated by
electrical energy, an electroactive polymer produces mechanical
deflection in one or more directions. This deflection may be used
to produce motion of a feature included in an animated device.
Electroactive polymer transducers offer customizable shapes and
deflections. Combining different ways to configure and constrain a
polymer, different ways to arrange active areas on a single
polymer, different animated device designs, and different polymer
orientations, permits a broad range of animated devices that use an
electroactive polymer transducer to produce motion. These animated
devices find use in a wide range of animated device
applications.
Inventors: |
Kornbluh; Roy D. (Palo Alto,
CA), Pelrine; Ronald E. (Longmont, CO), Pei; Qibing
(Calabasas, CA), Eckerle; Joseph S. (Woodside, CA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Kornbluh; Roy D.
Pelrine; Ronald E.
Pei; Qibing
Eckerle; Joseph S. |
Palo Alto
Longmont
Calabasas
Woodside |
CA
CO
CA
CA |
US
US
US
US |
|
|
Family
ID: |
26890424 |
Appl.
No.: |
12/855,589 |
Filed: |
August 12, 2010 |
Related U.S. Patent Documents
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Application
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Filing Date |
Patent Number |
Issue Date |
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11411007 |
May 1, 2007 |
7211937 |
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10393506 |
Jun 20, 2006 |
7064472 |
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09792431 |
Sep 30, 2003 |
6628040 |
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10154449 |
May 10, 2005 |
6891317 |
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10053511 |
Apr 19, 2005 |
6882086 |
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10393506 |
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09619847 |
Nov 2, 2004 |
6812624 |
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10007705 |
Oct 26, 2004 |
6809462 |
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09828496 |
Jul 1, 2003 |
6586859 |
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10066407 |
May 30, 2006 |
7052594 |
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09779203 |
Dec 16, 2003 |
6664718 |
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10090430 |
Oct 19, 2004 |
6806621 |
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60365472 |
Mar 18, 2002 |
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60184217 |
Feb 23, 2000 |
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60190713 |
Mar 17, 2000 |
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60293003 |
May 22, 2001 |
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60293005 |
May 22, 2001 |
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60327846 |
Oct 5, 2001 |
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60144556 |
Jul 20, 1999 |
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60153329 |
Sep 10, 1999 |
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60161325 |
Oct 25, 1999 |
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60181404 |
Feb 9, 2000 |
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60187809 |
Mar 8, 2000 |
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60192237 |
Mar 27, 2000 |
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60184217 |
Feb 23, 2000 |
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60293004 |
May 22, 2001 |
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60194817 |
Apr 5, 2000 |
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60181404 |
Feb 9, 2000 |
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60273108 |
Mar 2, 2001 |
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Reissue of: |
11696834 |
Apr 5, 2007 |
7411332 |
Aug 12, 2008 |
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Current U.S.
Class: |
310/311; 700/245;
310/326 |
Current CPC
Class: |
F04B
43/043 (20130101); A63H 13/00 (20130101); A63H
13/005 (20130101); H01L 41/083 (20130101); A63H
29/00 (20130101); F04B 43/14 (20130101); Y10S
310/80 (20130101) |
Current International
Class: |
H01L
41/08 (20060101) |
Field of
Search: |
;310/311,328,800,326
;700/245 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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4408618 |
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Sep 1995 |
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DE |
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0295907 |
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Jun 1988 |
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EP |
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55-42474 |
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Mar 1980 |
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JP |
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63-97100 |
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Apr 1988 |
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JP |
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2001-136598 |
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May 2001 |
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JP |
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WO 99/37921 |
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Jul 1999 |
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WO |
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WO 01/06575 |
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Jan 2001 |
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WO |
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WO 01/06579 |
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Jan 2001 |
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WO |
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WO 01/59852 |
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Aug 2001 |
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WO |
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|
Primary Examiner: Dougherty; Thomas
Attorney, Agent or Firm: K&L Gates LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation and claims priority under 35 USC
.sctn. 120 from U.S. patent application Ser. No. 11/411,007 filed
Apr. 24, 2006 which claimed priority under U.S.C. .sctn. 120 from
U.S. patent application Ser. No. 10/393,506, filed Mar. 18, 2003
(now U.S. Pat. No. 7,064,472 issued Jun. 20, 2006) and entitled,
"Electroactive Polymer Devices for Moving Fluid";
this '506 patent application is incorporated herein for all
purposes and claims priority under 35 U.S.C. .sctn. 119(e) from
U.S. Provisional Patent Application No. 60/365,472, by Pelrine et
al., "Electroactive Polymer Devices For Moving Fluid," filed Mar.
18, 2002 which is incorporated by reference for all purposes;
and the '506 patent application is a continuation-in-part and
claims priority from U.S. patent application Ser. No. 09/792,431,
now U.S. Pat. No. 6,628,040 entitled "Electroactive Polymer Thermal
Electric Generators," filed Feb. 23, 2001, which is incorporated
herein by reference in its entirety for all purposes and which
claims priority under 35 U.S.C. .sctn.119(e) from a) U.S.
Provisional Patent Application No. 60/184,217 filed Feb. 23, 2000,
naming Q. Pei et al. as inventors, and titled "Electroelastomers
and Their Use For Power Generation", which is incorporated by
reference herein for all purposes and which also claims priority
under 35 U.S.C. .sctn. 119(e) from b) U.S. Provisional Patent
Application No. 60/190,713 filed Mar. 17, 2000, naming Eckerle et
al. as inventors, and titled "Artificial Muscle Generator", which
is incorporated by reference herein for all purposes;
and the '506 patent application is a continuation-in-part and
claims priority from U.S. patent application Ser. No. 10/154,449,
now U.S. Pat. No. 6,891,317 entitled "Rolled Electroactive
Polymers:" filed May 21, 2002, which is incorporated herein by
reference in its entirety for all purposes which claims priority
under 35 U.S.C. .sctn. 119(e) from U.S. Provisional Patent
Application No. 60/293,003 filed on May 22, 2001, which is also
incorporated by reference for all purposes;
and the '506 patent application is a continuation-in-part and
claims priority from U.S. patent application Ser. No. 10/053,511,
now U.S. Pat. No. 6,882,086 entitled "Variable Stiffness
Electroactive Polymer Systems," filed Jan. 16, 2002 which is
incorporated herein by reference in its entirety for all purposes
which claims priority a) under 35 U.S.C. .sctn. 119(e) from U.S.
Provisional Patent Application No. 60/293,005 filed May 22, 2001,
which is incorporated by reference herein for all purposes; and
which claims priority b) under 35 U.S.C. .sctn. 119(e) from U.S.
Provisional Patent Application No. 60/327,846 entitled Enhanced
Multifunctional Footwear and filed Oct. 5, 2001, which is also
incorporated by reference herein for all purposes;
and the '506 patent application is a continuation-in-part and
claims priority from U.S. patent application Ser. No. 09/619,847,
now U.S. Pat. No. 6,812,624 entitled "Improved Electroactive
Polymers," filed Jul. 20, 2000 which is incorporated herein by
reference in its entirety for all purposes which claims priority a)
under 35 U.S.C. .sctn. 119(e) from U.S. Provisional Patent
Application No. 60/144,556 filed Jul. 20, 1999, naming Pelrine et
al. as inventors, and titled "High-speed Electrically Actuated
Polymers and Method of Use", which is incorporated by reference
herein for all purposes and which claims priority b) under 35
U.S.C. .sctn. 19(e) from U.S. Provisional Patent Application No.
60/153,329 filed Sep. 10, 1999, naming Pelrine et al. as inventors,
and titled "Electrostrictive Polymers As Microactuators", which is
incorporated by reference herein for all purposes and which claims
priority c) under 35 U.S.C. .sctn. 119(e) from U.S. Provisional
Patent Application No. 60/161,325 filed Oct. 25, 1999, naming
Pelrine et al. as inventors, and titled "Artificial Muscle
Microactuators", which is incorporated by reference herein for all
purposes and which claims priority d) under 35 U.S.C. .sctn. to
119(e) from U.S. Provisional Patent Application No. 60/181,404
filed Feb. 9, 2000, naming Kornbluh et al. as inventors, and titled
"Field Actuated Elastomeric Polymers", which is incorporated by
reference herein for all purposes and which claims priority e)
under 35 U.S.C. .sctn. 119(e) from U.S. Provisional Patent
Application No. 60/187,809 filed Mar. 8, 2000, naming Pelrine et
al. as inventors, and titled "Polymer Actuators and Materials",
which is incorporated by reference herein for all purposes; and
which claims priority f) under 35 U.S.C. .sctn. 119(e) from U.S.
Provisional Patent Application No. 60/192,237 filed Mar. 27, 2000,
naming Kornbluh et al. as inventors, and titled "Polymer Actuators
and Materials II", which is incorporated by reference herein for
all purposes and which claims priority g) under 35 U.S.C. .sctn.
119(e) from. U.S. Provisional Patent Application No. 60/184,217
filed Feb. 23, 2000, naming Pelrine et al. as inventors, and titled
"Electroelastomers and their use for Power Generation", which is
incorporated by reference herein for all purposes;
and the '506 patent application is a continuation-in-part and
claims priority from U.S. patent application Ser. No. 10/007,705,
now U.S. Pat. No. 6,809,462 entitled "Electroactive Polymer
Sensors," filed Dec. 6, 2001, which claims priority under 35 U.S.C.
.sctn. 119(e) from U.S. Provisional Patent Application No.
60/293,004 filed May 22, 2001, which is incorporated by reference
herein for all purposes and which is also a continuation in part of
U.S. patent application Ser. No. 09/828,496, now U.S. Pat. No.
6,586,859, which claims priority from U.S. Provisional Application
No. 60/194,817 filed Apr. 5, 2000, all of which are incorporated by
reference herein for all purposes;
and the '506 patent application is a continuation-in-part and
claims priority from co-pending U.S. patent application Ser. No.
10/066,407 entitled "Devices and Methods for Controlling Fluid Flow
Using Elastic Sheet Deflection," filed Jan. 31, 2002, which is
incorporated by reference herein for all purposes
and the '506 patent application is a continuation-in-part and
claims priority from U.S. patent application Ser. No. 09/779,203,
now U.S. Pat. No 6,664,718, filed Feb. 7, 2001, by Pelrine et al.,
and entitled, "Monolithic Electroactive Polymers," which claims
priority under 35 U.S.C. .sctn. 119(e) from U.S. Provisional Patent
Application No. 60/181,404, which is incorporated by reference for
all purposes
and the '506 patent application is a continuation-in-part and
claims priority from U.S. patent application Ser. No. 10/090,430,
now U.S. Pat. No. 6,806,621, filed on Feb. 28, 2002, by Heim et al.
and titled, "Electroactive Polymer Rotary Motors," which claims
priority under 35 U.S.C. .sctn. 119(e) from U.S. Provisional Patent
Application No. 60/273,108, filed Mar. 2, 2001 and titled,
"Electroactive Polymer Motors," both of which are incorporated by
reference for all purposes.
Claims
What is claimed is:
1. An animated .[.toy.]. .Iadd.device .Iaddend.comprising: a
feature capable of motion between a first position and a second
position; and a rolled electroactive polymer transducer either
included in the feature or coupled to the feature and configured to
provide at least a portion of the motion between the first position
and the second position for the feature, the transducer comprising
an active area, which includes at least two electrodes coupled to a
portion of an electroactive polymer, the portion capable of
deflection in response to a change in electric field provided by
the at least two electrodes.
2. The .[.toy.]. .Iadd.device .Iaddend.of claim 1 wherein the
electroactive polymer is elastically pre-strained.
3. The .[.toy.]. .Iadd.device .Iaddend.of claim 1 wherein the
electroactive polymer is a dielectric elastomer.
4. The .[.toy.]. .Iadd.device .Iaddend.of claim 1 wherein the
electroactive polymer is molded.
5. The animated .[.toy.]. .Iadd.device .Iaddend.of claim 1 wherein
the animated .[.toy.]. .Iadd.device .Iaddend.is one of a doll, a
puppet, and an animatronic device.
6. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 1 wherein
the .[.toy.]. .Iadd.animated device .Iaddend.is included in one of
an animated display, a set, a prop, and a moving display of an
amusement park ride.
7. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 1 wherein
the device is configured such that the transducer is used in a
sensor configured to detect a parameter included in the device or
detect a parameter from the environment around the device.
8. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 7 further
comprising a second transducer, the second transducer comprising a
second active area, which includes at least two second active area
electrodes coupled to a portion of a second electroactive polymer,
the portion capable of deflection in response to a change in
electric field provided by the at least two second active area
electrodes.
9. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 8 wherein
the sensor provides one of haptic feedback and force feedback for
motion between the first position and the second position for the
feature.
10. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 1 wherein
the animated .[.toy.]. .Iadd.device .Iaddend.is backdrivable
between the first position and the second position by overcoming
the stiffness of the rolled electroactive polymer during motion
between the first position and the second position.
11. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 1 wherein
motion between the first position and the second position for the
feature has human likeness.
12. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 1 wherein
the first position and the second position are included in legged
locomotive positions of the .[.toy.]. .Iadd.animated
device.Iaddend..
13. An animated .[.toy.]. .Iadd.device .Iaddend.comprising: a
feature capable of motion between a first position and a second
position; and a rolled electroactive polymer transducer either
included in the feature or coupled to the feature and configured to
provide at least a portion of the motion between the first position
and the second position for the feature, the transducer comprising
an active area, which includes at least two electrodes coupled to a
portion of an electroactive polymer, the portion capable of
deflection in response to a change in electric field provided by
the at least two electrodes, wherein the device is configured such
that the transducer is used in a sensor configured to detect a
parameter included in the device or detect a parameter from the
environment around the device.
14. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 13
wherein the sensor provides one of haptic feedback and force
feedback for motion between the first position and the second
position for the feature.
15. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 14
wherein the sensor provides position feedback for the feature
between the first position and the second position.
16. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 14
wherein the first position and the second position are included in
legged locomotive positions of the .[.toy.]. .Iadd.animated
device.Iaddend..
17. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 13
wherein the animated .[.toy.]. .Iadd.device .Iaddend.is one of a
doll, a puppet, and an animatronic device.
