Pop-Up Laminate Structures with Integrated Electronics

Patent metadata

Field	Value
Publication number	US-2016184041-A1
Application number	US-201414909792-A
Country	US
Kind code	A1
Filing date	Aug 4, 2014
Priority date	Aug 4, 2013
Publication date	Jun 30, 2016
Grant date	—

Abstract

A multi-layer, super-planar laminate structure can be formed from distinctly patterned layers. The layers in the structure can include at least one rigid layer and at least one flexible layer; the rigid layer includes a plurality of rigid segments, and the flexible layer can extend between the rigid segments to serve as a joint. The layers are then stacked and bonded at selected locations to form a laminate structure with inter-layer bonds, and the laminate structure is flexed at the flexible layer between rigid segments to produce an expanded three-dimensional structure, wherein the layers are joined at the selected bonding locations and separated at other locations. A layer with electrical wiring can be included in the structure for delivering electric current to devices on or in the laminate structure.

First claim

1 . A pop-up laminate device with integrated electronics, comprising:
at least one segmented rigid layer with gaps between segments of the rigid layer; at least one flexible layer laminated to the rigid layer and extending across the gaps the separate the segments of the rigid layer to form hinges, wherein the flexible layer is less rigid than the rigid layer; and a plurality of layers of electrically conductive wiring extending across or through the rigid segments, wherein at least one of the layers of electrically conductive wiring extends from rigid segments to form at least one of the following: (a) a bridge across the hinges and (b) a via structure separating layers in the pop-up laminate.

2 . The pop-up laminate of claim 1 , further comprising an electronic transducer coupled with the electrically conductive wiring.

3 . The pop-up laminate of claim 2 , wherein the electronic transducer is selected from an electromagnetic actuator configured to generate displacement, a light-emitting-diode/phototransistor pair coupled with an optical encoder, and a Hall effect sensor.

4 . The pop-up laminate of claim 2 , wherein the electronic transducer is included as one of the rigid layers.

5 - 7 . (canceled)

8 . The pop-up laminate of claim 1 , further comprising a strain gauge mounted on at least one of the rigid segments.

9 - 10 . (canceled)

11 . A method for fabricating a three-dimensional structure with voice-coil actuation, the method comprising:
stacking a plurality of patterned layers and bonding the plurality of patterned layers at selected locations to form a laminate structure with inter-layer bonds, wherein one of the layers comprises part of a magnetic core, and wherein a first layer of discrete electrically conductive parallel paths is stacked on a first side of the magnetic core part, and wherein a second layer of discrete electrically conductive parallel paths is stacked on a second side of the magnetic core part opposite from the first side, wherein each path comprises a first end and a second end; respectively bonding the first ends of the paths in the first layer with the second ends of the paths in the second layer and respectively bonding the second ends of the paths in the first layer with the first ends of the paths in the second layer to form a plurality of windings in an electrically conductive coil; attaching one or more secondary magnetic structures to the magnetic core part enclosed by the electrically conductive coil to form a complete magnetic core; and expanding the laminate structure into an expanded three-dimensional configuration by selectively distorting at least one of the layers to produce gaps between layers while maintaining at least some of the inter-layer bonds, wherein the expansion of the laminate structure positions the electrically conductive coil about the magnetic core, where the electrically conductive coil and the magnetic core form a voice-coil actuator, and where that the electrically conductive coil is displaced relative to the magnetic core when electric current passes through the electrically conductive coil.

12 . The method of claim 11 , further comprising incorporating a pop-up constraint mechanism into the voice coil actuator, where the pop-up constraint mechanism constrains displacement and orientation of the coil with respect to the magnetic core.

13 . The method of claim 11 , wherein the pop-up constraint mechanism positions the electrically conductive coil about the magnetic core such that substantially reduced friction is generated between the electrically conductive coil and the magnetic core as the electrically conductive core is displaced.

14 . The method of claim 11 , wherein the secondary magnetic structures are stacked on the magnetic core part by a pick-and-place deposit.

15 . A method for fabricating an electromagnetically actuated three-dimensional structure comprising:
stacking a plurality of patterned layers and bonding the plurality of patterned layers at selected locations to form a laminate structure with inter-layer bonds and with a plurality of platforms on which components can be mounted; mounting an electrically conductive coil on a first of the platforms; mounting a permanent magnet on a second of the platforms; and expanding the laminate structure into an expanded three-dimensional configuration by selectively distorting at least one of the layers to produce gaps between layers while maintaining at least some of the inter-layer bonds, wherein expanding the laminate structure displaces the platforms on which the electrically conductive coil and the permanent magnet are mounted to displaceably insert the permanent magnet inside the electrically conductive coil so that the permanent magnet is displaced relative to the electrically conductive coil when electric current is passed through the electrically conductive coil.

16 . The method of claim 15 , wherein at least one of the platforms is coated with a conductive circuit.

17 . A method for forming a pop-up laminate with integrated electronics, comprising:
forming a laminate stack up including at least one segmented rigid layer, at least one flexible layer that is less rigid than the rigid layer, and a plurality of electrically conductive layers including pathways for electrical current flow; bonding the layers in the stack up; and folding the flexible layer and electrically conductive layer to deform the laminate.

18 . The method of claim 17 , further comprising including the following in the laminate stack up:
a sensor included in a sensor layer or as a coating bonded to at least one of rigid segments and electrically coupled with at least one of the electrically conductive layers.

19 . The method of claim 17 , wherein the electrically conductive layers are in the form of traces that provide a plurality of electrical pathways through the electrically conductive layers.

20 - 22 . (canceled)

23 . A laminate device for manipulating or altering structures, the device comprising:
a laminate stack comprising two sub-modules, each comprising at least one rigid substrate laminated to a less-rigid flexible layer, wherein each sub-module includes a body and a jaw extending from the body, and wherein the sub-modules are joined at the body and biased so that the jaws are in contact (closed) or spread apart (open); and an actuation device incorporated into or coupled with the jaws and configured to overcome the bias and open or close the jaws when actuated.

24 . The laminate device of claim 23 , wherein the jaws include end effectors configured to grasp or join structures.

25 . The laminate device of claim 23 , wherein the jaws includes blades for cutting structures.

26 . The laminate device of claim 23 , wherein the jaws are configured to separate by a maximum of 0.1 to 10 mm when opened.

27 . The laminate device of claim 23 , further comprising an electrically conductive layer including electrical wiring in at least one of the sub-modules.

28 . The laminate device of claim 27 , further comprising a strain gauge mounted on or in at least one of the jaws, electrically coupled with the electrical wiring, and configured to detect force acting on the jaw.

29 . The laminate device of claim 27 , further comprising at least one electrode in at least one of the jaws for electrocauterization or ablation, wherein the electrode is electrically coupled with the electrical wiring.

Assignees

• Harvard College

Inventors

• Gafford Joshua B
• Kesner Samuel B
• Walsh Conor J
• Karpelson Michael
• Wood Robert J
• Dubrovsky Zivthan
• Goldberg Benjamin I
• O'Donnell Kathleen
• Smith Michael J

Classifications

• A61B2017/00402

  Piezo electric actuators · CPC title

• B81B2207/99

  Microstructural systems or auxiliary parts thereof not provided for in B81B2207/01 - B81B2207/115 · CPC title

• A61B2017/00345

  Micromachines, nanomachines, microsystems · CPC title

• A61B2017/00203

  with speech control or speech recognition · CPC title

• A61B2017/2926

  Details of heads or jaws · CPC title