Method of making piezoelectric pressure-sensitive key or keyboard and product of the method |
|||||||
申请号 | EP93810439.5 | 申请日 | 1993-06-21 | 公开(公告)号 | EP0576400A1 | 公开(公告)日 | 1993-12-29 |
申请人 | ALGRA HOLDING AG; | 发明人 | Bühlmann, Albert; Schenk, Hans; | ||||
摘要 | A method of manufacturing a pressure-sensitive electronic key or keyboard by providing a base layer (1;21) having at least one first electrically conductive area (2;241); applying at least one thin layer of a fluid piezoelectric precursor material onto the first electrically conductive area; transforming the thin layer of precursor material into an essentially coherent and uniform solid film (3) of a composite piezoelectric material firmly adhering to the electrically conductive area; forming a second electrically conductive (4;242) area spaced from the first electrically conductive area (2;241) and firmly adhering to the solid composite piezoelectric material (3) which bridges the space between the electrically conductive areas (2,4;241,242) for providing at least one essentially monolithic piezoelectric element which firmly adheres to the base layer (1) and comprises the solid composite piezoelectric material (3) with the first and second electrically conductive areas (2,4;241,242); and polarizing the composite piezoelectric material (3) with respect to the first and electrically conductive areas (2,4;241,242). | ||||||
权利要求 | |||||||
说明书全文 | This invention relates to a method of manufacturing piezoelectric elements known as pressure-sensitive keys or keyboards, and to the elements obtained by this method. In most piezoelectric applications, such as for keys or keyboards, the piezoelectric portion is used in the form of prefabricated elements or platelets provided with electrodes; these platelets must be individually mounted when a keyboard is assembled. A typical keyboard of this type is shown in EP 0 472 888 and CH 600 581 and such production is quite laborious and time-consuming. A keyboard of this type consists of at least two films which carry strip conductors and contact surfaces, and one piezoceramic platelet is needed for each key. When assembling the keyboard, the films and the piezoceramic platelets must be positioned relative to one another and fixed by means of glue and attempts at increasing the efficiency and/or reducing the costs of producing such keys or keyboards run into a limit. It is therefore a main object of the invention to provide piezoelectric elements which can be made by a method in which manual operations are significantly reduced or substantially eliminated and in which the laborious mounting of individual piezoelectric structural elements can be omitted. These and further objects are achieved according to the invention by a method as defined in claim 1. Preferred method embodiments are as defined in claims 2 - 8. The products of the method and a specific embodiment are as defined in claims 9 and 10. Generally, the invention provides a piezoelectric key or keyboard of such structure that manual interventions can be substantially omitted in the course of production. The piezoelectric layer can be put into it's operative position in an improved manner and without laborious assembly and mounting of individual prefabricated piezoelectric elements. Another advantage of the invention is that all topically defined elements including electrically conductive layers and/or paths, piezoelectric layer areas as well as topically defined insulating or spacing areas can be produced by applying them onto a base, carrier or substrate in a sequence of methodically uniform and essentially similar layer-forming steps, such as by means of the so-called "thick-film" or "thin-film" application technology, and in the form of structured coatings of substantially any desired shape and configuration. According to the invention, piezoelectric keyboards of almost any desired complexity can be produced in a more economical manner and in large or small series, without sacrificing operational properties or even with improved properties. It is a particular advantage of the invention that the constituents which are "topically critical" i. e. require placement at a predetermined location or position can be applied as layers by essentially similar process step, all of which can be automated, even if the layers have an essentially arbitrary structure. Another advantage is the fact that that, in addition to conducting, insulating, and piezoelectric layer structures, additional elements can be integrated easily, such as resistors, capacitors or diodes. Distancing means of various types known to increase the sensitivity of piezoelectric keys or keyboards can also be applied more economically if produced by fluid-deposition techniques as well, regardless of how the other constituents of the