18. An animated .[.toy.]. .Iadd.device .Iaddend.comprising: a
feature capable of motion between a first position and a second
position; and a rolled electroactive polymer transducer either
included in the feature or coupled to the feature and configured to
provide at least a portion of the motion between the first position
and the second position for the feature, the transducer comprising
an active area, which includes at least two electrodes coupled to a
portion of an electroactive polymer, the portion capable of
deflection in response to a change in electric field provided by
the at least two electrodes, wherein the animated .[.toy.].
.Iadd.animated device .Iaddend.is backdrivable between the first
position and the second position by overcoming the stiffness of the
rolled electroactive polymer during motion between the first
position and the second position.
19. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 18
wherein the first position and the second position are included in
legged locomotive positions of the .[.toy.]. .Iadd.animated
device.Iaddend..
20. The .[.toy.]. .Iadd.animated device .Iaddend.of claim 18
wherein the electroactive polymer is a dielectric elastomer.
Description
U.S. GOVERNMENT RIGHTS
This application was made in part with government support awarded
by the Office of Naval Research under contract numbers
N00014-96-C-0026, N00014-97-C-0352, N00014-02-C-0252 and
N00174-99-C-0032; and by the Defense Advanced Research Projects
Agency under contract number DABT63-98-C-0024. The government has
certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates generally to animated devices
comprising one or more electroactive polymers. More particularly,
the present invention relates to animated devices having motion
powered by electroactive polymer transducers, and their use in
various applications such as toys and animatronics.
BACKGROUND OF THE INVENTION
An animatronic device is an animated device with motion likeness of
a human, creature, or animal. Conventional animatronic devices
include animatronic puppets, robots, creatures, special effects
make-up, scenic props, sets, etc. These devices find wide use in
themed rides, dark walks, scenery, and special effects for the film
and television industries.
Motion for an animatronic device is typically powered by an
electric or mechanical source. The most common source of power for
an animatronic device is electric motors such as AC, DC, servo, and
stepper motors. Compressed air and pressurized hydraulic fluid are
also used to power air and hydraulic motors in larger animatronic
devices. Each of these forms of power has advantages and
disadvantages that determines its usage.
AC and DC motors provide continuous rotary output, which is often
not suitable for simple animatronic devices. For example, a simple
animatronic device may require a lead screw and other mechanical
assistance to convert continuous rotary output of a motor into
simple linear motion. AC motors provide continuous rotary motion
but are limited to a few speeds that are a function of the AC line
frequency, e.g., 1800 and 3600 rpm based on 60 Hz in the U.S. If
other outputs speeds are desired for an animatronic device, a
gearbox speed reducer is required; thus further complicating the
animatronic device. Servomotors are fast response, closed loop
control motors capable of providing programmed motion. In addition
to the above rotary to linear complications, these devices are also
very expensive. Unlike servomotors, stepper motors are open loop,
meaning they receive no feedback as to whether the output device
has responded as requested. While being relatively good at holding
an output in one position, stepper motors often are poor with
motion, get out of phase with a desired control, moderately
expensive, require special controllers, and thus not ideal for many
animatronic devices.
Air and hydraulic motors have more limited application in
animatronics than electric motors since they require the
availability of a compressed air or hydraulic source. The
additional weight, complexity and relative inefficiency of the
power source makes these devices unsuitable for many animatronic
applications, particularly for small mobile devices, since
extremely small compressors and valves are currently unobtainable.
Although individual air motors and air cylinders are relatively
cheap, these pneumatic systems are also quite expensive when the
cost of all the ancillary equipment is considered.
In addition to the specific drawbacks discussed with respect to
each source of power, all of the above systems are generally heavy,
bulky and not suitable for many applications where light weight and
small size is desirable. Conventional electromagnetic technologies
also typically do not have sufficient energy densities (the work
output on a per volume or per mass basis) to construct many
animatronic devices. The deficiency of many conventional devices is
greater at small scales. As electromagnetic devices are scaled-down
in size, their efficiency decreases. Further, the above
technologies provide strict mechanical output. Many animatronic
applications require a high degree of mobility or dexterity that is
difficult to achieve with conventional actuation technologies.
In view of the foregoing, alternative devices that convert from an
input energy to mechanical energy would be desirable.
SUMMARY OF THE INVENTION
The present invention relates to animated devices that comprise one
or more polymer based transducers. When a voltage is applied to
electrodes contacting an electroactive polymer, the polymer
deflects. Deflection of the transducer may then be converted into
motion of a feature included in an animated device. Electroactive
polymer transducers enable complex and customized animatronic
devices by overcoming many of the actuator limitations described
above. In this application, electroactive polymer transducers
represent a simple, light weight, customizable, and efficient
replacement for conventional actuators in animatronic devices.
In one aspect, the present invention relates to an animated device.
The device comprises a feature capable of motion between a first
position and a second position. The animated device also comprises
a transducer configured to provide at least a portion of the motion
between the first position and the second position for the feature.
The transducer comprises an active area, which includes at least
two electrodes coupled to a portion of an electroactive polymer.
The portion is capable of deflection in response to a change in
electric field provided by the at least two electrodes.
In another aspect, the present invention relates to an animated
face. The face comprises a facial feature capable of motion between
a first position and a second position. The face also comprises a
transducer configured to provide at least a portion of the motion
between the first position and the second position for the facial
feature. The transducer comprises an active area, which includes at
least two electrodes coupled to a portion of an electroactive
polymer. The portion capable of deflection in response to a change
in electric field provided by the at least two electrodes.
In yet another aspect, the present invention relates to an animated
toy. The toy has a feature capable of motion between a first
position and a second position. The animated toy also comprises a
transducer configured to provide at least a portion of the motion
between the first position and the second position. The transducer
comprising an active area, which includes at least two electrodes
coupled to a portion of an electroactive polymer. The portion
capable of deflection in response to a change in electric field
provided by the at least two electrodes.
In still another aspect, the present invention relates to an
animated skin. The animated skin comprises a feature capable of
motion between a first position and a second position. The animated
skin also comprises a transducer configured to provide at least a
portion of the motion between the first position and the second
position for the feature. The transducer comprises an active area,
which includes at least two electrodes coupled to a portion of an
electroactive polymer. The portion is capable of deflection in
response to a change in electric field provided by the at least two
electrodes.
In another aspect, the present invention relates to an animated
device. The animated device has a feature capable of motion between
a first position and a second position. The animated device
comprises a transducer configured to provide at least a portion of
the motion between the first position and the second position for
the feature. The transducer comprises an active area, which
includes at least two electrodes coupled to a portion of an
electroactive polymer. The portion is capable of deflection in
response to a change in electric field provided by the at least two
electrodes. The animated device also comprises a sensor.
In yet another aspect, the present invention relates to an animated
device. The animated device has a feature capable to of motion
between a first position and a second position. The animated device
comprises a transducer configured to provide at least a portion of
the motion between the first position and the second position for
the feature. The transducer comprising an active area, which
includes at least two electrodes coupled to a portion of an
electroactive polymer, the portion capable of deflection in
response to a change in electric field provided by the at least two
electrodes. The animated device also capable of acoustic
emission.
In still another aspect, the present invention relates to an
animated device capable of surface based locomotion. The animated
device has a feature capable of motion between a first position and
a second position. The animated device comprises a transducer
configured to provide at least a portion of the motion between the
first position and the second position for the feature. The
transducer comprises an active area, which includes at least two
electrodes coupled to a portion of an electroactive polymer, the
portion capable of deflection in response to a change in electric
field provided by the at least two electrodes. The device is
configured such that motion between the first position and the
second position for the feature provides at least a portion of the
surface based locomotion.
In another aspect, the present invention relates to a doll. The
doll comprises a body comprising a torso having a pair of arms
extending therefrom, a head, a pair of legs extending downwardly
therefrom, a neck portion supporting the head. The doll also
comprises a transducer configured to move a feature on the doll.
The transducer comprises an active area, which includes at least
two electrodes coupled to a portion of an electroactive polymer.
The portion capable of deflection in response to a change in
electric field provided by the at least two electrodes.
In yet another aspect, the present invention relates to an animated
device having likeness of a human and a feature capable of motion
between a first position and a second position. The animated device
comprises a transducer configured to provide at least a portion of
the motion between the first position and the second position for
the feature. The transducer comprises an active area, which
includes at least two electrodes coupled to a portion of an
electroactive polymer. The portion capable of deflection in
response to a change in electric field provided by the at least two
electrodes. The feature has a human likeness.
These and other features and advantages of the present invention
will be described in the following description of the invention and
associated figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B illustrate a top perspective view of a transducer
before and after application of a voltage in accordance with one
embodiment of the present invention.
FIG. 1C illustrates a cross-sectional side view of a diaphragm
transducer including an electroactive polymer before application of
a voltage in accordance with one embodiment of the present
invention.
FIGS. 2A and 2B illustrate a linear motion actuator suitable for
use with some animated devices of the present invention.
FIG. 2C illustrates cross-sectional side view of a multilayer
actuator suitable for use with some animated devices of the present
invention.
FIGS. 2D and 2E illustrate an actuator suitable for use some
animated devices of the present invention.
FIG. 2F illustrates a cross-sectional side view of a diaphragm
actuator before application of a voltage in accordance with one
embodiment of the present invention.
FIG. 2G illustrates a cross-sectional view of the diaphragm
actuator of FIG. 2F after application of a voltage in accordance
with one embodiment of the present invention.
FIGS. 2H and 2I illustrate a bending beam actuator suitable for use
with some animated devices of the present invention.
FIGS. 3A-B illustrate an animatronic face in accordance with one
embodiment of the present invention.
FIGS. 3C-D illustrate an animatronic eye in accordance with one
embodiment of the present invention.
FIGS. 3E-F illustrate an animatronic face in accordance with
another embodiment of the present invention.
FIG. 3G illustrates a toy dog in accordance with one embodiment of
the present invention.
FIG. 3H illustrates leg assembly for the toy dog of FIG. 3G in
accordance with a specific embodiment of the present invention.
FIG. 3I illustrates leg assembly in accordance with another
specific embodiment of the present invention.
FIG. 3J-L illustrate a toy bird in accordance with another
embodiment of the present invention.
FIG. 3M illustrates a front perspective view of a toy doll
constructed in accordance with another embodiment of the present
invention.
FIGS. 4A-4D illustrate a rolled electroactive polymer device in
accordance with one embodiment of the present invention.
FIG. 4E illustrates an end piece for the rolled electroactive
polymer device of FIG. 2A in accordance with one embodiment of the
present invention.
FIG. 4F illustrates a monolithic transducer comprising a plurality
of active areas on a single polymer, before rolling, in accordance
with one embodiment of the present invention.
FIG. 4G illustrates a rolled transducer that produces
two-dimensional output in accordance with one environment of the
present invention.
FIG. 4H illustrates the rolled transducer of FIG. 4G with actuation
for one set of radially aligned active areas.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with
reference to a few preferred embodiments thereof as illustrated in
the accompanying drawings. In the following description, numerous
specific details are set forth in order to provide a thorough
understanding of the present invention. It will be apparent,
however, to one skilled in the art, that the present invention may
be practiced without some or all of these specific details. In
other instances, well known process steps and/or structures have
not been described in detail in order to not unnecessarily obscure
the present invention.
Overview
The present invention relates to animated devices that include one
or more electroactive polymers. When actuated by electrical energy,
an electroactive polymer produces mechanical deflection. Deflection
of the electroactive polymer transducer may be used to produce
motion of a feature of an animated device. The feature may be a leg
or other body part included in an animated toy, for example.
Electroactive polymer transducers offer customizable deflections by
arranging one or more active areas on a single polymer and offer
customizable shapes. e.g., rolls, diaphragms. etc. Multiple
polymers may be included in a device by stacking or otherwise
combining individual polymers. Combining different ways to arrange
a polymer in a device, different polymer actuators, different ways
to arrange active areas on a single polymer and different animated
device designs, permits a broad range of animated devices that use
an electroactive polymer to produce motion. These animated devices
find use in a wide range of animated device applications.
As the term is used herein, an animated device refers to a device,
figure or object that simulates motion of a living organism or a
portion of an organism. Exemplary animated devices include
animatronic devices, toys, masks, mannequins, displays, scenic and
entertainment industry set decorations, novelty items, etc.
Typically, the animated device is designed or configured to seem
alive or moving or has some form of lifelike movement. In one
embodiment, the devices are configured to simulate human actions
and movements. This also includes non-living objects that simulate
life-like Characteristics, e.g., tea cups having actuated facial
features that simulate talking. As mentioned above, an animatronic
device is one class of animated device with motion likeness of a
human, creature, or animal.
General Structure of Electroactive Polymers
The transformation between electrical and mechanical energy in
devices of the present invention is based on energy conversion of
one or more active areas of an electroactive polymer. Electroactive
polymers are capable of converting between mechanical energy and
electrical energy. In some cases, an electroactive polymer may
change electrical properties (for example, capacitance and
resistance) with changing mechanical strain.
To help illustrate the performance of an electroactive polymer in
converting between electrical energy and mechanical energy, FIG. 1A
illustrates a top perspective view of a transducer portion 10 in
accordance with one embodiment of the present invention. The
transducer portion 10 comprises a portion of an electroactive
polymer 12 for converting between electrical energy and mechanical
energy. In one embodiment, an electroactive polymer refers to a
polymer that acts as an insulating dielectric between two
electrodes and may deflect upon application of a voltage difference
between the two electrodes (a `dielectric elastomer`). Top and
bottom electrodes 14 and 16 are attached to the electroactive
polymer 12 on its top and bottom surfaces, respectively, to provide
a voltage difference across polymer 12, or to receive electrical
energy from the polymer 12. Polymer 12 may deflect with a change in
electric field provided by the top and bottom electrodes 14 and 16.
Deflection of the transducer portion 10 in response to a change in
electric field provided by the electrodes 14 and 16 is referred to
as `actuation`. Actuation typically involves the conversion of
electrical energy to mechanical energy. As polymer 12 changes in
size, the deflection may be used to produce mechanical work.
