Methods for manufacturing a tactile sensor using an electrically conductive elastomer

• US 7,066,376 B2
• Filed: 11/14/2003
• Issued: 06/27/2006
• Est. Priority Date: 08/06/2001
• Status: Expired due to Term

• Current Assignee: Siemens Corp. (Siemens AG)
• Original Assignee: Siemens Technology-To-Business Center LLC (Siemens AG)
• Inventors: Scher, Irving S., Benson, Daniel Conrad
• Primary Examiner(s): JOHNSON, JONATHAN J
• Application Number:
  US10/714,262
• Publication Number:
  US 20040104260A1
• Time in Patent Office: 956 Days
• Field of Search: 228/175, 228/123.1, 228/121
• US Class Current: 228/175
• CPC Class Codes: G01L 1/205 using distributed sensing elements
• CPC Class Codes: H01H 2207/008 Adhesive means; Conductive adhesive
• CPC Class Codes: H01H 2207/014 Plated through holes
• CPC Class Codes: H05K 3/321 by conductive adhesives
• CPC Class Codes: H05K 3/325 by abutting or pinching, i.e. without alloying process; mechanical auxiliary parts therefor adaptations of leads inserted in holes for press-fit connections H05K3/308
• CPC Class Codes: H05K 3/341 Surface mounted components
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/49128 Assembling formed circuit to base
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49142 including metal fusion
• CPC Class Codes: Y10T 29/49144 by metal fusion
• CPC Class Codes: Y10T 29/49147 Assembling terminal to base
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base

Abstract

The present invention provides methods for connecting electrically conductive elastomer to electronics that reduce cost and time for manufacturing a tactile sensor that includes an electrically conductive elastomer such as a conductive foam. The methods provide a good connection between the electrically conductive elastomer and the electrodes connected to the electronics, which provide for repeatable measurements. The methods can be used for all cases of electrically conductive elastomers and elastomers made to be conductive with the addition of conductive particles (such as carbon, silver, nickel, gold, etc.) including thermoplastic and some thermosetting elastomers.

Claims

1. A method of manufacturing a tactile sensor including an electrically conductive elastomer, said method comprising the steps of:

providing a base having a plurality of electrodes thereon, each of said plurality of electrodes having at least one spike extending out from said base at a defined angle θ

, wherein said at least one spike of one of said plurality of electrodes protrudes from said base in an outward direction away from a direction of said at least one spike of said other of said plurality of electrodes;

stretching said electrically conductive elastomer outward a certain distance;

placing said electrically conductive elastomer onto said base such that said electrically conductive elastomer becomes gripped by said spikes of said plurality of electrodes when said electrically conductive elastomer is no longer stretched;

locally heating said electrically conductive elastomer to slightly higher than a melting point of said electrically conductive elastomer to melt locally said electrically conductive elastomer around said spikes of said plurality of electrodes.

2. The method of claim 1 wherein said angle θ

is between about 10 and 80 degrees.

3. The method of claim 1 wherein said angle θ

is between about 45 and 75 degrees.

4. The method of claim 1 wherein said certain distance comprises at least two times a length of said spike multiplied by cos θ

.

5. The method of claim 1 wherein said certain distance does not exceed an elastic range of said electrically conductive elastomer.

6. The method of claim 1 wherein at least one of said plurality of electrodes is elliptically shaped.

7. The method of claim 1 wherein at least one of said plurality of electrodes is polygonally shaped.

8. The method of claim 1 wherein at least one of said plurality of electrodes is rectangularly shaped.

9. The method of claim 1 wherein said spikes are tooth-like.

10. The method of claim 1 wherein said electrically conductive elastomer comprises a foam.