piezoelectric structure are produced. According to a preferred general embodiment of the invention, a base layer or support having at least one first electrically conductive area is provided. A thin layer of fluid piezoelectric precursor material is applied onto the first electrically conductive area and transformed into an essentially coherent uniform solid film of a composite piezoelectric material firmly adhered to the first electrically conductive area. A second electrically conductive area is formed spaced from the first electrically conductive area, either in a "stacked" or "sandwich" configuration, or in a co-planar arrangement, and in either case firmly adhering to the solid composite piezoelectric material. This provides an essentially monolithic piezoelectric element at a key location which firmly adheres to the base layer and includes the composite piezoelectric material and the first and second electrically conductive areas. The composite piezoelectric material is polarized. A cover layer may be provided. Preferably, a distancing means such as a spacer is provided in the area adjacent to the monolithic sandwich element so as to correspond with the array of the keys and to increase sensitivity in a manner known per se. The various layers, namely the electrically conductive areas, the piezoelectric layer and - preferably - the distancing means are formed by fluid deposition techniques, such as printing, e.g. by screen-printing methods. Depending upon the material used and the desired thickness of the piezoelectric material, multiple application and transforming steps may be performed. To further increase the thickness of the total key structure, first electrically conductive areas may be provided on both sides of the base layer and have a pair of sandwich structures formed thereon. Also a bimorphic piezoelectric sandwich element maybe formed. The process is modified by forming a second composite piezoelectric material on the second electrode and forming an additional electrode on the second piezoelectric material. The invention will be explained without restriction by means of examples and drawings in which:
Figure 1 illustrates a construction of an individual piezoelectric key of a keyboard. It has a carrier or base layer 1, a first conductor layer 2, a piezoelectric layer 3, a second conductor layer 4, an insulating or protective layer 5 and a bonding or distancing layer 6 which connects the key with a support foil or support plate 8. In the bonding layer 6, a hollow space 7 is recessed underneath a pressure point 9 which fixes the key. A force applied to the pressure point 9 in the direction of the drawn arrow, in the case of this arrangement, results in a bending of the piezoelectric layer 3 which, by way of the piezoelectric effect, leads to the generating of an electric voltage between the conductor layers 2 and 4. The conductor layers 2 and 4 are connected with an electronic circuit which permits the detecting of this voltage and emits a keyboard actuating signal. In this example, the manufacturing of the key takes place by several screen printing steps in which the layers 2 to 6 are printed onto the carrier layer 1 as coatings or are glued on as foils. The piezoelectric layer 3 and conductor layers 2 and 4 firmly adhere to each other to form an essential monolithic piezoelectric sandwich element firmly adhering to the carrier layer 1. In this case, typical layer thicknesses are in the order of from 1 to 100 µm. It should be noted that the construction according to Figure 1 may be varied. Thus, a thin metal lamina may, for example, be used as the carrier layer 1, onto which the structures are printed, as indicated in Figure 2. The metal lamina 1 may in this case be used directly as the front plate of a keyboard. According to the application, it is useful in this case to use the metal lamina 1 directly as the common electrode, whereby, as indicated in Figure 2, the conducting layer 2 is omitted. Also an additional insulating layer may be inserted between the metal lamina and the conducting layer 2. In the case of another embodiment, the bonding layer 6 and the support plate 8 may be omitted. A bending of the piezoelectric layer will then be caused by the concentration of the actuation force on one point of the key surface. This may be accomplished, for example, by a suitable development of the back side of the front plate 1. In the case of another embodiment, the insulating layer 5 may, for example, be omitted, particularly when the support plate 8 is not electrically conducting or is at the same electric potential as the conductor layer 4. The fact that the layers to be applied can be patterned makes it possible to also apply much more complicated structures with a plurality of separate piezoelements on a single carrier layer. Figures 