Without wishing to be bound by any particular theory, in some
embodiments, the polymer 12 may be considered to behave in an
electrostrictive manner. The term electrostrictive is used here in
a generic sense to describe the stress and strain response of a
material to the square of an electric field. The term is often
reserved to refer to the strain response of a material in an
electric field that arises from field induced intra-molecular
forces but we are using the term more generally to refer to other
mechanisms that may result in a response to the square of the
field. Electrostriction is distinguished from piezoelectric
behavior in that the response is proportional to the square of the
electric field, rather than proportional to the field. The
electrostriction of a polymer with compliant electrodes may result
from electrostatic forces generated between free charges on the
electrodes (sometimes referred to as "Maxwell stress") and is
proportional to the square of the electric field. The actual strain
response in this case may be quite complicated depending on the
internal and external forces on the polymer, but the electrostatic
pressure and stresses are proportional to the square of the
field.
FIG. 1B illustrates a top perspective view of the transducer
portion 10 including deflection. In general, deflection refers to
any displacement, expansion, contraction, torsion, linear or area
strain, or any other deformation of a portion of the polymer 12.
For actuation, a change in electric field corresponding to the
voltage difference applied to or by the electrodes 14 and 16
produces mechanical pressure within polymer 12. In this case, the
unlike electrical charges produced by electrodes 14 and 16 attract
each other and provide a compressive force between electrodes 14
and 16 and an expansion force on polymer 12 in planar directions 18
and 19, causing polymer 12 to compress between electrodes 14 and 16
and stretch in the planar directions 18 and 19.
Electrodes 14 and 16 are compliant and change shape with polymer
12. The configuration of polymer 12 and electrodes 14 and 16
provides for increasing polymer 12 response with deflection. More
specifically, as the transducer portion 10 deflects, compression of
polymer 12 brings the opposite charges of electrodes 14 and 16
closer and the stretching of polymer 12 separates similar charges
in each electrode. In one embodiment, one of the electrodes 14 and
16 is ground. For actuation, the transducer portion 10 generally
continues to deflect until mechanical forces balance the
electrostatic forces driving the deflection. The mechanical forces
include elastic restoring forces of the polymer 12 material, the
compliance of electrodes 14 and 16, and any external resistance
provided by a device and/or load coupled to the transducer portion
10, etc. The deflection of the transducer portion 10 as a result of
an applied voltage may also depend on a number of other factors
such as the polymer 12 dielectric constant and the size of polymer
12.
Electroactive polymers in accordance with the present invention are
capable of deflection in any direction. After application of a
voltage between the electrodes 14 and 16, the electroactive polymer
12 increases in size in both planar directions 18 and 19. In some
cases, the electroactive polymer 12 is incompressible, e.g. has a
substantially constant volume under stress. In this case, the
polymer 12 decreases in thickness as a result of the expansion in
the planar directions 18 and 19. It should be noted that the
present invention is not limited to incompressible polymers and
deflection of the polymer 12 may not conform to such a simple
relationship.
Application of a relatively large voltage difference between
electrodes 14 and 16 on the transducer portion 10 shown in FIG. 1A
will cause transducer portion 10 to change to a thinner, larger
area shape as shown in FIG. 1B. In this manner, the transducer
portion 10 converts electrical energy to mechanical energy. The
transducer portion 10 may also be used to convert mechanical energy
to electrical energy.
For actuation, the transducer portion 10 generally continues to
deflect until mechanical forces balance the electrostatic forces
driving the deflection. The mechanical forces include elastic
restoring forces of the polymer 12 material, the compliance of
electrodes 14 and 16, and any external resistance provided by a
device and/or load coupled to the transducer portion 10, etc. The
deflection of the transducer portion 10 as a result of an applied
voltage may also depend on a number of other factors such as the
polymer 12 dielectric constant and the size of polymer 12.
In one embodiment, electroactive polymer 12 is pre-strained.
Pre-strain of a polymer may be described, in one or more
directions, as the change in dimension in a direction after
pre-straining relative to the dimension in that direction before
pre-straining. The pre-strain may comprise elastic deformation of
polymer 12 and be formed, for example, by stretching the polymer in
tension and fixing one or more of the edges while stretched.
Alternatively, as will be described in greater detail below, a
mechanism such as a spring may be coupled to different portions of
an electroactive polymer and provide a force that strains a portion
of the polymer. For many polymers, pre-strain improves conversion
between electrical and mechanical energy. The improved mechanical
response enables greater mechanical work for an electroactive
polymer, e.g., larger deflections and actuation pressures. In one
embodiment, prestrain improves the dielectric strength of the
polymer. In another embodiment, the prestrain is elastic. After
actuation, an elastically pre-strained polymer could, in principle,
be unfixed and return to its original state.
In one embodiment, pre-strain is applied uniformly over a portion
of polymer 12 to produce an isotropic pre-strained polymer. By way
of example, an acrylic elastomeric polymer may be stretched by 200
to 400 percent in both planar directions. In another embodiment,
pre-strain is applied unequally in different directions for a
portion of polymer 12 to produce an anisotropic pre-strained
polymer. In this case, polymer 12 may deflect greater in one
direction than another when actuated. While not wishing to be bound
by theory, it is believed that pre-straining a polymer in one
direction may increase the stiffness of the polymer in the
pre-strain direction. Correspondingly, the polymer is relatively
stiffer in the high pre-strain direction and more compliant in the
low pre-strain direction and, upon actuation, more deflection
occurs in the low pre-strain direction. In one embodiment, the
deflection in direction 18 of transducer portion 10 can be enhanced
by exploiting large pre-strain in the perpendicular direction 19.
For example, an acrylic elastomeric polymer used as the transducer
portion 10 may be stretched by 10 percent in direction 18 and by
500 percent in the perpendicular direction 19. The quantity of
pre-strain for a polymer may be based on the polymer material and
the desired performance of the polymer in an application.
Pre-strain suitable for use with the present invention is further
described in commonly owned, co-pending U.S. patent application
Ser. No. 09/619,848, which is incorporated by reference for all
purposes.
Generally, after the polymer is pre-strained, it may be fixed to
one or more objects or mechanisms. For a rigid object, the object
is preferably suitably stiff to maintain the level of pre-strain
desired in the polymer. A spring or other suitable mechanism that
provides a force to strain the polymer may add to any prestrain
previously established in the polymer before attachment to the
spring or mechanisms, or may be responsible for all the prestrain
in the polymer. The polymer may be fixed to the one or more objects
or mechanisms according to any conventional method known in the art
such as a chemical adhesive, an adhesive layer or material,
mechanical attachment, etc.
Transducers and pre-strained polymers of the present invention are
not limited to any particular rolled geometry or type of
deflection. For example, the polymer and electrodes may be formed
into any geometry or shape including tubes and multi-layer rolls,
rolled polymers attached between multiple rigid structures, rolled
polymers attached across a frame of any geometry--including curved
or complex geometries, across a frame having one or more joints,
etc. Similar structures may be used with polymers in flat sheets.
Deflection of a transducer according to the present invention
includes linear expansion and compression in one or more
directions, bending, axial deflection when the polymer is rolled,
deflection out of a hole provided on an outer cylindrical around
the polymer, etc. Deflection of a transducer may be affected by how
the polymer is constrained by a frame or rigid structures attached
to the polymer.
Materials suitable for use as an electroactive polymer with the
present invention may include any substantially insulating polymer
or rubber (or combination thereof) that deforms in response to an
electrostatic force or whose deformation results in a change in
electric field. One suitable material is NuSil CF19-2186 as
provided by NuSil Technology of Carpenteria, Calif. Other exemplary
materials suitable for use as a pre-strained polymer include
silicone elastomers, acrylic elastomers such as VHB 4910 acrylic
elastomer as produced by 3M Corporation of St. Paul, Minn.,
polyurethanes, thermoplastic elastomers, copolymers comprising
PVDF, pressure-sensitive adhesives, fluoroelastomers, polymers
comprising silicone and acrylic moieties, and the like. Polymers
comprising silicone and acrylic moieties may include copolymers
comprising silicone and acrylic moieties, polymer blends comprising
a silicone elastomer and an acrylic elastomer, for example.
Combinations of some of these materials may also be used as the
electroactive polymer in transducers of this invention.
Materials used as an electroactive polymer may be selected based on
one or more material properties such as a high electrical breakdown
strength, a low modulus of elasticity--(for large or small
deformations), a high dielectric constant, etc. In one embodiment,
the polymer is selected such that is has an elastic modulus at most
about 100 MPa. In another embodiment, the polymer is selected such
that is has a maximum actuation pressure between about 0.05 MPa and
about 10 MPa, and preferably between about 0.3 MPa and about 3 MPa.
In another embodiment, the polymer is selected such that is has a
dielectric constant between about 2 and about 20, and preferably
between about 2.5 and about 12. The present invention is not
limited to these ranges. Ideally, materials with a higher
dielectric constant than the ranges given above would be desirable
if the materials had both a high dielectric constant and a high
dielectric strength.
An electroactive polymer layer in transducers of the present
invention may have a wide range of thicknesses. In one embodiment,
polymer thickness may range between about 1 micrometer and 2
millimeters. Polymer thickness may be reduced by stretching the
film in one or both planar directions. In many cases, electroactive
polymers of the present invention may be fabricated and implemented
as thin films. Thicknesses suitable for these thin films may be
below 50 micrometers.
As electroactive polymers of the present invention may deflect at
high strains, electrodes attached to the polymers should also
deflect without compromising mechanical or electrical performance.
Generally, electrodes suitable for use with the present invention
may be of any shape and material provided that they are able to
supply a suitable voltage to, or receive a suitable voltage from,
an electroactive polymer. The voltage may be either constant or
varying over time. In one embodiment, the electrodes adhere to a
surface of the polymer. Electrodes adhering to the polymer are
preferably compliant and conform to the changing shape of the
polymer. Correspondingly, the present invention may include
compliant electrodes that conform to the shape of an electroactive
polymer to which they are attached. The electrodes may be only
applied to a portion of an electroactive polymer and define an
active area according to their geometry. Several examples of
electrodes that only cover a portion of an electroactive polymer
will be described in further detail below.
Various types of electrodes suitable for use with the present
invention are described in commonly owned, co-pending U.S. patent
application Ser. No. 09/619,848, which was previously incorporated
by reference above. Electrodes described therein and suitable for
use with the present invention include structured electrodes
comprising metal traces and charge distribution layers, textured
electrodes comprising varying out of plane dimensions, conductive
greases such as carbon greases or silver greases, colloidal
suspensions, high aspect ratio conductive materials such as carbon
fibrils and carbon nanotubes, and mixtures of ionically conductive
materials.
Materials used for electrodes of the present invention may vary.
Suitable materials used in an electrode may include graphite,
carbon black, colloidal suspensions, thin metals including silver
and gold, silver filled and carbon filled gels and polymers, and
ionically or electronically conductive polymers. In a specific
embodiment, an electrode suitable for use with the present
invention comprises 80 percent carbon grease and 20 percent carbon
black in a silicone rubber binder such as Stockwell RTV60-CON as
produced by Stockwell Rubber Co. Inc. of Philadelphia, Pa. The
carbon grease is of the type such as NyoGel 756G as provided by Nye
Lubricant Inc. of Fairhaven. Mass. The conductive grease may also
be mixed with an elastomer, such as silicon elastomer RTV 118 as
produced by General Electric of Waterford, N.Y., to provide a
gel-like conductive grease.
It is understood that certain electrode materials may work well
with particular polymers and may not work as well for others. By
way of example, carbon fibrils work well with acrylic elastomer
polymers while not as well with silicone polymers. For most
transducers, desirable properties for the compliant electrode may
include one or more of the following: low modulus of elasticity,
low mechanical damping, low surface resistivity, uniform
resistivity, chemical and environmental stability, chemical
compatibility with the electroactive polymer, good adherence to the
electroactive polymer, and the ability to form smooth surfaces. In
some cases, a transducer of the present invention may implement two
different types of electrodes, e.g. a different electrode type for
each active area or different electrode types on opposing sides of
a polymer.
Suitable actuation voltages for electroactive polymers, or portions
thereof, may vary based on the material properties of the
electroactive polymer (e.g., dielectric constant) and the
dimensions of the polymer (e.g., polymer film thickness). For
example, actuation electric fields used to actuate polymer 102 in
FIG. 1A may range in magnitude from about 0 V/m to about 440 MV/m.
Actuation electric fields in this range may produce a pressure in
the range of about 0 Pa to about 10 MPa. In order for the
transducer to produce greater forces, the thickness of the polymer
layer may be increased. Actuation voltages for a particular polymer
may be reduced by increasing the dielectric constant, decreasing
the polymer thickness, and decreasing the modulus of elasticity,
for example.
Generally, electrodes suitable for use with the present invention
may be of any shape and material provided that they are able to
supply a suitable voltage to an electroactive polymer. The voltage
may be either constant or varying over time. In one embodiment, the
electrodes adhere to a surface of the polymer. As electroactive
polymers of the present invention may deflect at high strains,
electrodes attached to the polymers should also deflect without
compromising mechanical or electrical performance. Correspondingly,
the present invention may include compliant electrodes that conform
to the changing shape of an electroactive polymer to which they are
attached. The electrodes may be only applied to a portion of an
electroactive polymer and define an active area according to their
geometry. In many cases, such as the pupil described below with
respect to FIG. 3C, the shape of the electrode provides substantial
simulation of a feature in an animated device.
Various types of electrodes suitable for use with the present
invention are described in copending U.S. patent application Ser.
No. 09/619,848, which was previously incorporated by reference
above. Electrodes described therein and suitable for use with the
present invention include structured electrodes comprising metal
traces and charge distribution layers, textured electrodes
comprising varying out of plane dimensions, conductive greases such
as carbon greases or silver greases, colloidal suspensions, high
aspect ratio conductive materials such as carbon fibrils and carbon
nanotubes, and mixtures of ionically conductive materials.
Materials used for electrodes of the present invention may vary.
Suitable materials used in an electrode may include graphite,
carbon black, colloidal suspensions, thin metals including silver
and gold, silver filled and carbon filled gels and polymers, and
ionically or electrically conductive polymers. In a specific
embodiment, an electrode suitable for use with the present
invention comprises 80 percent carbon grease and 20 percent carbon
black in a silicone rubber binder such as Stockwell RTV60-CON as
produced by Stockwell Rubber Co. Inc. of Philadelphia, Pa. The
carbon grease is of the type such as NyoGel 756G as provided by Nye
Lubricant Inc. of Fairhaven, Mass. The conductive grease may also
be mixed with an elastomer, such as silicon elastomer RTV 118 as
produced by General Electric of Waterford, N.Y., to provide a
gel-like conductive grease.
