Ultrasonic motor

Abstract: Provided herein is an ultrasonic motor in which at least fluorocarbon polymer is present on the contact surface of at least either of the rotor (3) or the stator (2).

Description: The present invention relates to an ultrasonic motor which is so designed as to produce a driving force by the aid of traveling waves of ultrasonic frequency vibration generated by piezoelectric elements. An ultrasonic motor driven by traveling waves, as disclosed in, for example, U.S. Patent No. 4,562,373, is made up of a flat piezoelectric element, a flat stator to which is attached said piezoelectric element, a rotor which is in contact under pressure with said stator, and a friction material interposed between said stator and said rotor. To run the motor, an electric power of ultrasonic frequency is applied to the piezoelectric element, with the time difference and phase difference properly controlled. The applied electric power generates transverse traveling waves in synchronism with the ultrasonic vibration in the thickness direction of the piezoelectric element and stator. The wave crests of the traveling waves drive the rotor forward through the friction material. The ultrasonic motor of traveling wave type will be described with reference to Fig. 4. There are shown a piezoelectric element 1 , a stator 2 which is bonded andfixed to the piezoelectric element 1 , a rotor 3 placed on the stator 2 , and a friction material 4 firmly attached to the rotor 3 . When energized, the piezoelectric element 1 generates traveling waves of ultrasonic frequency which propagate in the direction of arrow A in the stator 2 . The vibration causes each particle of the stator 2 to move along the elliptic orbit indicated by arrow B. The wave crest of the traveling wave advances horizontally in the direction opposite to that of the traveling wave, and the wave trough of the traveling wave advances horizontally in the same direction as the traveling wave. Therefore, the rotor 3 placed on the stator 2 is in contact with the wave crests only and is driven horizontally in the direction of arrow C by frictional force generated between the rotor 3 and the stator 2 . An important factor in the ultrasonic motor of such structure is how the rotor is in contact under pressure with the stator. It greatly affects the starting torque, no-load speed, motor efficiency, and motor life. Heretofore, much has been studied on increasing friction between the rotor and the stator. To this end, a variety of materials have been investigated. For example, there was proposed a method of increasing friction by attaching a metallic material or rubber having a high coefficient of friction to the rotor and bringing the rotor into contact with the stator under pressure. However, attaching a metallic material to the rotor needs precision working for the contact surfaces of the metallic material and the stator. An additional disadvantage is that the metal-to-metal contact produces a noise which is a problem in practical use. A friction material other than metallic ones is a rubber slider which has a high coefficient of friction. The commercial one, however, has a disadvantage. That is, it is liable to wear as the contact surface is rubbed. The wearing adversely affects the starting torque, no-load speed, and motor efficiency, and eventually shortens the motor life. In addition, the rubber slider does not keep the holding torque (or braking torque) constant. (Holding torque is a force to hold the rotor in position when the motor is at rest.) Patent Abstracts of Japan, Vol. 11, No 240 (E-529) [2687] 6 th August 1987 ; & JP-A-62 53 182 discloses an ultrasonic motor wherein a fluorocarbon is present on the contact surface of the stator. EP-A-0 209 865 discloses an ultrasonic motor in which the contact member is made of a composite material made of organic fiber and a resin. The present invention was completed to solve the above-mentioned problems involved in the prior art. Accordingly, it is an object of the present invention to provide an ultrasonic motor which meets the following requirements for practical use. (1) The noise level is as low as possible when the motor is running. (2) The drive force (torque) produced by contact under pressure should be as great as possible. (3) The wear of the contact surface should be as small as possible so that the motor keeps its performance over a long period of time. (4) The holding torque to keep the rotor in position when the motor is at rest should be constant. The present invention provides an ultrasonic motor comprising a planar stator provided with a planar piezoelectric element and a rotor arranged to be in contact under pressure with said stator whereby said rotor is driven by way of friction between said rotor and stator by wave crests of a transverse traveling wave of ultrasonic frequency generated on the planar surface of the stator by the application of electric power of ultrasonic frequency to said piezoelectric element, characterized in