3 to 5 show, for example, a portion of a keyboard matrix. In this case, the conductor layers 2 and 4 are constructed as a plurality of parallel row and column conductor strips respectively intersecting at island-shaped elements of the piezoelectric layer 3. Figure 6 shows an embodiment of the patterned element which is of converting converts mechanical into electric energy. In this case, the conducting layer 2 and the piezolayer 3 are applied as unpatterned surfaces. According to the application, the second conducting layer 4 may be patterned in a strip shape or in an island shape. When a structural element which is constructed in this manner is mechanically stressed by bending, for example, when it flutters in the wind as a "flag", positive or negative charges collect on the island or strips of the layer 4 which may be rectified by diodes 14 and charge capacitors 15. In this case, the diodes 14 as well as the capacitors 13 may be integrated in the structural element by means of thin-film or thick-film technology. The electrostrictive effect which accompanies the piezoeffect permits the operating of a structural element according to the invention also in reverse. In this case, by feeding an electric voltage to the electrodes, a deformation of the piezoelectric layer can be caused. Thus, for example, very low-cost sound generators may be constructed. According to a most preferred embodiment of the invention a keyboard or key is produced according to a method of Figure 9 comprising the following steps:
By lowering or raising the temperature during the polarization operation, it is also possible to reduce the relative permittivity and the coercive field of the ferroelectric and thus facilitate polarization. Preferably, poling is effected at elevated temperatures (e.g. 80 - 150°C) when the piezoelectric layer is a composite with a polymer matrix. Pressure may, but need not, be applied simultaneously. Further, poling can be effected before or after application of a cover layer and any additional support layers, such as substantially rigid mounting plates 8. In order to avoid breakdowns between the electrodes during the polarization process, the polarization may be carried out by corona polarization. This takes place after the solidification of the piezomaterial 3 but before the application of the second electrode layer 4. In this case, as illustrated in Figure 8, the first conducting layer 2 is connected to the earth or ground potential. Then, an electrode needle 12, which is situated a few centimeters away from the substrate, is connected with a high-voltage source 13. The resulting corona discharge leads to surface charges on the piezomaterial which is polarized as a result. The different methods of polarization, particularly the electrode polarization, permit the polarization of the piezomaterial only locally at desired points, whereby the inductive disturbances between adjacent areas can be reduced. Another implementation of the piezomaterial consists of a suitable piezoelectric polymer, such as polarized polyvinylidenefluoride (PVDF). In this case, the polymer is printed either in a dissolved form or above the melting point of from 160° to 180°C. The material may also be applied, for example, by an electrostatic powder spray method. After the application, it is polarized by an electric field, in which case the above-described methods may be used. This must take place above the glass temperature or when the film is not yet dry. It is also possible to use a polarized foil of this type as a carrier foil onto which all other layers are applied, for example, by printing techniques. As shown in Figure 9, the combined thickness of the piezomaterial 3 and electrically conductive layer 4 is less than the thickness of spacer 16. This will produce the gap below the sandwich allowing it to flex as does the bonding layer 6 in Figure 1. Conventional distancing or spacing means may include, e.g. a piece of cardboard or plastic having openings matching with the pattern of the keyboard. In this context, reference is made to EP-A-0 472 888 the disclosure of which is incorporated herein by way of reference. The art also shows various means of sealing a cover sheet which may, but need not be, of the same type as the base layer in its preferred form as a film of organic polymer material. Generally, the distancing means serves to provide a tiny hollow space below each key such that the piezoelectric layer is supported around its periphery but is not or less supported at its center so that a pressure acting upon the top of the keyboard will cause a bending stress for increasing the electric signal. Since this feature is known in the art, further explanation is not required here. As also is know per se in the piezoelectric art, keys or keyboards can have a so-called