It is understood that certain electrode materials may work well
with particular polymers and may not work as well for others. For
example, carbon fibrils work well with acrylic elastomer polymers
while not as well with silicone polymers. For most transducers,
desirable properties for the compliant electrode may include one or
more of the following: low modulus of elasticity, low mechanical
damping, low surface resistivity, uniform resistivity, chemical and
environmental stability, chemical compatibility with the
electroactive polymer, good adherence to the electroactive polymer,
and the ability to form smooth surfaces. In some cases, a
transducer of the present invention may implement two different
types of electrodes, e.g., a different electrode type for each
active area or different electrode types on opposing sides of a
polymer.
Devices of the present invention may also rely on conditioning
electronics that provide or receive electrical energy from
electrodes of an active area for one of the electroactive polymer
functions mentioned above. Conditioning electronics in electrical
communication with one or more active areas may include functions
such as stiffness control, energy dissipation, electrical energy
generation, polymer actuation, polymer deflection sensing, control
logic, etc.
For actuation, electronic drivers may be connected to the
electrodes. The voltage provided to electrodes of an active area
will depend upon specifics of an application. In one embodiment, an
active area of the present invention is driven electrically by
modulating an applied voltage about a DC bias voltage. Modulation
about a bias voltage allows for improved sensitivity and linearity
of the transducer to the applied voltage. For example, a transducer
used in an audio application may be driven by a signal of up to 200
to 100 volts peak to peak on top of a bias voltage ranging from
about 750 to 2000 volts DC.
Suitable actuation voltages for electroactive polymers, or portions
thereof, may vary based on the material properties of the
electroactive polymer, such as the dielectric constant, as well as
the dimensions of the polymer, such as the thickness of the polymer
film. For example, actuation electric fields used to actuate
polymer 12 in FIG. 4A may range in magnitude from about 0 V/m to
about 440 MV/m. Actuation electric fields in this range may produce
a pressure in the range of about 0 Pa to about 10 MPa. In order for
the transducer to produce greater forces, the thickness of the
polymer layer may be increased. Actuation voltages for a particular
polymer may be reduced by increasing the dielectric constant,
decreasing the polymer thickness, and decreasing the modulus of
elasticity, for example.
Transducers of the present invention are also capable of acoustic
emission. More specifically, transducers of the present invention
may be actuated at frequencies to produce sound in a medium such as
air. Thus, the same transducer responsible for actuation of a
feature in an animated device may also be responsible for acoustic
emission for the animated device. Typically, an audio signal is
provided to electrodes in contact with the polymer such that sound
waves are produced during rapid actuation and elastic contraction
of the transducer. The signal may be a signal from a stereo player
or microphone that has been amplified and converted to the correct
voltage range. For example, a transducer used to provide acoustic
emission may be driven by a signal of up to 200 to 1000 volts peak
to peak on top of a bias voltage ranging from about 750 to 2000
volts DC. However, it will be appreciated that the particular
voltages used may vary based on the parameters of an application.
Further description of electroactive polymer transducers used to
produce sound is described in commonly owned, co-pending U.S.
Patent Application entitled "Elastomeric Dielectric Polymer Film
Sonic Actuator" naming R. E. Pelrine et al. as inventors, filed on
Jul. 19, 1999 (U.S. application Ser. No. 09/356,801), which is
incorporated herein for all purposes.
Although the discussion so far has focused primarily on one type of
electroactive polymer commonly referred to as dielectric elastomers
(transducer 10 of FIG. 1A), animated devices of the present
invention may also incorporate other conventional electroactive
polymers. As the term is used herein, an electroactive polymer
refers to a polymer that responds to electrical stimulation. Other
common classes of electroactive polymer suitable for use with many
embodiments of the present invention include electrostrictive
polymers, electronic electroactive polymers, and ionic
electroactive polymers, and some copolymers. Electrostrictive
polymers are characterized by the non-linear reaction of a
electroactive polymers (relating strain to E2). Electronic
electroactive polymers typically change shape or dimensions due to
migration of electrons in response to electric field (usually dry).
Ionic electroactive polymers are polymers that change shape or
dimensions due to migration of ions in response to electric field
(usually wet and contains electrolyte). Irradiated copolymer of
polyvinylidene difluoride and trifluoroethelene P(VDF-TrFE) is an
electroactive polymer suitable for use with some embodiments of the
present invention.
Multiple Active Areas
In accordance with the present invention, the term "monolithic" is
used herein to refer to electroactive polymers, transducers, and
devices comprising a plurality of active areas on a single
electroactive polymer.
FIG. 1C illustrates a monolithic transducer 150 comprising a
plurality of active areas in accordance with one embodiment of the
present invention. The monolithic transducer 150 converts between
electrical energy and mechanical energy. The monolithic transducer
150 comprises an electroactive polymer 151 including two active
areas 152a and 152b. The polymer 151 can be held using, for
example, a rigid frame (not shown) attached at the edges of the
polymer 151.
The active area 152a has top and bottom electrodes 154a and 154b
attached to the polymer 151 on its top and bottom surfaces 151c and
151d, respectively. The electrodes 154a and 154b provide a voltage
difference across a portion 151a of the polymer 151. The portion
151a deflects with a change in electric field provided by the
electrodes 154a and 154b. The portion 151a comprises the polymer
151 between the electrodes 154a and 154b and any other portions of
the polymer 151 having sufficient electrostatic force to enable
deflection upon application of voltages using the electrodes 154a
and 154b.
The active area 152b has top and bottom electrodes 156a and 156b
attached to the polymer 151 on its top and bottom surfaces 151c and
151d, respectively. The electrodes 156a and 156b provide a voltage
difference across a portion 151b of the polymer 151. The portion
151b deflects with a change in electric field provided by the
electrodes 156a and 156b. The portion 151b comprises the polymer
151 between the electrodes 156a and 156b and any other portions of
the polymer 151 having sufficient stress induced by the
electrostatic force to enable deflection upon application of
voltages using the electrodes 156a and 156b.
Active areas for monolithic polymers and transducers of the present
invention may be flexibly arranged. In one embodiment, active areas
in a polymer are arranged such that elasticity of the active areas
is balanced. In another embodiment, a transducer of the present
invention includes a plurality of symmetrically arranged active
areas. Further description of monolithic transducers suitable for
use with the present invention are further described in commonly
owned U.S. patent application Ser. No. 09/779,203, which is
incorporated by reference herein for all purposes.
Actuator Designs
The deflection of an electroactive polymer can be used in a variety
of ways to produce mechanical energy. One common implementation of
a transducer in an animated device is within an actuator. Generally
speaking, animated devices of the present invention may be
implemented with a variety of actuators--including conventional
actuators retrofitted with a polymer and custom actuators specially
designed for one or more polymers. Conventional actuators include
extenders, bending beams, stacks, diaphragms, etc. Several
different exemplary actuators suitable for use with some animated
devices of the present invention will now be discussed.
A straightforward electroactive polymer drive is one where the
transducer acts as a linear actuator in much the same way as a
conventional pneumatic or hydraulic cylinder might be employed.
FIGS. 2A-2E illustrate several linear electroactive polymer
actuators suitable for use with the present invention.
The shape and constraint of an electroactive polymer may affect
deflection. An aspect ratio for an electroactive polymer is defined
as the ratio of its length to width. If the aspect ratio is high
(e.g., an aspect ratio of at least about 4:1) and the polymer is
constrained along its length by rigid members, than the combination
may result in a substantially one-dimensional deflection in the
width direction.
FIGS. 2A and 2B illustrate a linear motion actuator 230 suitable
for use with devices of the present invention. The linear motion
actuator 230 is a planar mechanism having mechanical deflection in
one direction. The linear motion actuator 230 comprises a polymer
231 having a length 233 substantially greater than its width 234
(e.g., an aspect ratio at least about 4:1). The polymer 231 is
attached on opposite sides to stiff members 232 of a frame along
its length 233. The stiff members 232 have a greater stiffness than
the polymer 231. The geometric edge constraint provided by the
stiff members 232 substantially prevents displacement in a
direction 236 along the polymer length 233 and facilitates
deflection almost exclusively in a direction 235. When the linear
motion actuator 230 is implemented with a polymer 231 having
anisotropic pre-strain, such as a higher pre-strain in the
direction 236 than in the direction 235, then the polymer 231 is
stiffer in the direction 236 than in the direction 235 and large
deflections in the direction 235 may result.
A collection of electroactive polymers or actuators may be
mechanically linked to form a larger actuator with a common output,
e.g. force and/or displacement. By using a small electroactive
polymer as a base unit in a collection, conversion of electric
energy to mechanical energy may be scaled according to an
application. By way of example, multiple linear motion actuators
230 may be combined in series in the direction 235 to form an
actuator having a cumulative deflection of all the linear motion
actuators in the series.
FIG. 2C illustrates cross-sectional side view of a multilayer
actuator 240 for converting from electrical energy to mechanical
energy. The multilayer actuator 240 includes four pre-strained
polymers 241 arranged in parallel and each attached to a rigid
frame 242 such that they have the same deflection. Electrodes 243
and 244 are deposited on opposite surfaces of each polymer 241 and
are in electrical communication such that they provide simultaneous
electrostatic actuation to the four pre-strained polymers 241. The
multilayer actuator 240 provides cumulative force output of the
individual polymer layers 241. In one embodiment, electrodes 243
and 244 are arranged to provide separate actuation for each polymer
241. In this manner, one may use on-off voltage control actuation
of each polymer 241. This arrangement provides a user relatively
simple control of force magnitude for the multilayer actuator 240.
the
FIGS. 2D and 2E illustrate a linear actuator 300 suitable for use
some animated devices of the present invention. The actuator 300
includes a polymer 302 arranged in a manner which causes a portion
of the polymer to deflect in response to a change in electric
field. Electrodes 304 are attached to opposite surfaces (only the
foremost electrode is shown) of the polymer 302 and cover a
substantial portion of the polymer 302. Two stiff members 308 and
310 extend along opposite edges 312 and 314 of the polymer 302.
Flexures 316 and 318 are situated along the remaining edges of the
polymer 302. The flexures 316 and 318 improve conversion from
electrical energy to mechanical energy for the actuator 300.
The flexures 316 and 318 couple polymer 302 deflection in one
direction into deflection in another direction. In one embodiment,
each of the flexures 316 and 318 rest at an angle about 45 degrees
in the plane of the polymer 302. Upon actuation of the polymer 302,
expansion of the polymer 302 in the direction 320 causes the stiff
members 308 and 310 to move apart, as shown in FIG. 2E. In
addition, expansion of the polymer 302 in the direction 322 causes
the flexures 316 and 318 to straighten, and further separates the
stiff members 308 and 310. In this manner, the actuator 300 couples
expansion of the polymer 302 in both planar directions 320 and 322
into mechanical output in the direction 320.
One advantage of the actuator 300 is that the entire structure is
planar. In addition to simplifying fabrication, the planar
structure of the actuator 300 allows for easy mechanical coupling
to produce multilayer designs. By way of example, the stiff members
308 and 310 may be mechanically coupled (e.g., glued or similarly
fixed) to their respective counterparts of a second actuator 300 to
provide two actuators 300 in parallel in order to increase the
force output over single actuator 300. Similarly, the stiff member
308 from one actuator may be attached to the stiff member 310 from
a second actuator in order to provide multiple actuators in series
that increase the deflection output over a single actuator 300.
In another embodiment, electroactive polymers suitable for use the
present invention may be rolled or folded into linear transducers
and actuators that deflect axially while converting from electrical
energy to mechanical energy. As fabrication of electroactive
polymers is often simplest with fewer numbers of layers, rolled
actuators provide an efficient manner of squeezing large layers of
polymer into a compact shape. Rolled or folded transducers and
actuators typically include two or more layers of polymer. Rolled
or folded actuators are applicable wherever linear actuators are
used, such as legs and fingers, high force grippers, or some of the
animated designs described below.
FIG. 2F-G illustrate a cross-sectional side view of a monolithic
diaphragm actuator 130 comprising a monolithic polymer 131 before
deflection in accordance with one embodiment of the present
invention. The polymer 131 is attached to a frame 132. The frame
132 includes apertures 133a and 133b that allow deflection of
polymer portions 131a and 131b perpendicular to the area of the
apertures 133a and 133b, respectively. The diaphragm device 130
comprises electrodes 134a and 134b attached on either side of the
portion 131a to provide a voltage difference across the portion
131a. Electrodes 136a and 136b are deposited on either side of the
portion 131b to provide a voltage difference across the portion
131b. The electrodes 134 and 136 are compliant and change shape
with polymer 131 as it deflects. In the voltage-off configuration
of FIG. 2F, polymer 131 is stretched and secured to frame 132 with
tension to achieve pre-strain.
Using electrodes 134 and 136, portions 131a and 131b are capable of
independent deflection. For example, upon application of a suitable
voltage between electrodes 134a and 134b, portion 131a expands away
from the plane of the frame 132, as illustrated in FIG. 2G. Each of
the portions 131a and 131b is capable of expansion in both
perpendicular directions away from the plane. In one embodiment,
one side of polymer 131 comprises a bias pressure that influences
the expansion of the polymer film 131 to continually actuate upward
in the direction of arrows 143 (FIG. 2G). In another embodiment, a
swelling agent such as a small amount of silicone oil is applied to
the bottom side to influence the expansion of polymer 131 in the
direction of arrows 143. The swelling agent allows the diaphragm to
continually actuate in a desired direction without using a bias
pressure. The swelling agent causes slight permanent deflection in
one direction as determined during fabrication, e.g. by supplying a
slight pressure to the bottom side when the swelling agent is
applied. The swelling agent allows the diaphragm to continually
actuate in a desired direction without using a bias pressure.
FIG. 2H illustrates a bending beam actuator 280 suitable for use
with animated devices of the present invention. The bending beam
actuator 280 includes a polymer 281 fixed at one end by member 282
and attached to a flexible thin material 283 such as polyimide or
mylar using an adhesive layer, for example. The flexible thin
material 283 has a modulus of elasticity greater than the polymer
281. The difference in modulus of elasticity for the top and bottom
sides 286 and 287 of the bending beam actuator 280 causes the
bending beam actuator 280 to bend upon actuation. Electrodes 284
and 285 are attached to the opposite sides of the polymer 281 to
provide electrical energy. The bending beam actuator 280 includes a
free end 288 having a single bending degree of freedom. Deflection
of the free end 288 may be measured by the difference in angle
between the free end 288 and the end fixed by the rigid support
282. FIG. 2I illustrates the bending beam actuator 280 with a 90
degree bending angle. The maximum bending angle for the bending
beam actuator 280 will vary with a number of factors including the
polymer material, the actuator length, the bending stiffness of the
electrodes 284 and 285 and flexible thin material 283, etc.
