Hybrid tactile sensor

• US 20060260417A1
• Filed: 05/18/2005
• Published: 11/23/2006
• Est. Priority Date: 05/18/2005
• Status: Active Grant

• Current Assignee: Pressure Profile Systems Inc. (PPS U.K. Limited)
• Original Assignee: Pressure Profile Systems Inc. (PPS U.K. Limited)
• Inventors: Son, Jae S., Parks, Tom
• Granted Patent: US 7,430,925 B2
• Time in Patent Office: Days
• US Class Current: 73/862.46
• CPC Class Codes: G01L 1/205 using distributed sensing elements
• CPC Class Codes: G01L 5/228 using tactile array force sensors

Abstract

A hybrid tactile sensor includes a flexible cloth-based tactile sensor array including a plurality of electrodes, each of the electrodes connected to a corresponding connecting zone of an intermediate connecting harness made from a flexible film such as Kapton®. The harness includes a common bundle of parallel conductors etched or printed onto the harness and connecting each of the connecting zones to a common terminal for further attaching to a control unit of the sensor. The use of the harness allows repeatable manufacturing of sensor arrays with large number of electrodes or when they are located close to each other. Each connecting zone may include an interconnecting pad for crimping, soldering, or adhering the electrode thereto using a conductive epoxy. Alternative embodiments describe the use of U-shaped malleable connectors, jumper wires including those equipped with U-shaped clips, and other means of attaching electrodes to corresponding connecting zones. The use of alternating connections with electrodes of the array allows to double the distance between individual electrodes available for making a connection.

Claims

1. A hybrid tactile sensor comprising:

a flexible tactile sensor array including a first plurality of parallel electrodes overlapping a second plurality of parallel electrodes with a non-conductive isolation therebetween, and

an intermediate connecting harness formed by a flexible non-conductive film and a conductive layer attached thereto, said flexible non-conductive film including a plurality of connecting zones, each of said connecting zones located adjacent to and adapted to be connected to the corresponding electrode of at least a portion of said first or said second plurality of parallel electrodes, said conductive layer including a plurality of conductors, each conductor originating from a corresponding connecting zone, said conductors extended to a common terminal.

2. The hybrid tactile sensor as in claim 1, wherein said plurality of conductors forming a common bundle extended to said terminal.

3. The hybrid tactile sensor as in claim 1, wherein said conductive layer is attached to said flexible non-conductive film by printing thereof on said non-conductive film.

4. The hybrid tactile sensor as in claim 1, wherein said conductive layer is formed by first covering said flexible non-conductive film entirely with a conductive material layer and then etching away some sections thereof to form said conductors.

5. The hybrid tactile sensor as in claim 1, wherein each of said connecting zones including an interconnection pad formed in said conductive layer together with said conductor originating therefrom.

6. The hybrid tactile sensor as in claim 5, wherein each of said connecting zones including a slot sized to accept said electrode passed therethrough.

7. The hybrid tactile sensor as in claim 6, wherein each of said connecting zones further including a connector adapted to crimp said electrode to said interconnection pad.

8. The hybrid tactile sensor as in claim 1, wherein each of said connecting zones including an H-shaped double-sided forked electrically conductive clip, one side of said clip adapted to be attached to said connecting zone and make an electrical connection with said conductor originating therefrom, the other side of said clip adapted to retain and make electrical connection with said electrode.

9. The hybrid tactile sensor as in claim 1, wherein each of said connecting zones including a jumper wire attached to a corresponding conductor originating from said connecting zone.

10. The hybrid tactile sensor as in claim 9, wherein said jumper wire is coiled.

11. The hybrid tactile sensor as in claim 9, wherein said jumper wire is equipped with a clip adapted for attaching to said electrode of said cloth-based tactile array.

12. The hybrid tactile sensor as in claim 1, wherein said intermediate connecting harness extending throughout said tactile sensor array, said conductors extending beyond said connecting zones and forming said first or said second plurality of parallel electrodes.