bimorphic structure. This can be achieved in an improved manner according to the invention by a repetition of steps (C) to (E). As shown in Figure 10, the monolithic piezoelectric sandwich according to this embodiment will include two coherent films 3A and 3B of solid piezoelectric material between the first and second electrode layers 2, 3 and separated by an intermediate or "third" electrode layer 17. Also, additional or intermediate layers may be provided for improved adhesion, coherence or compatibility of adjacent layers. Another multi-layered piezomaterial embodiment is illustrated in Figure 11 for increasing the thickness of the sandwich without compromising the integrity of coherency of the piezomaterial. A base 1A has first electrode layers 2A and 2B on each side thereof. Piezoelectric material islands 3A and 3B are formed on a respective first electrode layer 1A and 1B and a second electrode layer 4A and 4B are formed on the islands 3A and 3B. In all preferred embodiments of the invention, the key or keyboard should incorporate a stable "monolithic" structure of the piezoelectric sandwich element, i.e. a multi-layered structure comprising the base layer, an electrode layer and the piezoelectric film layer in the form of an integral structure in which the layers are in a mutually adhering relation of the type produced by applying layers from corresponding precursors, i.e. compositions or substances containing or providing the required constituents in a system that is fluid rather than solid and, consequently, is not used or applied as a prefabricated element. The following example is given to illustrate without limitation preferred embodiments of the invention. Parts and percentages are by weight unless otherwise indicated. A pressure sensitive keyboard was produced as follows: The base layer used for producing the keyboard was a commercial polyethylene terephthalate film (thickness 175 µm; trade mark Melinex, type 505 ST supplied by ICI) having a conventional primer layer or being chlorinated in a conventional manner on its surface for improved adhesion. A commercial silver paint (e.g. as obtainable from Acheson Industries USA or Olin Hunt, UK) was applied topically on the base layer by screen printing (screen standard 90T corresponding with 230 T mesh) at a thickness (dry) of about 7.5 µm to produce a keyboard pattern of a type know per se consisting of sixteen key areas and a first pattern of conductor paths for individual or group (row/column) connections. The pattern was obtained in conventional photographic manner to form sixteen circular electrode areas and connecting conductor paths. The printed pattern was air-dried during 20 minutes at 110°C. A printing ink was prepared by milling on a laboratory mill; 100 parts of commercial PZT-type ceramic powder (supplied by Philips, Netherlands, type PXE 5 or type PXE 52) having particle sizes in the range of from 0.5 to 2.5 micrometer; 20 parts of commercial screen printing lacquer (supplied form Printcolor, Switzerland, as resin 290-05; 5 parts of acryl lacquer (Printcolor, type 290); 1 part of evaporation-retarding agent (Printcolor, type 10-99); Milling was repeated 3 times to achieve homogeneity (by visual appearance) and a viscosity in the conventional screen printing range. The ink was applied topically onto the base layer in the area of the electrode portions produced in paragraph (b) by printing three times with a screen of 43 T (110 mesh T) taking care to avoid formation of air bubbles in the layer. A photographically produced pattern was used to concentrically cover the electrode areas produced in paragraph (b) and overlapping them by a margin of about 1 mm. After each printing operation, the applied layer was air-dried 30 min at 100°C. Total thickness of the resulting dried piezoelectric film was about 50 µm. A pattern of electrodes substantially as in section (b) and with a corresponding set of connecting paths for individual activation of each key was applied onto the base layer in the areas matching with the pattern produced in paragraphs (b) and (c) by screen printing with a 120 T (305 T mesh) screen in the manner explained in paragraph (b). The printed layer was air-dried 20 min at 110°C. A sealing layer was applied over the area of the connector ends by applying a layer of UV-polymerizable lacquer (supplied by Olin Hunt, type Iso UV) through a 120 T screen (305 mesh) Irradiation with actinic UV radiation was effected using a commercial UV-lamp. The product of paragraph (e) was heated to about 150°C between two plates pressed against each other (0.0 bar) and a potential of 100 V DC was applied between each pair of electrodes via the conductor paths. Poling was continued for 10 minutes. A sheet of polyethylene terephthalate of 125 µm thickness was connected adhesively