Mini EAP - Miniaturisation of electroactive polymer systems for sensor and actuator applications

The ERDF-funded project investigates the miniaturisation of dielectric elastomers in the millimetre range. Both metal-carbon, sandwich-like thin films for the production of electrodes and new types of applications are being researched.

The project is a collaboration between the Chair of Intelligent Material Systems headed by Prof. Seelecke from Saarland University and the Sensors and Thin Film Technology Research Group headed by Prof. Schultes from Saarland University of Applied Sciences.

problem

Electroactive polymers (EAP) are becoming increasingly important due to their properties such as low weight, low production costs, energy efficiency and simultaneous usability as an actuator and sensor. Previous applications, however, are more in the macroscopic range. A miniaturization of this technology would open up new fields of application and lead to systems with new functionality.

Particular attention is paid to medical applications and human-machine interaction. For example, cost-effective pumps, valves and pressure sensors for lab-on-a-chip systems in the medical sector are conceivable.
Control panels (touch screens) with reconfigurable topology or gesture controls (e.g. by glove) are also conceivable with this technology.
In both cases, haptic feedback can also be generated to provide the operator with a mechanically palpable response.

objective

In order to realize the miniaturization of the technology, new and improved production methods are necessary on the one hand, and on the other hand, relevant, adapted tools and miniaturized pre-tensioning mechanisms are necessary for system design. The former is focused in particular on the Schultes working group and the second part is being developed by the Seelecke working group.

The project is dedicated to fundamental research on the miniaturization of electro-active sensor and actuator systems. Starting from today's prototypes in the cm range, dimensions in the mm range and smaller are sought. At the same time, the technological basis for new actuator and sensor applications will be expanded. The resolution of the controllable elements (pixels) could thus be significantly increased. For this purpose, on the one hand, the system design is processed by researching suitable array arrangements with miniaturized mechanical pretensioning mechanisms. Mechanically bistable, polymer-based prestressing elements emerging from the plane of the film form the element basis for the various pixels.

On the other hand, new materials and methods for the production of conformal electrodes are investigated. Plasma coating processes (sputtering) are used to apply conductive thin metal-carbon layers in the nanometer range. The structuring of such layers is to be realized with the help of an ultrashort-time laser. In order to achieve a high extensibility and conformity of the conductive electrode layers, the thin layer is sputtered onto a pre-stretched film.

approach

This project brings together two complementary expertises from Saarland universities. The research group of Prof. S. Seelecke is internationally renowned and has broad experience in the field of EAP systems. In particular, the production of the film composites, the complete system design up to the actuator-acting mechanisms, their modeling, measurement and characterization are in the foreground. The application reference is given by many cooperation projects from the industry. The research group of Prof. G. Schultes, on the other hand, contributes long-standing know-how in sensor technology, manufacturing and microstructuring of thin films and the design of force and pressure sensors. Experience and research results on highly sensitive sensor thin films developed in the working group form the basis for EAP electrodes. Necessary and complex systems and measuring devices are available in both groups.

The first demonstrators are being developed in cooperation between the two research groups, with the Schultes group focusing in particular on the production of new sputtered electrodes as well as the structuring of the electrodes and the Seelecke group on the design of the sensor-actuator system and research into miniaturised preload mechanisms.

Results / Project status

The project was launched in early 2018 and will run for at least 3 years. The work plan is structured in such a way that the contents of the work packages start in parallel and a common project status in the form of a demonstrator is achieved at the end of the project. The sputtered electrodes can be applied with good resolution and flexible pre-tensioning mechanisms based on polymer film can be designed with comparable performance to metal-based pre-tensioning mechanisms.

Recovery concept:

Within the project, a demonstrator is first developed for 1 actuator element and then for several actuator elements.
In addition, the demonstrator and the research results are used to apply for and carry out further research projects. In addition, the equipment and the findings on teaching and further education measures are used.

Duration: 01.01.2019 – 31.12.2021
Funded by: EU ERDF