Multilayer coextrusion is applied to produce a tape containing layers of alternating electrical properties to demonstrate the potential for using coextrusion to manufacture capacitors. To obtain the desired properties, we develop two filled polymer systems, one for conductive layers and one for dielectric layers. We describe numerical models used to help determine the material and processing parameters that impact processing and layer stability. These models help quantify the critical ratios of densities and viscosities of the two layers to maintain stable layers, as well as the effect of increasing the flow rate of one of the two materials. The conducting polymer is based on polystyrene filled with a blend of low-melting-point eutectic metal and nickel particulate filler, as described by Mrozek et al. (2010). The appropriate concentrations of fillers are determined by balancing measured conductivity with processability in a twin screw extruder. Based on results of the numerical models and estimates of the viscosity of emulsions and suspensions, a dielectric layer composed of polystyrene filled with barium titanate is formulated. Despite the fact that the density of the dielectric filler is less than the metallic filler of the conductive phase, as well as rheological measurements that later showed that the dielectric formulation is not an ideal match to the viscosity of the conductive material, the two materials can be successfully coextruded if the flow rates of the two materials are not identical. A measurable capacitance of the layered structure is obtained.
The purpose of this project is to develop multi-layered co-extrusion (MLCE) capabilities at Sandia National Laboratories to produce multifunctional polymeric structures. Multi-layered structures containing layers of alternating electrical, mechanical, optical, or structural properties can be applied to a variety of potential applications including energy storage, optics, sensors, mechanical, and barrier applications relevant to the internal and external community. To obtain the desired properties, fillers must be added to the polymer materials that are much smaller than the end layer thickness. We developed two filled polymer systems, one for conductive layers and one for dielectric layers and demonstrated the potential for using MLCE to manufacture capacitors. We also developed numerical models to help determine the material and processing parameters that impact processing and layer stability.
The three-year LDRD ''CNC Micromachines'' was successfully completed at the end of FY02. The project had four major breakthroughs in spatial motion control in MEMS: (1) A unified method for designing scalable planar and spatial on-chip motion control systems was developed. The method relies on the use of parallel kinematic mechanisms (PKMs) that when properly designed provide different types of motion on-chip without the need for post-fabrication assembly, (2) A new type of actuator was developed--the linear stepping track drive (LSTD) that provides open loop linear position control that is scalable in displacement, output force and step size. Several versions of this actuator were designed, fabricated and successfully tested. (3) Different versions of XYZ translation only and PTT motion stages were designed, successfully fabricated and successfully tested demonstrating absolutely that on-chip spatial motion control systems are not only possible, but are a reality. (4) Control algorithms, software and infrastructure based on MATLAB were created and successfully implemented to drive the XYZ and PTT motion platforms in a controlled manner. The control software is capable of reading an M/G code machine tool language file, decode the instructions and correctly calculate and apply position and velocity trajectories to the motion devices linear drive inputs to position the device platform along the trajectory as specified by the input file. A full and detailed account of design methodology, theory and experimental results (failures and successes) is provided.
In PKM Machines, the Cartesian position and orientation of the tool point carried on the platform is obtained from a kinematic model of the particular machine. Accurate positioning of these machines relies on the accurate knowledge of the parameters of the kinematic model unique to the particular machine. The parameters in the kinematic model include the spatial locations of the joint centers on the machine base and moving platform, the initial strut lengths, and the strut displacements. The strut displacements are readily obtained from sensors on the machine. However, the remaining kinematic parameters (joint center locations, and initial strut lengths) are difficult to determine when these machines are in their fully assembled state. The size and complexity of these machines generally makes it difficult and somewhat undesirable to determine the remaining kinematic parameters by direct inspection such as in a coordinate measuring machine. In order for PKMs to be useful for precision positioning applications, techniques must be developed to quickly calibrate the machine by determining the kinematic parameters without disassembly of the machine. A number of authors have reported techniques for calibration of PKMs (Soons, Masory, Zhuang et. al., Ropponen). In two other papers, the authors have reported on work recently completed by the University of Florida and Sandia National Laboratories on calibration of PKMs, which describes a new technique to sequentially determine the kinematic parameters of an assembled parallel kinematic device. The technique described is intended to be used with a spatial coordinate measuring device such as a portable articulated CMM measuring arm (Romer, Faro, etc.), a Laser Ball Bar (LBB), or a laser tracker (SMX< API, etc.). The material to be presented is as follows: (1) methods to identify the kinematic parameters of 6--6 variant Stewart platform manipulators including joint center locations relative to the workable and spindle nose, and initial strut lengths, (2) and example of the application of the method, and (3) results from the application of the technique.