with a paper sheet having openings corresponding essentially with the electrode pattern so as to provide disk-shaped hollow spaces below each sandwich of two electrodes and the intermediate piezoelectric layer upon mutual sealing. This sheet was aligned with the polarized product and adhesively sealed therewith using commercial adhesive such as adhesive type 467 supplied by 3M (Minnesota, Mining and Manufacturing Co). The final product produced a maximum signal strength of about 10 V. A pressure sensitive keyboard was produced as follows: The base layer 1A used for producing the keyboard was a commercial polyethylene terephthalate film (thickness 175 µm; trade mark Melinex 505st supplied by ICI), having a conventional primer layer or being chlorinated in a conventional manner on both surfaces for improved adhesion. The same silver paint was applied topically on both sides of the base layer 1A in the same way as the first conductive layer of Example I. A pattern 2A, 2B of sixteen key areas and connection conductor path was obtained on both sides of the base layer. A piezoelectric printing ink was prepared in the same way as in Example I. The ink was applied by screen printing onto both sides of the base layer on the area of the sixteen conducting key areas produced in paragraph (b). The printing was repeated three times in the same way as in Example I, also overlapping the key areas produced in paragraph (b). Total thickness of each of the resulting films 3A, 3B was again about 50 µm. A pattern of electrodes was applied onto the same piezoelectric layers on both sides of the base layer in the same was as the second electrode layer 4A, 4B of Example I. A sealing layer to protect and electrically insulate the sandwich structure produced in paragraphs (a) to (d) was applied on both sides of the base layer in the same way as the protective layer of Example I. For poling the resulting bimorphic structure produced in paragraphs (a) to (e), the base conductive layers 2A and 2B of all the thirty-two sandwich elements were connected together in series. The exterior conductive layers of 4A of the sixteen sandwich elements on one side of the base layer were connected together and the sixteen conductive areas of layer 4B on the other side were connected together. A voltage of 200 V DC was applied across the two exterior conductive layers 4A, 4B and the product was heated to 150°C. The poling was continued for 10 minutes. While poling, the sandwich elements of the both sides of the base layer were connected in series. After poling, the two corresponding sandwich elements were connected in parallel by connecting the base and exterior conductive layers of the same. A sheet of polyethylene terephthalate of 125 µm thickness was connected adhesively with a paper sheet having openings corresponding essentially with the electrode pattern so as to provide disk-shaped hollow spaces below each sandwich of two electrodes and the intermediate piezoelectric layer upon mutual sealing. This sheet was aligned with the polarized product and adhesively sealed therewith using commercial adhesive such as adhesive type 467 supplied by 3M (Minnesota, Mining and Manufacturing Co). The final product produced a maximum signal strength of about 10 V. This example illustrates a preferred embodiment of producing the distancing means for a key or keyboard according to the invention by fluid-deposition technique rather than by using a prefabricated insert. Example I was repeated except that the distancing means, i.e. spacer layer 16 (Fig. 9), was applied by printing prior to step (d) to form a layer of a total thickness of about 100 µm. Printing can be effected as in Example I, paragraph (c), except that addition of the ceramic material to the ink base is replaced by an "inert" constituent as explained below. Alternatively, spacing layers may be produced according to the invention by printing a pattern using an ink made of a UV-curable polymer as above or a reactive polymer composition, such as commercial epoxide polymers with suitable curing agents, e.g. Araldit®, provided that such polymer is "inert" as well. This is explained as follows: any ingredient of distancing means or spacer layer produced by a fluid-application technique according to the invention should preferably be "piezoelectrically inert"; this term is based upon the conventional piezoelectric strain constant indicated typically in picoCoulomb per Newton (Pc/N), generally also identifying the directions of piezoelectric charge or impulse versus mechanical strain by subscripts "dxy", e.g. d₃₁. Thus, any material used as a constituent of the distancing layer should have a piezoelectric strain constant not exceeding about 1 percent (numeric basis) of the piezoelectric strain constant of the associated piezoelectric