13. The hybrid tactile sensor as in claim 1, wherein each of said interconnecting zones further including an individual mechanical attachment means for securing said electrode thereto.

14. The hybrid tactile sensor as in claim 13, wherein said individual mechanical attachment means is selected from a group comprising a clip, a wedge, a rivet, a clamp, and a screw.

15. The hybrid tactile sensor as in claim 1, wherein said terminal further including an edge connector formed from in said harness from said conductors.

16. The hybrid tactile sensor as in claim 1 further including a rigid substrate supporting said tactile sensor array on one side of said substrate and supporting said intermediate connecting harness on the other side thereof.

17. The hybrid tactile sensor as in claim 1, wherein said first plurality of parallel electrodes comprising a first side plurality of electrodes and a second side plurality of electrodes, said electrodes of said first side plurality alternating with said electrodes of said second side plurality, said electrodes of said first side plurality of electrodes extending on a first side of said sensor array for connecting to said intermediate connecting harness, said electrodes of said second side plurality of electrodes extending an a second side of said sensor array opposite said first side.

18. The hybrid tactile sensor as in claim 17 further including a rigid substrate supporting said tactile sensor array on one side of said substrate and supporting said intermediate connecting harness on the other side thereof, said first side plurality of electrodes wrapped about said substrate and connected to said intermediate connecting harness on said first side of said sensor, said second side plurality of electrodes wrapped about said substrate and connected to said intermediate connecting harness on said second side of said sensor.

19. A hybrid tactile sensor comprising:

a flexible tactile sensor array including a first plurality of parallel electrodes overlapping a second plurality of parallel electrodes with a non-conductive isolation therebetween,

a first intermediate connecting harness formed by a flexible non-conductive film and a conductive layer attached thereto, said flexible non-conductive film including a first plurality of connecting zones, each of said connecting zones located adjacent to and adapted to be connected to the corresponding electrode of at least a portion of said first plurality of parallel electrodes, said conductive layer including a first plurality of conductors, each conductor originating from a corresponding connecting zone, said conductors extended to a first common terminal, and

a second intermediate connecting harness formed by a flexible non-conductive film and a conductive layer attached thereto, said flexible non-conductive film including a second plurality of connecting zones, each of said connecting zones located adjacent to and adapted to be connected to the corresponding electrode of at least a portion of said second plurality of parallel electrodes, said conductive layer including a second plurality of conductors, each conductor originating from a corresponding connecting zone, said conductors extended to a second common terminal.

20. A hybrid tactile sensor comprising a flexible tactile sensor array including a first plurality of parallel electrodes overlapping a second plurality of parallel electrodes with a non-conductive isolation therebetween, said first plurality of parallel electrodes comprising a first side plurality of electrodes and a second side plurality of electrodes, said electrodes of said first side plurality alternating with said electrodes of said second side plurality of electrodes, said electrodes of said first side plurality of electrodes extending on a first side of said sensor array beyond thereof, said electrodes of said second side plurality of electrodes extending an a second side of said sensor array beyond thereof, said second side being opposite said first side.

21. The hybrid tactile sensor as in claim 20, wherein said second plurality of parallel electrodes comprising a third side plurality of electrodes and a fourth side plurality of electrodes, said electrodes of said third side plurality alternating with said electrodes of said fourth side plurality of electrodes, said electrodes of said third side plurality of electrodes extending on a third side of said sensor array beyond thereof, said electrodes of said fourth side plurality of electrodes extending an a fourth side of said sensor array beyond thereof, said fourth side being opposite said third side.

22. The hybrid sensor as in claim 20 further including a rigid substrate supporting said tactile sensor array on one side of said substrate, said first side plurality of electrodes wrapped about said rigid substrate from said first side of said sensor, said second side plurality of electrodes wrapped about said rigid substrate and from said second side of said sensor.