Although FIGS. 2A-2I illustrate several actuators suitable for use
with motors of the present invention, other actuators including one
or more electroactive polymers may also be used. Other exemplary
actuators include bending beam actuators, diaphragm actuators and
inchworm actuators are also suitable for use with the present
invention. Additional exemplary linear and non-linear actuators
suitable for use with the present invention are described in
commonly owned U.S. patent application Ser. No. 09/619,848, which
was previously incorporated by reference.
FIGS. 4A-4E show a rolled electroactive polymer device 20 in
accordance with one embodiment of the present invention. The rolled
electroactive polymer device may be used for actuation in EPAM
devices for performing thermodynamic work on a fluid and may also
act as part of a fluid conduit or other types of structures
immersed in an external or internal flow field that is used with
the devices for performing thermodynamic work. The rolled
electroactive polymer devices may provide linear and/or
rotational/torsional motion for operating the EPAM devices. For
instance, see the fan embodiment in FIG. 2H. FIG. 4A illustrates a
side view of device 20. FIG. 4B illustrates an axial view of device
20 from the top end. FIG. 4C illustrates an axial view of device 20
taken through cross section A-A. FIG. 4D illustrates components of
device 20 before rolling. Device 20 comprises a rolled
electroactive polymer 22, spring 24, end pieces 27 and 28, and
various fabrication components used to hold device 20 together.
As illustrated in FIG. 4C, electroactive polymer 22 is rolled. In
one embodiment, a rolled electroactive polymer refers to an
electroactive polymer with, or without electrodes, wrapped round
and round onto itself (e.g., like a poster) or wrapped around
another object (e.g., spring 24). The polymer may be wound
repeatedly and at the very least comprises an outer layer portion
of the polymer overlapping at least an inner layer portion of the
polymer. In one embodiment, a rolled electroactive polymer refers
to a spirally wound electroactive polymer wrapped around an object
or center. As the term is used herein, rolled is independent of how
the polymer achieves its rolled configuration.
As illustrated by FIGS. 4C and 4D, electroactive polymer 22 is
rolled around the outside of spring 24. Spring 24 provides a force
that strains at least a portion of polymer 22. The top end 24a of
spring 24 is attached to rigid endpiece 27. Likewise, the bottom
end 24b of spring 24 is attached to rigid endpiece 28. The top edge
22a of polymer 22 (FIG. 4D) is wound about endpiece 27 and attached
thereto using a suitable adhesive. The bottom edge 22b of polymer
22 is wound about endpiece 28 and attached thereto using an
adhesive. Thus, the top end 24a of spring 24 is operably coupled to
the top edge 22a of polymer 22 in that deflection of top end 24a
corresponds to deflection of the top edge 22a of polymer 22.
Likewise, the bottom end 24b of spring 24 is operably coupled to
the bottom edge 22b of polymer 22 and deflection bottom end 24b
corresponds to deflection of the bottom edge 22b of polymer 22.
Polymer 22 and spring 24 are capable of deflection between their
respective bottom top portions.
As mentioned above, many electroactive polymers perform better when
prestrained. For example, some polymers exhibit a higher breakdown
electric field strength, electrically actuated strain, and energy
density when prestrained. Spring 24 of device 20 provides forces
that result in both circumferential and axial prestrain onto
polymer 22.
Spring 24 is a compression spring that provides an outward force in
opposing axial directions (FIG. 4A) that axially stretches polymer
22 and strains polymer 22 in an axial direction. Thus, spring 24
holds polymer 22 in tension in axial direction 35. In one
embodiment, polymer 22 has an axial prestrain in direction 35 from
about 50 to about 300 percent. As will be described in further
detail below for fabrication, device 20 may be fabricated by
rolling a prestrained electroactive polymer film around spring 24
while it the spring is compressed. Once released, spring 24 holds
the polymer 22 in tensile strain to achieve axial prestrain.
Spring 24 also maintains circumferential prestrain on polymer 22.
The prestrain may be established in polymer 22 longitudinally in
direction 33 (FIG. 4D) before the polymer is rolled about spring
24. Techniques to establish prestrain in this direction during
fabrication will be described in greater detail below. Fixing or
securing the polymer after rolling, along with the substantially
constant outer dimensions for spring 24, maintains the
circumferential prestrain about spring 24. In one embodiment,
polymer 22 has a circumferential prestrain from about 100 to about
500 percent. In many cases, spring 24 provides forces that result
in anisotropic prestrain on polymer 22.
End pieces 27 and 28 are attached to opposite ends of rolled
electroactive polymer 22 and spring 24. FIG. 4E illustrates a side
view of end piece 27 in accordance with one embodiment of the
present invention. Endpiece 27 is a circular structure that
comprises an outer flange 27a, an interface portion 27b, and an
inner hole 27c. Interface portion 27b preferably has the same outer
diameter as spring 24. The edges of interface portion 27b may also
be rounded to prevent polymer damage. Inner hole 27c is circular
and passes through the center of endpiece 27, from the top end to
the bottom outer end that includes outer flange 27a. In a specific
embodiment, endpiece 27 comprises aluminum, magnesium or another
machine metal. Inner hole 27c is defined by a hole machined or
similarly fabricated within endpiece 27. In a specific embodiment,
endpiece 27 comprises 1/2 inch end caps with a 3/8 inch inner hole
27c.
In one embodiment, polymer 22 does not extend all the way to outer
flange 27a and a gap 29 is left between the outer portion edge of
polymer 22 and the inside surface of outer flange 27a. As will be
described in further detail below, an adhesive or glue may be added
to the rolled electroactive polymer device to maintain its rolled
configuration. Gap 29 provides a dedicated space on endpiece 27 for
an adhesive or glue than the buildup to the outer diameter of the
rolled device and fix to all polymer layers in the roll to endpiece
27. In a specific embodiment, gap 29 is between about 0 mm and
about 5 mm.
The portions of electroactive polymer 22 and spring 24 between end
pieces 27 and 28 may be considered active to their functional
purposes. Thus, end pieces 27 and 28 define an active region 32 of
device 20 (FIG. 4A). End pieces 27 and 28 provide a common
structure for attachment with spring 24 and with polymer 22. In
addition, each end piece 27 and 28 permits external mechanical and
detachable coupling to device 20. For example, device 20 may be
employed in a robotic application where endpiece 27 is attached to
an upstream link in a robot and endpiece 28 is attached to a
downstream link in the robot. Actuation of electroactive polymer 22
then moves the downstream link relative to the upstream link as
determined by the degree of freedom between the two links (e.g.,
rotation of link 2 about a pin joint on link 1).
In a specific embodiment, inner hole 27c comprises an internal
thread capable of threaded interface with a threaded member, such
as a screw or threaded bolt. The internal thread permits detachable
mechanical attachment to one end of device 20. For example, a screw
may be threaded into the internal thread within end piece 27 for
external attachment to a robotic element. For detachable mechanical
attachment internal to device 20, a nut or bolt to be threaded into
each end piece 27 and 28 and pass through the axial core of spring
24, thereby fixing the two end pieces 27 and 28 to each other. This
allows device 20 to be held in any state of deflection, such as a
fully compressed state useful during rolling. This may also be
useful during storage of device 20 so that polymer 22 is not
strained in storage.
In one embodiment, a stiff member or linear guide 30 is disposed
within the spring core of spring 24. Since the polymer 22 in spring
24 is substantially compliant between end pieces 27 and 28, device
20 allows for both axial deflection along direction 35 and bending
of polymer 22 and spring 24 away from its linear axis (the axis
passing through the center of spring 24). In some embodiments, only
axial deflection is desired. Linear guide 30 prevents bending of
device 20 between end pieces 27 and 28 about the linear axis.
Preferably, linear guide 30 does not interfere with the axial
deflection of device 20. For example, linear guide 30 preferably
does not introduce frictional resistance between itself and any
portion of spring 24. With linear guide 30, or any other suitable
constraint that prevents motion outside of axial direction 35,
device 20 may act as a linear actuator or generator with output
strictly in direction 35. Linear guide 30 may be comprised of any
suitably stiff material such as wood, plastic, metal, etc.
Polymer 22 is wound repeatedly about spring 22. For single
electroactive polymer layer construction, a rolled electroactive
polymer of the present invention may comprise between about 2 and
about 200 layers. In this case, a layer refers to the number of
polymer films or sheets encountered in a radial cross-section of a
rolled polymer. In some cases, a rolled polymer comprises between
about 3 and about 100 layers. In a specific embodiment, a rolled
electroactive polymer comprises between about 15 and about 50
layers.
In another embodiment, a rolled electroactive polymer employs a
multilayer structure. The multilayer structure comprises multiple
polymer layers disposed on each other before rolling or winding.
For example, a second electroactive polymer layer, without
electrodes patterned thereon, may be disposed on an electroactive
polymer having electrodes patterned on both sides. The electrode
immediately between the two polymers services both polymer surfaces
in immediate contact. After rolling, the electrode on the bottom
side of the electroded polymer then contacts the top side of the
non-electroded polymer. In this manner, the second electroactive
polymer with no electrodes patterned thereon uses the two
electrodes on the first electroded polymer.
Other multilayer constructions are possible. For example, a
multilayer construction may comprise any even number of polymer
layers in which the odd number polymer layers are electroded and
the even number polymer layers are not. The upper surface of the
top non-electroded polymer then relies on the electrode on the
bottom of the stack after rolling. Multilayer constructions having
2, 4, 6, 8, etc., are possible this technique. In some cases, the
number of layers used in a multilayer construction may be limited
by the dimensions of the roll and thickness of polymer layers. As
the roll radius decreases, the number of permissible layers
typically decrease is well. Regardless of the number of layers
used, the rolled transducer is configured such that a given
polarity electrode does not touch an electrode of opposite
polarity. In one embodiment, multiple layers are each individually
electroded and every other polymer layer is flipped before rolling
such that electrodes in contact each other after rolling are of a
similar voltage or polarity.
The multilayer polymer stack may also comprise more than one type
of polymer For example, one or more layers of a second polymer may
be used to modify the elasticity or stiffness of the rolled
electroactive polymer layers. This polymer may or may not be active
in the charging/discharging during the actuation. When a non-active
polymer layer is employed, the number of polymer layers may be odd.
The second polymer may also be another type of electroactive
polymer that varies the performance of the rolled product.
In one embodiment, the outermost layer of a rolled electroactive
polymer does not comprise an electrode disposed thereon. This may
be done to provide a layer of mechanical protection, or to
electrically isolate electrodes on the next inner layer. For
example, inner and outer layers and surface coating may be selected
to provide fluid compatibility as previously described. The
multiple layer characteristics described above may also be applied
non-rolled electroactive polymers, such as EPAM diaphragms
previously described.
Device 20 provides a compact electroactive polymer device structure
and improves overall electroactive polymer device performance over
conventional electroactive polymer devices. For example, the
multilayer structure of device 20 modulates the overall spring
constant of the device relative to each of the individual polymer
layers. In addition, the increased stiffness of the device achieved
via spring 24 increases the stiffness of device 20 and allows for
faster response in actuation, if desired.
In a specific embodiment, spring 24 is a compression spring such as
catalog number 11422 as provided by Century Spring of Los Angeles,
Calif. This spring is characterized by a spring force of 0.91
lb/inch and dimensions of 4.38 inch free length, 1.17 inch solid
length, 0.360 inch outside diameter, 0.3 inch inside diameter. In
this case, rolled electroactive polymer device 20 has a height 36
from about 5 to about 7 cm, a diameter 37 of about 0.8 to about 1.2
cm, and an active region between end pieces of about 4 to about 5
cm. The polymer is characterized by a circumferential prestrain
from about 300 to about 500 percent and axial prestrain (including
force contributions by spring 24) from about 150 to about 250
percent.
Although device 20 is illustrated with a single spring 24 disposed
internal to the rolled polymer, it is understood that additional
structures such as another spring external to the polymer may also
be used to provide strain and prestrain forces. These external
structures may be attached to device 20 using end pieces 27 and 28
for example.
In another embodiment, multiple active areas on an electroactive
polymer are disposed such subsets of the active areas radially
align after rolling. For example, the multiple the active areas may
be disposed such that, after rolling, active areas are disposed
every 90 degrees in the roll. These radially aligned electrodes may
then be actuated in unity to allow multiple degree of freedom
motion for a rolled electroactive polymer device. Thus, the rolled
polymer devices are one embodiment of multi degrees of freedom that
may be obtained with transducer configuration of the present
invention.
FIG. 4G illustrates a rolled transducer 180 capable of
two-dimensional output in accordance with one environment of the
present invention. Transducer 180 comprises an electroactive
polymer 182 rolled to provide ten layers. Each layer comprises four
radially aligned active areas. The center of each active area is
disposed at a 90 degree increment relative to its neighbor. FIG. 4G
shows the outermost layer of polymer 182 and radially aligned
active areas 184, 186, and 188, which are disposed such that their
centers mark 90 degree increments relative to each other. A fourth
radially aligned active area (not shown) on the backside of polymer
182 has a center approximately situated 180 degrees from radially
aligned active area 186.
Radially aligned active area 184 may include common electrical
communication with active areas on inner polymer layers having the
same radial alignment. Likewise, the other three radially aligned
outer active areas 182, 186, and the back active area not shown,
may include common electrical communication with their inner layer
counterparts. In one embodiment, transducer 180 comprises four
leads that provide common actuation for each of the four radially
aligned active area sets.
FIG. 4H illustrates transducer 180 with radially aligned active
area 188, and its corresponding radially aligned inner layer active
areas, actuated. Actuation of active area 188, and corresponding
inner layer active areas, results in axial expansion of transducer
188 on the opposite side of polymer 182. The result is lateral
bending of transducer 180, approximately 180 degrees from the
center point of active area 188. The effect may also be measured by
the deflection of a top portion 189 of transducer 180, which traces
a radial arc from the resting position shown in FIG. 4G to his
position at shown in FIG. 4H. Varying the amount of electrical
energy provided to active area 188, and corresponding inner layer
active areas, controls the deflection of the top portion 189 along
this arc. Thus, top portion 189 of transducer 180 may have a
deflection as shown in FIG. 4G, or greater, or a deflection
minimally away from the position shown in FIG. 4G. Similar bending
in an another direction may be achieved by actuating any one of the
other radially aligned active area sets.
