Piezo actuator fabrication method

1. A method of generating a piezoelectric actuator comprising:

forming a piezoelectric member upon a rigid substrate, wherein the piezoelectric member includes a first electrode layer on a first surface of the rigid substrate, a second electrode layer, and a piezoelectric material layer, forming the piezoelectric member including:

forming one or more recesses on the first surface of the rigid substrate;

filling the one or more recesses on the first surface of the rigid substrate with a filler material;

polishing the first surface of the rigid substrate to remove any filler material from the first surface of the rigid substrate; and

forming the first electrode layer on the first surface of the rigid substrate at least partially encapsulating the filler material within the one or more recesses;

removing one or more portions of the rigid substrate to form one or more gaps in the rigid substrate, thus defining at least one deformable portion of the piezoelectric member and at least one rigid portion of the piezoelectric member, wherein removing includes applying a first mask to the second electrode layer on the first surface of the rigid substrate and applying a second mask to a second surface of the rigid substrate; and

polling the piezoelectric actuator at an elevated temperature of approximately 150 degrees Celsius to condition the piezoelectric material layer.

2. The method of claim 1 wherein the piezoelectric material layer positioned between the first electrode layer and the second electrode layer.

3. The method of claim 2 wherein forming the piezoelectric member upon the rigid substrate includes:

forming the first electrode layer on the rigid substrate;

forming the piezoelectric material layer on the first electrode layer; and

forming the second electrode layer on the piezoelectric material layer.

4. The method of claim 3 wherein forming the piezoelectric material layer on the first electrode layer includes:

spinning a piezoelectric material onto the first electrode layer.

5. The method of claim 3 wherein forming the piezoelectric material layer on the first electrode layer includes:

sputtering a piezoelectric material onto the first electrode layer.

6. The method of claim 2 wherein forming the piezoelectric member upon the rigid substrate further includes:

thermally annealing the piezoelectric material layer.

7. The method of claim 1 wherein removing one or more portions of the rigid substrate to form one or more gaps in the rigid substrate further includes:

forming one or more recesses on the second surface of the rigid substrate.

8. The method of claim 7 wherein the one or more recesses on the second surface of the rigid substrate are positioned and configured to expose a portion of the filler material within the one or more recesses on the first surface of the rigid substrate.

9. The method of claim 7 wherein removing one or more portions of the rigid substrate to form one or more gaps in the rigid substrate further includes:

removing the filler material within the one or more recesses on the first surface of the rigid substrate to form the one or more gaps in the rigid substrate.

10. The method of claim 1 wherein the rigid substrate is a metallic plate.

11. The method of claim 1 further comprising:

removing a portion of the piezoelectric member from the rigid substrate.

12. A method of generating a piezoelectric actuator comprising:

forming a piezoelectric member upon a rigid substrate, including:

forming one or more recesses on a first surface of the rigid substrate;

filling the one or more recesses on the first surface of the rigid substrate;

polishing the first surface of the rigid substrate to remove any filler material from the first surface of the rigid substrate;

forming a first electrode layer on the first surface of the rigid substrate at least partially encapsulating the filler material within the one or more recesses,

forming a piezoelectric material layer on the first electrode layer,

forming a second electrode layer on the piezoelectric material layer, and

thermally annealing the piezoelectric material layer;

removing one or more portions of the rigid substrate to form one or more gaps in the rigid substrate, thus defining at least one deformable portion of the piezoelectric member and at least one rigid portion of the piezoelectric member, wherein removing includes applying a first mask to the second electrode layer on the first surface of the rigid substrate and applying a second mask to a second surface of the rigid substrate; and

polling the piezoelectric actuator at an elevated temperature of approximately 150 degrees Celsius to condition the piezoelectric material layer.

13. The method of claim 12 wherein removing one or more portions of the rigid substrate to form one or more gaps in the rigid substrate further includes:

forming one or more recesses on the second surface of the rigid substrate, wherein the one or more recesses on the second surface of the rigid substrate are positioned and configured to expose a portion of the filler material within the one or more recesses on the first surface of the rigid substrate.

14. The method of claim 13 wherein removing one or more portions of the rigid substrate to form one or more gaps in the rigid substrate further includes:

removing the filler material within the one or more recesses on the first surface of the rigid substrate to form the one or more gaps in the rigid substrate.

15. The method of claim 12 further comprising:

removing a portion of the piezoelectric member from the rigid substrate.

16. A method of generating a piezoelectric actuator comprising:

forming a piezoelectric member upon a rigid substrate, wherein the piezoelectric member includes a first electrode layer on a first surface of the rigid substrate, a second electrode layer, and a piezoelectric material layer, forming the piezoelectric member including:

forming one or more recesses on the first surface of the rigid substrate;

filling the one or more recesses on the first surface of the rigid substrate with a filler material;

polishing the first surface of the rigid substrate to remove any filler material from the first surface of the rigid substrate; and

forming the first electrode layer on the first surface of the rigid substrate at least partially encapsulating the filler material within the one or more recesses; and

removing one or more portions of the rigid substrate to form one or more gaps in the rigid substrate, thus defining at least one deformable portion of the piezoelectric member and at least one rigid portion of the piezoelectric member;

wherein removing one or more portions of the rigid substrate to form one or more gaps in the rigid substrate includes:

applying a first mask to the second electrode layer on the first surface of the rigid substrate;

applying a second mask to a second surface of the rigid substrate;

forming one or more recesses on the second surface of the rigid substrate,

filling the one or more recesses on the second surface of the rigid substrate with a filler material,

removing the filler material within the one or more recesses on the first surface and the second surface of the rigid substrate to form the one or more gaps in the rigid substrate, and

polling the piezoelectric actuator at an elevated temperature of approximately 150 degrees Celsius to condition the piezoelectric material layer.

17. The method of claim 16 wherein the rigid substrate is a metallic plate.

18. The method of claim 16 wherein the piezoelectric material layer positioned between the first electrode layer and the second electrode layer.

19. The method of claim 16 wherein forming a piezoelectric member upon a rigid substrate includes:

forming the first electrode layer on the rigid substrate;

forming the piezoelectric material layer on the first electrode layer;

forming the second electrode layer on the piezoelectric material layer; and

thermally annealing the piezoelectric material layer.

20. The method of claim 16 further comprising:

removing a portion of the piezoelectric member from the rigid substrate.