that at least the contact surface of said rotor is made from a composite plastic material comprising a fluorocarbon resin, carbon fiber and matrix resin. While the novel features of the invention re set forth in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description taken in conjunction with the drawings. Fig. 1 is a perspective view showing the basic structure of an ultrasonic motor; Fig. 2 is a perspective view showing the structure of a discoid ultrasonic motor; Fig. 3 is a perspective view showing the structure of a toroidal ultrasonic motor; and Fig. 4 is a schematic representation to explain the principle on which the ultrasonic motor works. The ultrasonic motor of the present invention has the basic structure as shown in Fig. 1. It is made up of a platy piezoelectric element 1 , a platy stator 2 to which is attached said piezoelectric element 1 , a rotor 3 which is in contact under pressure with said stator 2 , and at least a fluorocarbon polymer on the contact surface of at least either said stator 2 or said rotor 3 . The stator in contact with the rotor is usually made of a metallic material such as steel and stainless steel which has a low damping factor for vibration. Ultrasonic motors embodied according to the present invention include discoid one and toroidal one as shown in Figs. 1 and 2, respectively. Specific examples of the contact surface polymer composition are discussed in the following. Example 1 Five kinds of friction materials (A to E) in the form of 1 mm thick sheet were prepared by combining 4 kinds of matrix resins, 5 kinds of fluorocarbon resin powders, and 6 kinds of carbon fibers as shown in Table 1. For comparison, two kinds of friction materials (F and G) containing no fluorocarbon resin powder were prepared. The thus prepared friction material was bonded to a stainless steel disc, 40 mm in diameter and 1 mm thick, to make a test piece. The test piece was tested for dynamic friction which was produced when the test piece was turned at 30 rpm, with a stainless steel ball, 3 mm in diameter, in contact under a load of 200 g with the test piece at the position 15 mm apart from the center. The dynamic friction which changed with time was recorded. The results are shown in Table 2 It is noted from Tables 1 and 2 that the composite friction materials composed of a matrix resin, fluorocarbon resin powder, and carbon fiber have a high coefficient of friction (higher than 0.2) which changed very little with time. By contrast, the friction materials (F and G in Comparative Examples) which contain no fluorocarbon resin powder greatly changed with time in coefficient of friction. Example 2 Seven discoid ultrasonic motors as shown in Fig. 2 were prepared in which the friction material 4a is one of those which are designated as A to G in Example 1. The ultrasonic motor is made up of a piezoelectric element 1a , a stator 2a of stainless steel which is bonded to the surface of the piezoelectric element 1a , a rotor 4 of stainless steel, and a friction material 4a attached to the rotor 3a . The friction material 4a is made of the composite plastic sheet prepared in Example 1. The rotor 3a is pressed against the stator 2a by means of a spring so that an initial braking torque of 4.90 x 10⁻²N.m (500 gf·cm) is produced. The piezoelectric element is provided with four electrodes which are arranged so that four traveling waves are generated in the circumferential direction of the stator. The rotor 3a was driven at a no-load speed of 500 rpm by applying an electric field of resonance frequency, about 70 kHz. After running for a prescribed period of time, the motors were tested for restarting performance, braking torque (which is produced after de-energizing), and resonance frequency. The results are shown in Table 3. It is noted from Table 3 that the ultrasonic motors equipped with one of the friction materials A to E, which are composed of a matrix resin, fluorocarbon resin powder, and carbon fiber, changed with time very little in braking torque and resonance frequency. It is also noted that they had no problem with restarting and the stator 2a of stainless steel wore very little. By contrast, the ultrasonic motors equipped with one of the friction materials F and G, which do not contain fluorocarbon resin powder, greatly changed with time in braking torque and resonance frequency. In addition, they had a problem with restarting. Example 3 Five kinds of composite plastics friction materials (designated as I to M) were prepared from polyimide (as a matrix resin), tetrafluoroethylene resin powder having an average particle diameter of 3 µm (as a fluorocarbon resin powder), and PAN-based pulp-like carbon fiber according to the formulation shown in Table 4. Each friction material was formed into a 1-mm thick sheet. This sheet was attached to the same discoid ultrasonic motors as used in Example 2. The ultrasonic motors were driven by applying an electric field of resonance frequency in the same manner as in Example 2. After running