Combining actuation of the radially aligned active area sets
produces a two-dimensional space for deflection of top portion 189.
For example, radially aligned active area sets 186 and 184 may be
actuated simultaneously to produce deflection for the top portion
in a 45 degree angle corresponding to the coordinate system shown
in FIG. 4G. Decreasing the amount of electrical energy provided to
radially aligned active area set 186 and increasing the amount of
electrical energy provided to radially aligned active area set 184
moves top portion 189 closer to the zero degree mark. Suitable
electrical control then allows top portion 189 to trace a path for
any angle from 0 to 360 degrees, or follow variable paths in this
two dimensional space.
Transducer 180 is also capable of three-dimensional deflection.
Simultaneous actuation of active areas on all four sides of
transducer 180 will move top portion 189 upward. In other words,
transducer 180 is also a linear actuator capable of axial
deflection based on simultaneous actuation of active areas on all
sides of transducer 180. Coupling this linear actuation with the
differential actuation of radially aligned active areas and their
resulting two-dimensional deflection as just described above,
results in a three dimensional deflection space for the top portion
of transducer 180. Thus, suitable electrical control allows top
portion 189 to move both up and down as well as trace
two-dimensional paths along this linear axis.
Although transducer 180 is shown for simplicity with four radially
aligned active area sets disposed at 90 degree increments, it is
understood that transducers of the present invention capable of
two- and three-dimensional motion may comprise more complex or
alternate designs. For example, eight radially aligned active area
sets disposed at 45 degree increments. Alternatively, three
radially aligned active area sets disposed at 120 degree increments
may be suitable for 2D and 3-D motion.
In addition, although transducer 180 is shown with only one set of
axial active areas, the structure of FIG. 4G is modular. In other
words, the four radially aligned active area sets disposed at 90
degree increments may occur multiple times in an axial direction.
For example, radially aligned active area sets that allow two- and
three-dimensional motion may be repeated ten times to provide a
wave pattern that may be impressed on a fluid flow.
Animated Devices
Exemplary Animated Devices
Electroactive polymer transducers are well-suited for use in
animatronic devices such as animatronic faces. FIGS. 3A-B
illustrate front and back perspective views, respectively, of an
animatronic face 400 in accordance with one embodiment of the
present invention. The face 400 is made from a polymer mold 402 of
silicone rubber and is fabricated according to conventional
silicone rubber molding techniques. Attached on the inside of the
mold 402 are a series of actuators 404a-e. Each of the actuators
404a-e comprise a transducer having an electroactive polymer 403
and electrodes attached on opposing surfaces of the electroactive
polymer 403. The polymer mold 402 is flexible and changes shape
with deflection of the actuators 404a-e. The flexibility of the
polymer may be controlled so that the motion occurs primarily in
certain regions of interest. This control may be accomplished by
molding the polymer thinner in certain areas. A relatively rigid
frame with hinged joints may also be incorporated beneath the
polymer to ensure that motion only occurs between specific regions
of the polymer.
Each actuator 404 is responsible for providing motion of a separate
feature of face 400. In one embodiment, each actuator 404 is a
linear actuator similar to the linear actuator of FIGS. 2D and 2E
and has opposing rigid members 407 attached to mold 402. The rigid
members 407 translate deflection of each electroactive polymer
transducer into motion of a feature for the face 400. For example,
actuator 404e has upper and lower rigid members 405a and 405b that
are attached above and below a mouth 416.
Referring to the outer appearance of the face 400 (FIG. 3A),
actuation and deflection of actuator 404a vertically opens right
eye 406. When electrical energy is removed from actuator 404a,
elastic return of electroactive polymer 403a included in actuator
404a, and elastic return of the mold 402, return right eye 406 to
its resting position. Similarly, deflection of actuator 404b
vertically opens a left eye 408. When electrical energy is removed
from actuator 404b, elastic return of mold 402 and electroactive
polymer 403b return left eye 408 to its resting position.
Deflection and elastic return of actuators 404c and 404d provide
motion for right and left cheeks 412 and 414, respectively.
Deflection and elastic return of actuator 404e provides motion for
mouth 416.
Actuators 404a-e are capable of independent actuation and may be
individually or collectively used to simulate motion of a human
face. For example, independent actuation of actuator 404e may be
used to simulate mouth 416 movements corresponding to speech for
the face 400. As electroactive polymers are capable of independent
and complex time varying deflections, controlled actuation of
multiple actuators 404a-e may be used to simulate complicated
motions such as those that simulate human emotion. In a specific
embodiment, independent actuation of actuators 404a-d are used to
provide facial expressions that correspond emotionally to speech
provided by mouth 416. For example, actuators 404a and 404b may
both be actuated to open both eyes 406 and 408, thereby simulating
surprise for face 400. The degree of surprise may be varied by
differing the speed and displacement magnitude of actuation of
actuators 404a and 404b. Eyebrows 418 may also accentuate the
effect of displacement and human-like simulation provided by
actuators 404a and 404b. Alternatively, actuators 404c and 404d may
be simultaneously actuated to simulate a human smile. The type of
smile, or degree of emotion conveyed by the smile, may be varied by
differential actuation of the actuators 404c and 404d. As one
skilled in animatronics will appreciate, controlled actuation of
actuators 404a-e may be performed in a variety of ways to convey
emotion and facial expressions for face 400.
Actuator 404e is configured such that the polymer included therein
is capable of producing sound. In this case, the same transducer
may be used for both actuation of mouth 416 and acoustic emission.
When actuation and acoustic emission is performed simultaneously,
the audio signal is superimposed on an actuation signal. The
actuation is distinguished from the acoustic emission signal
largely by frequency. The acoustic signal is typically of much
higher frequency and lower magnitude than the lower frequency
actuation signal. This high-frequency signal will have little
effect on the resultant motion. In many cases, a DC bias is
included with the high-frequency acoustic signal. This DC bias will
produce a small amount of actuator motion which is usually
acceptable. Often the acoustic emission is done at the same time as
the actuation. In this case, the bias may be part of the actuation
signal (linearly superimposed). The magnitude of the acoustic
signal may be scaled such that the magnitude of the acoustic
response is of the desired frequency profile, regardless of the
magnitude of the actuation signal.
Additional humanlike motions may be applied to the face 400 using
other animatronic devices used in conjunction with face 400. FIGS.
3C-D illustrate an animatronic eye 425 in accordance with one
embodiment of the present invention. Eye 425 is a planar transducer
having electrodes 426 patterned on opposite sides of polymer 427.
Polymer 427 is attached on its perimeter to a frame 428. Frame 428
allows attachment to the inner surface of polymer 402 of face 400
in regions 424 near each eye. Eye 425 need not be flat. In another
embodiment, eye 425 comprises a polymer stretched over a convex
surface. The surface may be a slippery material that allows polymer
427 to slide over it. A lubricant may also be disposed between
polymer 427 and the convex surface. A suitable lubricant might be a
petroleum oil in the case of acrylic materials. This approach could
also be used in allowing many of the facial motions described above
to move over a convex surface rather than operate in at a flat
plane.
Electrodes 426 cover a central circular portion of polymer 427, are
dark and opaque, and thus resemble a human eye pupil. Actuation
using electrodes 426 (attached on both sides of the film) causes
polymer 427 in the region of electrodes 426 to expand in the plane.
Electrodes 426 change shape with polymer 427. Thus, planar
expansion of polymer 427 increases the darkened surface area of
electrodes 426 and simulates dilation of a pupil, as illustrated in
FIG. 3D. Portions of the polymer 427 outside the active area
corresponding to electrodes 426 provide a contractile resistance to
actuation. To enhance aesthetic appeal, polymer 427 material not
covered by electrodes 426 may be colored white. When used with face
400, dilation and contraction of the electrodes 426 may be used to
contribute to the simulation of human emotions by face 400. For
example, actuation of eye 425 may be in conjunction with actuation
of actuators 404a and 404b to simulate surprise for face 400.
FIGS. 3E-F illustrate front and back perspective views,
respectively, of animatronic face 430 in accordance with another
embodiment of the present invention. Face 430 comprises a
monolithic transducer including polymer 432 and electrode pairs
434, 436, 438, and 442 attached to outer and inner surfaces 431a
and 431b of polymer 432 (e.g., 434a on inner surface 431a and 434b
on outer surface 431b). Thus, polymer 432 is a monolithic polymer
comprising four active areas that provide independent deflections
and motions for the face 430. Polymer 431 comprises silicone rubber
that is molded into a shape that provides the outer aesthetic
appearance for face 430. In one embodiment, polymer 432 is
relatively thin and has a thickness in the range of about 0.020 to
about 0.10 millimeters.
Each electrode pair 434, 436, 438, 440, and 442 is responsible for
actuation of a separate portion of the polymer 431 to produce
motion for a separate feature for face 430. Actuation of electrode
pair 434 moves right (FIG. 3E) eyebrow 441 down. Actuation of
electrode pair 436 moves left eyebrow 443 down. Actuation of
electrode pair 442 closes mouth 445. When electrical energy is
removed from electrode pairs 434, 436, and 442, elastic return of
polymer 432 returns each feature 441, 443, and 445 to its resting
position before actuation. Electrode pairs 438 and 440 are
patterned on the right and left cheek areas of face 430,
respectively, to provide active areas that expand out of the plane
similar to the monolithic diaphragm actuator described in FIGS. 2F
and 2G. Actuation of the active area 438 may be used to simulate
the bulging of the right cheek for face 430. Actuation of the
active area 442 may be used to simulate the bulging of the left
cheek. In one embodiment, a swelling agent such as a small amount
of silicone oil is applied to the inner side 431b of polymer 431 to
influence outward expansion of polymer 431. As one skilled in
animatronics will appreciate, electrodes may be arranged on polymer
mold 432 in a variety of ways to established desired skin
deformations, provide controlled facial expressions, and convey
emotions for face 430.
Electrode pairs 434, 436, 438, 440, and 442 are arranged with
separate electrical communication. Independence of the electrode
pairs allows electrical energy to be separately supplied to
different portions of the polymer; thus allowing independent
control for each of the active areas. Independent control may
include deflection at different times, rates, and degrees of
deflection. In another embodiment, two or more electrodes for face
430 are electrically coupled, e.g., electrode pairs 434 and 436 to
allow for common actuation of eyebrows 441 and 443.
The electroactive polymer 432 exploits the flexibility of the
electroactive polymer material as well as the ability to fabricate
structures with high degrees of freedom by patterning multiple
electrode pairs on a single polymer. In one embodiment, electrode
pairs are patterned on polymer mold 432 to simulate facial features
and facial muscle of a human. These simulated facial muscles may
then be used to provide motion for features of the face 432 that
simulates human facial movements. As one of skill in the art will
appreciate, there are an abundant number of facial features, facial
muscles, facial movements, and facial expressions that may be
simulated using individual or multiple dedicated active areas on an
electroactive polymer.
While the face 430 is illustrated as having a symmetrical
appearance, it is understood that animated faces and devices of the
present invention may comprise multiple active areas having a
non-symmetrical and custom geometries. It is also understood that
active areas may be combined in any configuration. These custom
geometry active areas and configurations may be used, alone or a
combination, to produce any custom two-dimensional deflection. In
some cases, two active areas responsible for motion of separate
features may be actuated together to provide movement for a
separate portion of face 430 not specifically associated with the
features associated with each of the active areas. For example,
simultaneous actuation of electrode pairs 434 and 436 may also
cause polymer material between the active areas in the central
forehead region 439 to raise with eyebrows 441 and 443. It is also
contemplated that elastic return may be used to provide controlled
deflection. Similar to simultaneous actuation, elastic return of
one portion of the polymer 432 corresponding to first active area
may be combined with actuation of a second active area to provide a
specialized movement for face 430, e.g., to provide movement for a
separate portion of face 430 not specifically associated with the
features associated with each of the active areas
In one embodiment, polymer 432 is substantially thin and flexible,
and may be attached conformably to solid structures having flat and
curved surfaces as if polymer 432 is an external skin. Face 430
then takes the shape of the structure that it is fixed to.
Non-fixed portions are then be capable of motion as determined by
active areas arranged on polymer 432. As described above, face 430
may be partially attached to a convex surface that allows motion
for features communicating with an electroactive polymer
transducer. The convex surface would then allow for non-linear
motion of the flexible polymer 432 about the convex surface. As
illustrated in FIGS. 3E-F, electrode pairs are deposited on both
sides, outward and hidden, of face 430. To hide opaque or unsightly
electrode pairs on the outside and showing surface of the face 430,
a cosmetic outer skin may cover the face 430. The outer cosmetic
skin may be made of polyurethane, pigmented silicone rubber or
natural latex rubber, for example. In another embodiment, the outer
surface of polymer 432 is painted to hide the outer electrodes.
In another aspect, electroactive polymer transducers of the present
invention are used in toys. FIG. 3G illustrates a top perspective
view of toy dog 450 in accordance with one embodiment of the
present invention. Frame 465 (FIG. 3H) provides structural support
for dog 450. Skin 467 is attached to frame 465 and provides an
outer cover that protects internal components and provides an
aesthetic appearance. Dog 450 is capable of legged surface based
locomotion and includes four leg assemblies 452a-d powered by one
or more electroactive polymer transducers.
FIG. 3H illustrates a cutaway side view of leg assembly 452a
showing the leg assembly inside skin 467 in accordance with a
specific embodiment of the present invention. Leg assembly 452a is
a two degree of freedom structure having a first-degree freedom
about pin 453 and a second degree of freedom about pin 454. Pin 453
is fixed to frame 465 of toy dog 450.
A first transducer 455 operates against a bias spring 456 to
provide rotational motion between lower member 461 and upper member
463 of leg assembly 452a. Transducer 455 is a linear transducer
rotably coupled to a central portion of lower member 461 at one end
and rotably coupled to a central portion of upper member 463 at its
opposite end. Bias spring 456 provides a counterclockwise bias
force for leg 457 about pin 454 that maintains a resting position
for leg 457 when transducer 455 is not actuated. As shown,
actuation of transducer 455 rotates the lower member 461 of leg 457
clockwise about pin 454 to push lower member 461 down. When
electricity is removed from transducer 455, elastic energy stored
in bias spring 456 rotates lower member 461 counterclockwise and
returns leg 457 to its resting position.