layer, e.g. d₃₁(layer 16) ≦ 0.01 d₃₁(layer 3). An ink suitable for use in producing a distancing layer can be applied in a single application step if it has sufficient consistency or body, e.g. as obtained by use of a solvent-free liquid polymer composition or by using a filler, such as typically a glass powder or any particulate solid substance that is "inert" in the above sense as well as in the normal chemical sense; many inorganic silicates, carbonates and oxides meet this requirement and are of use. Preferred particle sizes are below 50 µm, e.g. up to 30 µm. Example II is repeated except that the distancing means 16A, 16B (Fig. 10) are produced by printing using an ink composed of glass powder (particle size below about 20 µm) and a commercial ink base, such as the base used in example I, paragraph (c), in a proportion of about 2:3, i.e. containing about 35 % by weight of glass powder. The distancing layer 16A is applied after forming the first piezoelectric layer 3A by printing and prior to forming the third electrode layer 17; distancing layer 16B is applied with the same ink as layer 16A but after forming of the second piezoelectric print layer 3B and prior to forming the electrode layer 4. The procedure essentially as described in Example III was repeated for producing a key or keyboard structure of the type shown in Figure 11. Starting from base layer 1A, a first "sandwich" structure is formed thereon by applying, in sequence, conducting electrode layer 2A, piezoelectric layer 3A, spacing layer 16A and electrode layer 2A. Then, a second sandwich structure was formed on the reverse side of base layer 1A by applying, in sequence, conducting electrode layer 2B, piezoelectric layer 3B, spacing layer 16B and electrode layer 4B. Thereupon, a covering layer 1B was applied as in Example I. Of course, the sequence of producing the two sandwich structures could be inverted starting with application of electrode layer 2B on the reverse side of base layer 1A. A key or keyboard with a structure as illustrated in Figures 12 - 14 was produced according to the invention as follows: a base layer 21 was provided, by means of sieve printing as in Example I, or by vacuum deposition (or any other technique suitable for producing relatively thin, electrically conductive layers on a polymer substrate), with an electrically conductive pattern in the manner of conventional interdigital transducers and consisting of two mutually distanced coplanar electrodes 241, 242 each having a connecting path 243, 244. Then, the piezoelectric layer 23 is applied in the same manner as in paragraph (c) of Example I. For the sake of better understanding, layer 23 is shown as overlapping on the sides but without completely covering electrodes 241, 242. This is not critical, however, and it is preferred for many purposes that layer 23 essentially covers or even overlaps electrodes 241,242. Then, spacing layer 26 is produced in the manner explained above, and any further processing towards the desired final product may follow. Poling can be effected by means of an electrical field applied between each pair of digits of electrodes 241, 242 via the conductive paths 243, 244. A part of the field penetrates into piezoelectric layer 23 and causes poling in the area around the digits. When a mechanical strain is made to act upon the sensitive area of a key or keyboard so produced, i.e. in the area of the interspace between the co-planar electrode layers with the co-acting piezoelectric layer 23, an electrical signal of typically about 5 V is generated between electrodes 241,242. Signal processing can be effected as shown in Figure 6. Various modifications within the scope of the invention will be apparent to those experienced in the production of piezoelectric keys or keyboards - the latter being a repetition of the former plus the required circuitry in a given pattern of 10, 26, 48 or more individual keys representing any symbol, such as alphanumeric characters or other symbols used for a system that can be controlled from a keyboard. For example, various other piezoelectric materials could be used, and could applied in the form of compositions that involve a fluid (i. e. liquid or gaseous) precursor system containing materials suitable for forming a coherent piezoelectric layer. For example, the polymer of the matrix of the composite piezoelectric layers explained above could be piezoelelectrically active rather than inert. Also, application methods other then screen printing, e.g. spraying, brushing, dip-coating etc., can be used provided that the required topically defined patterns needed for piezoelectric keys or keyboards can be obtained in commercial manufacture such that an essentially automated assembly of all constituent is achieved in production of piezoelectric keys or keyboards. |