Synthetic jet with non-metallic blade structure

Abstract

A system and method for lowering resonant frequency in a synthetic jet device for less noise, as well as lowering vibration, is disclosed. A synthetic jet device includes a first plate, a second plate spaced apart from the first plate, a spacing component coupled to and positioned between the first and second plates to form a chamber and including an orifice therein, and an actuator element coupled to at least one of the first or second plates to selectively cause deflection thereof, wherein the first and second plates are formed at least in part of a non-metallic material.

What is claimed is: 
     
         1 . A synthetic jet device comprising:
 a first plate;   a second plate spaced apart from the first plate;   a spacing component coupled to and positioned between the first and second plates to form a chamber and including an orifice therein; and   an actuator element coupled to at least one of the first or second plates to selectively cause deflection thereof;   wherein the first and second plates are formed at least in part of a non-metallic material.   
     
     
         2 . The synthetic jet device of  claim 1  wherein the non-metallic material comprises an electrically non-conductive material. 
     
     
         3 . The synthetic jet device of  claim 2  wherein the non-metallic material comprises at least one of a thermoplastic, thermoset, and a filler material. 
     
     
         4 . The synthetic jet device of  claim 2  wherein each of the first and second plates includes an electrically conductive metallic material, the electrically conductive metallic material comprising one of a filler material, a metalizing layer, and internally or externally formed leads. 
     
     
         5 . The synthetic jet device of  claim 4  wherein each of the first and second plates comprises:
 an electrically non-conductive, non-metallic substrate; and 
 an electrically conductive metalizing layer applied onto the electrically non-conductive, non-metallic substrate. 
 
     
     
         6 . The synthetic jet device of  claim 4  wherein each of the first and second plates comprises a copper-plated printed circuit board (PCB) blank. 
     
     
         7 . The synthetic jet device of  claim 4  wherein each of the first and second plates comprises:
 a flexible dielectric layer; and 
 electrically conductive leads formed on an exterior surface of the flexible dielectric layer or internally within the flexible dielectric layer. 
 
     
     
         8 . The synthetic jet device of  claim 1  wherein the first and second plates comprise a single piece of non-metallic material folded along a bridge thereof to form the first and second plates. 
     
     
         9 . The synthetic jet device of  claim 8  wherein a continuous electrically conductive lead is formed internally in the single piece of non-metallic material and extends through the bridge and to the actuator element on the respective first and second plates. 
     
     
         10 . The synthetic jet device of  claim 8  wherein a discontinuous electrically conductive lead is formed internally in the single piece of non-metallic material and extends through the bridge and to the actuator element on the first and second plates. 
     
     
         11 . A method of fabricating a synthetic jet device comprising:
 constructing a first plate and a second plate at least in part of a non-metallic material;   attaching an actuator element to at least one of the first and second plates to selectively cause deflection thereof;   positioning the first plate relative to the second plate by way of a spacing component, the spacing component securing the first plate to the second plate in a spaced apart arrangement to form a chamber and including an orifice therein; and   attaching electrical connections to the actuator element and the respective one of the first and second plates to which the actuator element is attached so as to enable a selective applying of voltage to the actuator element.   
     
     
         12 . The method of  claim 11  wherein constructing each of the first plate and the second plate comprises selecting a material composition of the first and second plates to set a stiffness of the first and second plates to a desired amount, so as to adjust a resonant frequency of the synthetic jet device to a desired level. 
     
     
         13 . The method of  claim 11  wherein constructing each of the first plate and the second plate comprises:
 providing an electrically non-conductive, non-metallic substrate; and 
 applying an electrically conductive metalizing layer onto the electrically non-conductive, non-metallic substrate. 
 
     
     
         14 . The method of  claim 11  wherein constructing each of the first plate and the second plate comprises providing a copper-plated printed circuit board (PCB) blank. 
     
     
         15 . The method of  claim 11  wherein constructing each of the first plate and the second plate comprises providing an electrically non-conductive, non-metallic material having an electrically conductive filler material mixed therein. 
     
     
         16 . The method of  claim 11  wherein constructing each of the first plate and the second plate comprises providing a flexible dielectric layer that includes electrically conductive leads formed on an exterior surface of the flexible dielectric layer or internally within the flexible dielectric layer, the electrically conductive leads providing for electrical coupling of the actuator element and the electrical connections thereto. 
     
     
         17 . The method of  claim 11  wherein constructing the first plate and the second plate comprises:
 providing a single piece of electrically non-conductive, non-metallic material comprising a first plate portion, a second plate portion, and a bridge portion; and 
 folding the single piece of electrically non-conductive, non-metallic material at the bridge portion to orient the first plate portion in a substantially parallel arrangement with the second plate portion, so as to form the first plate and the second plate; 
 wherein the single piece of electrically non-conductive, non-metallic material includes one of a lead formed internally therein that extends through the bridge portion and to the actuator element on the at least one of the first and second plates. 
 
     
     
         18 . The method of  claim 17  wherein the lead formed internally in the single piece of electrically non-conductive, non-metallic material comprises one of a continuous lead and a non-continuous lead. 
     
     
         19 . A synthetic jet device comprising:
 a first plate;   a second plate spaced apart from the first plate to form a chamber; and   an actuator element coupled to at least one of the first or second plates to selectively cause deflection thereof so as to change a volume of the chamber;   wherein each of the first and second plates comprises:
 a first material comprising an electrically insulating, non-metallic material; and 
 a second material comprising an electrically conductive material, the second material being formed as one of a filler material, a metalizing layer, and internally or externally formed leads provided on or in the first material. 
   
     
     
         20 . The synthetic jet device of  claim 19  further comprising a spacing component coupled to and positioned between the first and second plates to maintain the first and second plates in a spaced apart relationship, wherein the first plate, second plate and spacing component collectively form the chamber and wherein the spacing component includes an orifice therein. 
     
     
         21 . The synthetic jet device of  claim 19  wherein the first and second plates comprise a folded plate structure formed of a single piece of electrically non-conductive, non-metallic material, the folded plate structure including:
 a first plate portion; 
 a second plate portion; 
 a bridge portion connecting the first plate portion to the second plate portion; and 
 a lead formed internally in the double-folded plate structure that extends through the bridge portion and to the actuator element on the at least one of the first and second plates; 
 wherein the folded plate structure is folded at the bridge portion to orient the first plate portion in a substantially parallel arrangement with the second plate portion so as to form the first plate and the second plate. 
 
     
     
         22 . The synthetic jet device of  claim 19  wherein the composition of the first and second materials in each of the first plate and the second plate sets a stiffness of the first and second plates to a pre-determined amount, so as to set a resonant frequency of the synthetic jet device at a desired level.