Method of manufacturing a piezoelectric actuator

1. A method for making a piezoelectric actuator comprising:

(1) coating at least one of a first surface and a second surface of a piezoelectric element with a polyimide adhesive;

(2) heating the piezoelectric element to dry the adhesive; then

(3) inserting the piezoelectric element between a first metallic layer and a second metallic layer to form an assembly;

(4) placing the assembly in a press;

(5) while the assembly is in the press, curing the polyimide adhesive at a curing temperature which does not depole the piezoelectric element, thereby bonding the piezoelectric element between the first metallic layer and the second metallic layer.

2. The method of claim 1 , wherein step (1) comprises coating the piezoelectric with a thin layer of polyimide adhesive no more than 0.005 inch thick.

3. The method of claim 1 , further comprising, as act (2) using heat to initiate a polymerization process.

4. The method of claim 1 , wherein the polyimide adhesive is a polyimide gel adhesive, and further comprising, as act (2) using heat to remove solvent from the polyimide gel adhesive.

5. The method of claim 1 , further comprising performing act (3) only after the polyimide adhesive is dry to the touch.

6. The method of claim 1 , further comprising, at least during act (5), applying uniform pressure to the piezoelectric actuator formed by bonding the piezoelectric element between the first metallic layer and the second metallic layer.

7. The method of claim 6 , wherein the act of applying pressure comprises:

(a) laying a polyimide film on a bottom plate of a press;

(b) placing the piezoelectric actuator on the polyimide film;

(c) covering the piezoelectric actuator with a sheet of rubber;

(d) tightening the press whereby the bottom plate and a top plate of the press apply uniform pressure to the piezoelectric situated therebetween.

8. The method of claim 6 , further comprising:

(e) cooling the piezoelectric actuator in the press;

(f) removing the piezoelectric actuator from the press.

9. The method of claim 1 , wherein act (5) comprises inserting the assembly in the press, and then placing the press in a heater.

10. The method of claim 1 , further comprising using a polycrystalline material as the piezoelectric element.

11. The method of claim 1 , further comprising using stainless steel as the first metallic layer.

12. The method of claim 1 , further comprising using aluminum as the second metallic layer.

13. The method of claim 1 , further comprising forming the first metallic layer with a rim arranged to serve as a clamping surface.

14. The method of claim 13 , further comprising forming the first metallic layer to have a larger surface area than the piezoelectric element.

15. The method of claim 14 , further comprising forming the second metallic layer to have a smaller surface area than the piezoelectric element.

16. The method of claim 1 , further comprising:

forming the first metallic layer to have a larger diameter than the piezoelectric element; and

forming the second metallic layer to have a smaller diameter than the piezoelectric element.

17. The method of claim 1 , further comprising using a flat element as the piezoelectric element.

18. The method of claim 1 , further comprising using as the polyimide adhesive as a gel which has a minimum of 25% solids.

19. The method of claim 1 , wherein the curing temperature does not melt the polyimide adhesive.

20. The method of claim 1 , wherein the curing temperature is no more than 200 degrees Centigrade.