A second transducer 459 operates against a bias spring 450 to
provide rotational motion between the upper member 463 of leg
assembly 452a and frame 465. Transducer 459 is a linear transducer
rotably coupled to a central portion of upper member 463 and
rotably coupled to frame 465 at its opposite end. As shown,
actuation of transducer 459 rotates upper member 463 clockwise
about pin 453 to move leg 457 backwards. When electricity is
removed from transducer 459, elastic energy stored in bias spring
450 moves leg 457 forward and returns leg 457 to its lateral
resting position.
Together, transducer 455 and transducer 459 may be used to provide
two degree of freedom motion for any part of lower member 461.
Thus, transducers 455 and 459 may be used to contribute to a legged
locomotion trajectory for a distal portion of leg 457. Leg assembly
452a may then be used in combination with other similar leg
assemblies to provide a legged locomotion for dog 450. For example,
electrical energy is removed from transducer 455 to pick lower
member 461 up, and electrical energy is removed from transducer 459
to move lower member 461 and upper member 463 forward. In this
case, elastic energy stored in springs 450 and 456 moves the distal
end of leg 457 forward by rotating upper member 463 about pin 453
and lower member 461 about pin 454. At some point during forward
displacement of leg 457, electrical energy is provided to
transducers 459 and 455, bringing the distal portion of leg 457
down. Electrical energy may be provided either simultaneously or
separately to provide a specific trajectory for the distal portion
of leg 457. Leg 457 also includes padding 458 at its distal end
attached to lower member 461. Padding 458 provides a compliant and
larger area of contact with a surface that dog 450 is traversing to
assist legged locomotion.
Although leg assembly 452a disk illustrated with transducers 459
and 455 providing clockwise rotation for their respective leg
members about the pin joints as shown, it is understood that
transducers 459 and 455 may each be oppositely coupled to their
respective leg members in order to provide counterclockwise
rotation for actuation of each transducer. In this case, activation
of the polymer provides rotation in the opposite direction. One of
skill in the art will appreciate that there are numerous
trajectories that the distal end 461 can take in legged locomotion
such as trajectories associated with walking, trotting, and
running, for example. In a specific embodiment, springs 450 and 456
supply a constant force for deflection about each pin. Deflection
about each pin may then follow a constant energy path to provide an
energy efficient method for legged locomotion of dog 450.
Deflection of an electroactive polymer using a constant energy path
is described in further detail in commonly owned. pending U.S.
patent application Ser. No. 09/779,373, which is incorporated by
reference for all purposes.
Each transducer 455 and 459 is driven by a dc-dc converter with a
maximum output of 5 kV and 500 mW of power. A dc-dc converter
suitable for use with transducers 455 and 459 is model Q50 as
provided by EMCO High Voltage of Sutter Creek, Calif. Actuation of
transducers 455 and 459 may be initiated in a number of ways. In
one embodiment, dog 450 includes a processor that coordinates
actuation of transducers included in all four leg assemblies
452a-d. A processor, such as the PIC18C family of processors as
provided by Microchip Technology Inc. of Chandler, Ariz., may be
suitable to control each of the transducers 455 and 459 as well as
their respective dc-dc converters. The processor may be coupled to
a switch or a depressible push button which the user actuates by
squeezing a portion of dog 450. Dog 450 may also include a battery
or other electrical storage device enclosed within frame 465 that
provides electrical energy to transducers 455 and 459 and the
processor.
FIG. 3I illustrates a leg assembly 560 in accordance with another
specific embodiment of the present invention. Leg assembly 560 is a
one degree of freedom structure having a rotational degree freedom
about brace 561. Brace 561 provides fixed attachment to a frame
465. Transducer 562 actuates antagonistically against transducer
563. Both transducers 562 and 563 are attached at their proximate
ends to member 564 and attached at their distal ends to frame 465.
Member 564 rotates at its central portion 564a about brace 561 and
has a free end 564b that is rotably coupled to leg 568. Member 567
provides torsional support for the leg assembly 560 and is rotably
coupled at its proximate end to brace 561 and rotably coupled at
its distal end to leg 568. Together, transducers 562 and 563
control the vertical position of leg 568. Leg assembly 560 may
include another transducer that controls lateral displacement of
leg assembly 560.
FIG. 3J-L illustrate top perspective and front views of a toy bird
470 in accordance with another embodiment of the present invention.
Bird 470 comprises a body 472 having a neck 471 and supports a pair
of legs 479. Bird 470 also comprises several bending beam actuators
280a-c. Each bending beam actuator 280 is attached at their
proximate end to body 472 and provides motion for a feature of bird
470 relative to body 472.
Deflection of bending beam actuator 280a rotates tail feathers 474
about a connection point 473 on body 472. Wings 475 and 476 are
connected to distal ends of bending beam actuators 280b and 280c,
respectively. In their resting position, wings 475 and 476 lie 180
degrees apart (FIG. 3K). Actuation of bending beam actuator 280b
rotates wing 475 upward about body 472 (FIG. 3L). Actuation of
bending beam actuator 280c rotates wing 476 upward about body 472.
Thus, actuation of bending beam actuators 280b and 280c causes
wings 475 and 476 to rotate upwards towards each other as
illustrated in FIG. 3L.
When electricity is removed from the electrodes included in
actuator 280b, elastic energy of the polymer included in the
actuator returns wing 475 to its resting position. A similar
elastic return occurs for actuator 280c and wing 476. Electrical
energy may be repeatedly provided to actuators 280b and 280c to
simulate flapping and flying for bird 470.
In another embodiment, a thin transducer, comprising an
electroactive polymer and electrodes, covers one of the wings 475
or 476. The thin transducer is custom patterned monolithically
according to simulate the shape of feathers for the bird 470. The
transducer may then be used to reconfigure the shape of each wing
according to the pattern of electrodes to simulate cruising and
evasive motions of birds in flight.
FIG. 3M illustrates a front perspective view of a hand held toy
doll 500 constructed in accordance with another embodiment of the
present invention. Doll 500 includes a body comprising a unitary
torso 501 having a neck 503 supporting a head 502. Torso 501
further supports a pair of arms 504 and 505 and a pair of legs 506
and 507. Arms 504 and 505 are passive. Preferably arms 504 and 505
are somewhat pivotal in their attachment to torso 501 such that a
user is able to induce motion of arms 504 and 505.
Legs 506 and 507 are also somewhat pivotal in their attachment to
torso 501 and each capable of user movement relative to torso 501
about the attachment. In addition, each leg 506 and 507 includes an
electroactive polymer transducer that simulates kicking motion for
doll 500. More specifically, transducer 509 is configured on the
anterior side of leg 506 and attached at one end to thigh portion
510 of leg 506 and attached at its opposite end to lower leg
portion 511. Actuation of transducer 509 causes lower leg portion
511 to rotate about knee joint 512, thus providing motion for leg
506. Doll 500 may be provided with a ball. A user, in conjunction
with actuation of transducer 509, may use doll 500 to simulate
kicking of the ball.
Actuation of transducer 509 may be initiated in a number of ways.
In one embodiment, the transducer 509 is coupled to a depressible
push button which the user actuates by squeezing a portion of doll
torso 501. The transducer 509 and actuates when the depressible
pushbutton is pushed or after the depressible pushbutton is
released. In another embodiment, doll 500 includes a microphone and
electric driving circuitry that allows voice activation of
transducer 509. Doll 500 may also include a battery or electrical
storage device enclosed within torso 501. Transducer 509 is driven
by a control circuit and dc-dc converter with an output of 5 kV and
300 mW of power. A dc-dc converter suitable for use with transducer
509 is model Q50 as provided by EMCO High Voltage Inc. of Sutter
Creek, Calif.
Doll 500 is intended to meet the need for more interactive hand
held dolls as opposed to more sophisticated dolls that 30 operate
on their own. In contrast; one of skill in the art will appreciate
that doll 500 may include numerous other electroactive polymer
transducers that are processor controlled and designed to operate
on their own without user assistance. Broadly speaking, one aspect
of the present invention relates 35 to articulated dolls including
one or more electroactive polymer transducers. The dolls may be
such devices employing an electroactive polymer that drives a
movement feature---that is manually activated or processor
activated. Thy dolls are a well known segment of the toy industry.
Thus, dolls have been provided which vary from large "life size"
dolls to small fashion dolls. Further variation is found in the
material of dolls varying from soft so-called "plush" dolls to hand
held hard plastic dolls and doll figures. By way of further
variation, dolls may be provided that vary from simple dolls which
have one or two moving features to dolls which are extremely active
and able to perform various movements or activities.
While the doll 500 has been described specifically with respect to
electroactive polymer transducers that provide motion that
simulates kicking, it is understood that there a so variety of
other lifelike actions and movements that doll 500 may designed to
simulate. Other exemplary lifelike actions whose movements an
electroactive polymer transducer may contribute to simulation of
include simulated skating action, liquid drinking action,
swallowing action, smiling, arm waving, dancing, talking, throwing,
blinking, burping, rolling over, etc. Lifelike movements that may
be powered by an electroactive polymer transducer include may also
any of those associated with the human actions listed above and any
movements associated with a specific body part. Exemplary head 503
movements relative to torso 501 include nodding, twisting and
universal movement of the head relative to the torso.
In general, toys in accordance with one aspect of the present
invention include any toy that simulates motion of a living
organism or a portion of an organism, such as hand held dolls,
stuffed and plush toys, articulated action figures, action figure
accessories, preschool learning toys, preschool talking & sound
toys, mechanical design kits, robotic/virtual pets, etc. Each toy
and may use one or more electroactive polymer transducers to
provide motion for limbs, body segments, or appendages such as
wings, antennae, etc. Toys of the present invention comprising one
or more electroactive polymer transducers may include animated
games. Exemplary animated games include those that use
electroactive polymer transducers to direct static devices into
motion for game purposes (e.g., to move a ball into a hole) and
fighting toys having movements powered by one or more electroactive
polymers and controlled by a user. As will be described in further
detail below, transducers included in the fighting toys may also
comprise electroactive polymer transducers with sensor
capabilities.
One manner of classifying the large number of toys having motion
powered by electroactive polymers of the present invention is by
the type of motion produced by electroactive polymer. In one
embodiment, electroactive polymer animated devices correspond to
toys having surface based locomotion such as ground based and/or
gravity-assisted locomotion powered by one more electroactive
polymer transducers. Exemplary surface based types of locomotion
include legged locomotion (bipedal, multiple legged, walking,
trotting, crawling, running, etc), hopping (e.g., rabbits, frogs,
kangaroos, etc.), wheeled locomotion (e.g., cars, trains,
bicycles), and slithering (e.g., snakes, snails, slugs, etc.).
Other exemplary types of locomotion include swimming (fish, eels,
etc.) and flying, flapping and soaring (e.g. birds, butterflies,
dragonflies, aircraft, etc.
In another embodiment, electroactive transducer powered toy has
mobility independent from its user, e.g., wheeled vehicles such as
trains and cars, legged animals such as dogs and dinosaurs, battery
operated vehicles, electric/battery car sets & accessories,
etc. In some cases, the devices may include remote control that
controls actuation and deflection of an electroactive polymer. One
of skill in the art will appreciate the abundant number of robotic
toys that may be designed including electroactive polymer
transducer and remote control.
An animated device that employs an electroactive polymer transducer
may be considered a direct drive device where the transducer
directly translates into motion of the feature. In many cases, back
drivability associated with electroactive polymers included in a
direct drive devices is desirable for an application. As the term
is used herein, back drivability refers to the ability to move a
transducer against a direction of its actuation. Electroactive
polymers typically have a low stiffness relative to their
conventional electromechanical counterparts. More specifically,
back drivability may be accomplished by overcoming the stiffness of
the polymer during motion between a first position and a second
position. This inherent low stiffness may provide a back
drivability that is advantageous in some applications. For example,
should an animated device in a theme park accidentally contact an
object during motion, motion may be stopped by overcoming the
stiffness of the polymer. As a result, the shock and initial force
would typically be low relative to conventional electromechanical
actuation, potentially reducing the amount of force experienced by
the object. Thus, an animated device is in accordance with the
present invention may be designed with a back drivability for
motion of a feature between two positions. In one embodiment, the
back drivability is accomplished by setting a maximum stiffness of
polymer and device for motion of the feature between the first and
second position.
In a specific embodiment, toys of the present invention comprise a
feature that is back drivable. Since electroactive polymers are
inherently compliant as discussed, back drivability for the toy may
be accomplished by overcoming the stiffness of the polymer during
motion between one position, e.g., a resting position, and a second
position, e.g., a position of actuation. In addition, polymer
material may be selected based on the back drivability requirements
of an application. Polymer that is more compliant may add a larger
compliance to the operation of an animatronic device by potentially
reducing impact forces if an undesired collision occurs.
Animated Device Overview
Having briefly discussed several exemplary animated devices, some
general aspects that may apply to animated devices of the present
invention will now be discussed. In general, an animated device in
accordance with the present invention comprises one or more
electroactive polymers configured to provide motion for a feature
of the device. The feature may be any portion of the device having
motion at least partially contributed to by deflection (actuation
or elastic return) of an electroactive polymer. There are an
abundant number of animated device designs suitable for use with
the present invention--including conventional animated devices
retrofitted with one or more electroactive polymers and custom
animated devices specially designed for electroactive polymer
usage. Since many electroactive polymer transducers can operate
well over a large range of sizes with little change in performance,
electroactive polymer powered animated devices have many potential
applications for both and large small devices.
An electroactive polymer may have customized deflections and
strokes; thus permitting customized motions for a particular
animated device. The use of multiple electroactive polymers in an
animated device allows for the development of dextrous devices with
numerous customized degrees of freedom. These customizable
deflections and strokes also provide power without the need for
complex transmission mechanisms such as cables and gears, resulting
in lightweight actuation that is ideal for small, compact, and
lightweight animated devices. Since no complex transmission
mechanisms are needed, the remainder of the animated device is
typically less complex and expensive than conventional forms of
actuation.