for a prescribed period of time, the motors were tested for restarting performance, braking torque (which is produced after de-energizing), and resonance frequency. The results are shown in Table 4. It is noted from Table 4 that the ultrasonic motors provided with one of the friction materials K, L, and M containing 5 wt% or more of fluorocarbon resin powder and 5 wt% or more of carbon fiber changed with time very little in braking torque and resonance frequency and had no problem with restarting. By contrast, the ultrasonic motors provided with one of the friction materials I and J containing 2 wt% or less of fluorocarbon resin powder greatly changed with time in braking torque and resonance frequency and were poor in restarting performance. Example 4 A composite plastic friction material was prepared by impregnating felt with a phenolic resin solution in which are uniformly dispersed carbon fiber and fluorocarbon resin powder. After preliminary drying, the friction material was compression molded into a 1-mm thick sheet. This sheet was used as the friction material 4a in the discoid ultrasonic motor as shown in Fig. 2. Example 5 A composite plastic friction material was prepared by impregnating laminated plain weaves of carbon fiber with a polyimide resin solution in which are uniformly dispersed fluorocarbon resin fine powder having an average particle diameter of 1 µm. After preliminary drying, the friction material was compression molded into a 1-mm thick sheet. This sheet was used as the friction material 4a in the discoid ultrasonic motor as shown in Fig. 2. The ultrasonic motors in both Examples 4 and 5 had an initial braking torque of 4.90 x 10⁻²N.m (500 gf·cm) which slightly changed to 5.20 x 10⁻² N.m (530 gf·cm) after running for 5 hours. They had resonance frequencies of 70.8 kHz and 70.6 kHz, respectively, which remained almost unchanged even after running for 5 hours. They had no problem with restarting. The friction material did not wear nor scratch the stator 2a of stainless steel with which it is in contact. The above-mentioned examples indicate that the following functions and effects are produced when the ultrasonic motor is constructed such that a friction material made according to this invention is present on the contact surface of at least either of the rotor or the stator. (1) The fluorocarbon polymer has the ability to absorb vibration of specific frequency on account of its characteristic flexibility. Consequently, it completely prevents the ultrasonic motor from producing noise. (2) Since the fluorocarbon polymer works as a solid lubricant on the contact surface and has an abhesive property, it provides smooth slipping between the stator and the rotor. Consequently, it permits the ultrasonic motor to produce a stable driving force. (3) Owing to its comparatively high heat resistance, the fluorocarbon polymer does not suffer from seizure or melting even under the severe friction conditions produced by ultrasonic vibration. Consequently, it greatly reduces the wear of the contact surfaces of the ultrasonic motor and permits the ultrasonic motor to maintain its performance over a long period of time. (4) Since the fluorocarbon resin has a lower hard-ness than the metallic material constituting the stator, it does not damage the contact surface of the stator and keeps the contact surface of the stator stable at all times. Therefore, the ultrasonic motor has a constant holding torque (which is a force to hold the rotor in position when the motor is at rest).

Claims: An ultrasonic motor comprising a planar stator (2) provided with a planar piezoelectric element (1) and a rotor (3) arranged to be in contact under pressure with said stator (2) whereby said rotor is driven by way of friction between said rotor and stator by wave crests of a transverse traveling wave of ultrasonic frequency generated on the planar surface of the stator (2) by the application of electric power of ultrasonic frequency to said piezoelectric element (1), characterized in that at least the contact surface (4) of said rotor (3) is made from a composite plastic material comprising a fluorocarbon resin, carbon fiber and matrix resin. An ultrasonic motor according to claim 1, in which only said contact surface (4) of said rotor (3) is made from said composite plastic material. An ultrasonic motor according to claim 1, in which substantially all of said rotor (3) is made from said composite plastic material. An ultrasonic motor according to claim 1, 2 or 3, in which said composite plastic material comprises carbon fiber in the form of woven cloth. An ultrasonic motor according to claim 1, 2 or 3 in which said composite plastic material comprises carbon fiber in the form of felt.

Inventors: IMASAKA YOSHINOBU, SUMIHARA MASANORI, YONENO HIROSHI, IMASAKA, YOSHINOBU, SUMIHARA, MASANORI, YONENO, HIROSHI
Applicants: MATSUSHITA ELECTRIC IND CO LTD, MATSUSHITA ELECTRIC INDUSTRIAL CO., LTD.
Application year: 1988
Main classification: H01L41
IPC codes: H02N2, H01L41