The simplicity and high-efficiency of electrical to mechanical
energy conversion provided by electroactive polymer transducers
also allows improved animated devices in mobile and lightweight
applications where available energy is limited. For example, mobile
toys such as animated animals and remote control vehicles may
benefit from the lightweight advantages of using an electroactive
polymer transducer. Since the transducer is substantially lighter
than a conventional electromagnetic motor, and the need for complex
transmission mechanisms is removed for many devices, less demanding
electrical energy storage devices are required. For example, the
lighter weight gained by using an electroactive polymer transducer
allows a smaller battery to be used or the same size battery may be
used for a longer duration.
The present invention is also suitable for animated devices having
a distributed transducer scheme. In a distributed transducer
scheme, multiple links and transducers are used wherein each
transducer drives a link directly, thus allowing a specific control
for each link and therefore greater dexterity for the entire
device. For example, an animatronic mannequin may have separate
electroactive polymer transducers that power an upper arm, lower
arm, wrist, and individual fingers. In this scheme, lightweight
transducers are advantageous since a transducer is often required
to move and support distal links that each include the added mass
of a downlink transducer. One of skill in the art will appreciate
the value of light weight in robotics, toys, and animatronics
devices having multiple links.
A collection of electroactive polymers or actuators may be
mechanically linked to form a larger actuator with a common output,
e.g. force and/or displacement. By using a small electroactive
polymer as a base unit in a collection, conversion of electric
energy to mechanical energy may be scaled according to an
application. By way of example, multiple linear motion devices 230
(FIG. 2C) may be combined in series in the direction 235 to form an
actuator having a cumulative deflection of all the linear motion
devices in the series. Electroactive polymer transducers and
actuators--either individually or mechanically linked in a
collection--may be referred to as `artificial muscle`. For purposes
herein, an artificial muscle is defined as one or more transducers
and/or actuators having a single output force and/or displacement.
Artificial muscles may be implemented on a micro or macro level and
may comprise any one or more of the transducers and actuators
described herein.
Given the customisable shape of electroactive polymers, animatronic
devices using electroactive polymer transducers may then be
designed to mimic any natural muscle based organism. Duplication of
natural muscle thus allows electroactive polymer transducer powered
animated devices to produce many natural motions and dynamics
related to living organisms; and thus animated devices based on
these organisms. For example, the large stroke capability of
electroactive polymers allows them to be used directly as linear
actuators in much the same way as muscle is used in biological
animals, e.g., a biceps muscle. Further, the performance of
electroactive polymer transducers is largely scale invariant, e.g.,
independent of size or mass. One can readily see the advantage of
artificial muscle transducers in animatronic devices by noting the
many conventional biological analogs to highly articulated
animatronic devices that operate using muscular-like actuation.
These include analogs such as fingers, hands, arms, legs, heads,
limbs, body segments, wings, and appendages for a variety of
insects and animals.
Animated devices of the present invention may also be designed and
configured such that a mechanical property of a transducer
substantially simulates a mechanical property of a real muscle.
Exemplary mechanical properties that may be simulated by an
electroactive polymer include stiffness, stroke, shape, strain,
pressure, speed of response, efficiency, compliance, modularity
(transducers may be stacked in parallel or linked in series)
damping, and bulging in the middle as the muscle contracts. In one
embodiment, electroactive polymer transducers are used to
substantially simulate open loop or passive behavior of natural
muscle. In this case, the transducers act as both a spring and
damper in a passive manner similar to their natural
counterparts.
Sensor Functionality
Animated devices of the present invention may also include a
sensor. The sensor may sense a quantity or item included in the
device and/or sense a quantity or item detected from the
environment around the device. Quantities sensed may include
haptic, acoustic, visual, or kinesthetic feedback, for example. In
one embodiment, the sensor is a conventional sensor technology,
e.g., a microphone or light sensor. In another embodiment, the
sensor is an electroactive polymer transducer operating as a
sensor.
FIGS. 1A and 1B may be used to show one manner in which the
transducer portion 10 converts mechanical energy to electrical
energy and acts as a sensor. If the transducer portion 10 is
mechanically stretched by external forces to a thinner, larger area
shape such as that shown in FIG. 1B, and a relatively small voltage
difference (less than that necessary to actuate the film to the
configuration in FIG. 1B) is applied between electrodes 14 and 16,
the transducer portion 10 will contract in area between the
electrodes to a shape such as in FIG. 1A when the external forces
are removed. Once the transducer portion 10 is stretched, the
relatively small voltage difference is provided such that the
resulting electrostatic forces are insufficient to balance the
elastic restoring forces of the stretch. The transducer portion 10
therefore contracts, and it becomes thicker and has a smaller
planar area in the plane defined by directions 18 and 19
(orthogonal to the thickness between electrodes). When polymer 12
becomes thicker, it separates electrodes 14 and 16 and their
corresponding unlike charges, thus raising the electrical energy
and voltage of the charge. Further, when electrodes 14 and 16
contract to a smaller area, like charges within each electrode
compress, also raising the electrical energy and voltage of the
charge. Thus, with different charges on electrodes 14 and 16,
contraction from a shape such as that shown in FIG. 1B to one such
as that shown in FIG. 1A raises the electrical energy of the charge
which may be detected and measured by a circuit in electrical
communication with the electrodes. That is, mechanical deflection
is being turned into electrical energy and the transducer portion
10 is acting as a mechanical deflection sensor. Sensing performance
of electroactive polymer is described in further described in
commonly owned U.S. Pat. No. 6,809,462, which was previously
incorporated by reference for all purposes. In one embodiment, a
device may be configured such that sensing may be performed
simultaneously with the actuation. In this case, a small amplitude
high frequency signal may be superimposed on the driving signal.
Circuitry may then measure the high frequency response of the
polymer as an indication of the capacitance. Such techniques are
well-known to those skilled in the art.
In a specific embodiment, an electroactive polymer transducer acts
as a large capacitor. By measuring changes in capacitance,
corresponding changes in polymer physical dimensions and force
loading may be calculated. Thus, the transducer may be used to
detect motion of a feature included in an animated device, e.g., an
arm. In one embodiment, the same electroactive polymer transducer
that provides mechanical output in an animated device also provides
sensing capabilities. These transducers may then be made into
"smart transducers" that intrinsically incorporate position, force,
tactile sensing, etc. These smart transducers may simplify feedback
control of mechanical output for an animated device, thus allowing
for enhanced dexterity and controlled mechanical output.
In one embodiment, transducers of the present invention act as a
haptic sensor for detecting touch. For example, transducer 432 of
face 430 may be used to detect whether the face 430 is in contact
with an object. Sensing contact may be advantageous for toys that
provide an interactive and automatic response with a user. Force
sensors, electroactive polymer based or other, may also be used to
detect touch applied to the toy.
In another embodiment, transducers of the present invention act as
kinesthetic interfaces. Since the transducers operate through a
simple drive mechanism rather than a complex transmission, position
and force measurements from the transducer may give a direct
measurement of the position and loading on a feature included in an
animatronic device.
In another embodiment, the animatronic eye of FIGS. 3C-3D is used
in an optical sensor. In this case, electrode 426 has an opacity
that varies with deflection. A transparent or substantially
translucent polymer 427 is attached to the opacity varying
electrode and deflection of the polymer 427 is used to modulate
opacity of the eye. In the case of an optical switch, the opacity
varying transducer interrupts a light source communicating with a
light sensor. Thus, deflection of the transparent polymer 427
causes the opacity varying electrode to deflect and affect the
light sensor (turn the switch on/off). In a specific embodiment,
the opacity varying electrode includes carbon fibrils or carbon
nanotubes that become less opaque as electrode area increases and
the area fibril density decreases.
Interactive Capability
Animated devices of the present invention may also be interactive
with their environment. Interactive abilities of the present
invention refer to both automatic interaction and manual
interaction.
In one embodiment, animated devices of the present invention
include a processor. Combining the ability to design animated
devices having customized motions, sensing abilities of
electroactive polymer transducers and conventional sensors, and
electrical communication with a processor, animated devices of the
present invention may be programmed with automatic interactive
capabilities.
In a specific embodiment, a stuffed toy comprises a processor that
communicates independently with electrodes that actuate transducers
in the toy. The toy may also comprise sensing capabilities that
provide haptic, acoustic, visual, or kinesthetic information. The
information is then provided to the processor, which is programmed
to make decisions based on the feedback. In more elaborate designs,
the sensor and processor may combine to make decisions based on
context of the quantity being sensed. In a specific embodiment,
electroactive polymer force sensors provide temporal and magnitude
force information that a processor differentiates in order to
provide interactive responses. For example, when a child user yanks
on a stuffed toy, the processor receives the force information from
the sensors and provides an acoustic signal to a transducer. The
stuffed toy then interactively responds with an acoustic output of
`ouch` from the transducer.
In one embodiment, an animated device provides biomimetic responses
to a person interacting with the device. As to term is used herein,
a biomimetic response refers to response of a device that copies or
mimics nature. For example, the stuffed toy just described may
provide a suitable empathetic response based on feedback from a
child. Thus, the sensors may sense a particular state of the child
playing with the stuffed toy and then respond accordingly, e.g.,
the sensors detect sadness in the child using voice recognition and
the processor responds by actuating facial transducers for the
stuffed toy similar to mask 430 of FIG. 4C to produce an empathetic
facial gesture. The biomimetic response may be selected to diffuse
the state of the person, e.g., the sensors detect sadness in the
child and the processor actuates electroactive polymer transducers
in the device to provide a happy response including both happy
facial gestures and an acoustic output. In this case, the stuffed
toy is designed with electroactive polymer transducers that provide
all movements associated with the appropriate empathetic responses
required for interaction between the toy and person. This may
include reactive eye movements, body language, facial gestures,
acoustic output, etc. In another embodiment, animated devices for
use in a theme park may be designed with biomimetic responses to a
user.
In another embodiment, an animated device of the present invention
provides tactile interaction with its environment. For example, one
or more haptic sensors may be arranged under the skin in various
places of the animated device. Each of the haptic sensors then
detects touch for different body portion of the animated device.
The same transducer may then be responsible for actuation in
response to user interaction. For example, a haptic electroactive
polymer sensor may be placed in the nose of the stuffed toy and the
nose wiggles when touched (via actuation of the electroactive
polymer). Alternatively, the stuffed toy may receive time varying
force feedback from its environment and react accordingly. For
example the stuffed toy previously discussed may be a teddy bear
that reactively pushes back when its paw is pushed. In a more
elaborate design, the magnitude of reactive push is proportional to
the force magnitude pushing on the paw. In another embodiment,
automatic toy interaction is designed not to stop an action based
on sensor feedback. For example, a toy dinosaur with biting
capabilities powered by electroactive polymer transducers uses
force feedback from the transducers to decide when not to keep
biting.
In another embodiment, an animated device has a set of responses
based on a given input. For example, a toy dinosaur comprising a
number of electroactive polymer transducers, a depressible button
switch on its back, and a processor that responds to depression of
the button, may have a series of programmed responses to depression
of the button, e.g., locomotion and acoustic output. The
depressible button may be an electroactive polymer transducer
acting as a sensor or a simple conventional electrical switch in
communication with the processor.
Interactive toys of the present invention need not include a
processor. For the exemplary fighting men game mentioned above, an
individual fighter in the game may include be designed with joint
compliance that provides an automatic and appropriate response when
hit by another fighter, e.g., the fighter falls down after being
hit hard in the head by the other fighter. In this case, a user may
provide manual control of the transducers in their corresponding
motions for the toy fighter.
Additional Applications
As the present invention includes transducers that may be
implemented in both the micro and macro scales, and with a wide
variety of designs, the present invention finds use in a broad
range of applications where animated motion is desired. Provided
below are some additional exemplary applications for electroactive
polymer transducer animated devices.
Animated devices of the present invention are also well-suited for
use in the entertainment industry. Exemplary applications include
animated device use in moving displays of theatre, theme parks,
theme park rides, dark walks, scenery, and special effects for the
film and television industries. Since downtime due to mechanical
failure and repair is a nontrivial consideration for conventional
animatronic devices in theme park rides, the simplicity and
reliability electroactive polymers provide make them well-suited
for this application. In many cases, fault tolerance may be built
into an electroactive polymer based animatronic device included in
theme park ride by using several smaller transducers in parallel,
thus increasing reliability of the device and minimizing downtime
of the ride.
One of skill in the art will appreciate the wide use of
animatronics in entertainment special effects work. Some exemplary
animated devices found in the entertainment industry suitable for
use with electroactive polymer transducers include animatronic
puppets, creatures and creature effects, sculptures, masks, special
effects make-up, figures, prosthetics, props, scenic and set
decorations, and character costumes. Exemplary creature effects
include masked monsters, aliens, apes, dinosaurs, animatronic
figures, etc. Special effects makeup include effects such as latex
masks and devices added to a person, animal or other device, e.g.,
to appear if skin is bulging by putting a prosthetic on their skin
and actuating it.
The present invention is also suitable for sporting animated
devices. Exemplary sporting animated devices include decoys such as
animated ducks used for attracting game and electroactive polymer
transducer powered fishing lures. The decoys may also be used in
animal and pest traps such as a flapping fly, crawling insect or
wiggling worm or insect used in a pest trap, for example.
Animated devices of the present invention may also be used in
medical training. This includes mannequins and training instruments
that incorporate sensing and interactive capabilities. For example,
a CPR training mannequin may include force sensors to detect the
degree of chest expansion provided by a CPR trainee. In addition,
the CPR training mannequin may include customized motions of a
feature that provides interactive response based on CPR trainee
performance, e.g., a diaphragm actuator that operates similar to
actuator 130 of FIG. 2F and repeatedly actuates to simulate a
pulse.
The present invention also finds use in novelty items that include
animated motion. Exemplary novelty items suitable for use with
present invention include singing fish, dancing flowers, Halloween
and Christmas novelty items such as dancing Santas, etc.
CONCLUSION
While this invention has been described in terms of several
preferred embodiments, there are alterations, permutations, and
equivalents that fall within the scope of this invention which have
been omitted for brevity's sake. By way of example, although the
present invention has been described in terms of several numerous
applied material electrodes, the present invention is not limited
to these materials and in some cases may include air as an
electrode. It is therefore intended that the scope of the invention
should be determined with reference to the appended claims.
* * * * *
References