Flexible sensors and related systems for determining forces applied to an object, such as a surgical instrument, and methods for manufacturing same
First Claim
1. A method of manufacturing a flexible force sensor, the method comprising:
- forming a first sensor part defining a central longitudinal axis and including a plurality of first electrode plates in a first non-conductive material, an inner rim, and an outer rim, the first electrode plates being circumferentially spaced from one another and located radially between the inner and outer rims relative to the longitudinal axis, wherein the inner and outer rims project axially beyond the first electrode plates in a direction of the longitudinal axis;
forming a second sensor part including a plurality of second electrode plates in a second non-conductive material, the second electrode plates being identical to the first electrode plates in at least shape and circumferential spacing; and
assembling the first sensor part to the second sensor part such that respective ones of the first electrode plates are aligned with and spaced from respective ones of the second electrode plates to establish a plurality of capacitive sensing components;
wherein the step of assembling includes the first sensor part in direct, abutting contact with the second sensor part at the inner and outer rims, including the first sensor part in direct, abutting contact with the second sensor part at a circumferential region of direct interface having a minimum radius that is greater than a maximum radius of the first electrode plates relative to the longitudinal axis;
wherein the respective first electrode plate of each of the capacitive sensing components is movable relative to the corresponding respective second electrode plate to establish a variable gap therebetween;
wherein the first and second sensor parts are ring-shaped, such that upon final assembly, the flexible force sensor defines a central bore.
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Accused Products
Abstract
Methods of manufacturing a flexible force sensor include forming a first sensor part providing a plurality of spaced first electrode plates in an electrically non-conductive material. A second sensor part is also formed and includes a plurality of second electrode plates in an electrically non-conductive material. The second electrode plates are identical to the first electrode plates at least in terms of spacing. The first part is assembled to the second part such that each of the first electrode plates are aligned with and parallel to, yet spaced from, respective ones of the second electrode plates, establishing a plurality of capacitive sensing components. The first electrode plates are movable relative to the corresponding second electrode plates, establishing a variable gap therebetween. The sensor parts can be ring-shaped. The sensor parts can be formed via MEMS techniques, with the non-conductive material being a polymer.
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Citations
13 Claims
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1. A method of manufacturing a flexible force sensor, the method comprising:
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forming a first sensor part defining a central longitudinal axis and including a plurality of first electrode plates in a first non-conductive material, an inner rim, and an outer rim, the first electrode plates being circumferentially spaced from one another and located radially between the inner and outer rims relative to the longitudinal axis, wherein the inner and outer rims project axially beyond the first electrode plates in a direction of the longitudinal axis; forming a second sensor part including a plurality of second electrode plates in a second non-conductive material, the second electrode plates being identical to the first electrode plates in at least shape and circumferential spacing; and assembling the first sensor part to the second sensor part such that respective ones of the first electrode plates are aligned with and spaced from respective ones of the second electrode plates to establish a plurality of capacitive sensing components; wherein the step of assembling includes the first sensor part in direct, abutting contact with the second sensor part at the inner and outer rims, including the first sensor part in direct, abutting contact with the second sensor part at a circumferential region of direct interface having a minimum radius that is greater than a maximum radius of the first electrode plates relative to the longitudinal axis; wherein the respective first electrode plate of each of the capacitive sensing components is movable relative to the corresponding respective second electrode plate to establish a variable gap therebetween; wherein the first and second sensor parts are ring-shaped, such that upon final assembly, the flexible force sensor defines a central bore. - View Dependent Claims (2, 3, 4, 5)
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6. A method of manufacturing a flexible force sensor, the method comprising:
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forming a first sensor part defining a central longitudinal axis and including a plurality of first electrode plates in a first non-conductive material, an inner rim, and an outer rim, the first electrode plates being circumferentially spaced from one another and located radially between the inner and outer rims relative to the longitudinal axis, wherein the inner and outer rims project axially beyond the first electrode plates in a direction of the longitudinal axis; forming a second sensor part including a plurality of second electrode plates in a second non-conductive material, the second electrode plates being identical to the first electrode plates in at least shape and circumferential spacing;
wherein forming the second sensor part includes forming a plurality of electrically isolated pads at an exterior of the second non-conductive material, respective ones of the pads being electrically connected to respective ones of the second electrode plates; andassembling the first sensor part to the second sensor part such that respective ones of the first electrode plates are aligned with and spaced from respective ones of the second electrode plates to establish a plurality of capacitive sensing components; wherein the step of assembling includes the first sensor part in direct, abutting contact with the second sensor part at the inner and outer rims, including the first sensor part in direct, abutting contact with the second sensor part at a circumferential region of direct interface having a minimum radius that is greater than a maximum radius of the first electrode plates relative to the longitudinal axis; wherein the respective first electrode plate of each of the capacitive sensing components is movable relative to the corresponding respective second electrode plate to establish a variable gap therebetween. - View Dependent Claims (7, 8, 9)
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10. A method of manufacturing a flexible force sensor, the method comprising:
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forming a first sensor part defining a central longitudinal axis and including a plurality of first electrode plates in a first non-conductive material, an inner rim, and an outer rim, the first electrode plates being circumferentially spaced from one another and located radially between the inner and outer rims relative to the longitudinal axis, wherein the inner and outer rims project axially beyond the first electrode plates in a direction of the longitudinal axis;
wherein the first non-conductive material is a polymer;forming a second sensor part including a plurality of second electrode plates in a second non-conductive material, the second electrode plates being identical to the first electrode plates in at least shape and circumferential spacing; and assembling the first sensor part to the second sensor part such that respective ones of the first electrode plates are aligned with and spaced from respective ones of the second electrode plates to establish a plurality of capacitive sensing components; wherein the step of assembling includes the first sensor part in direct, abutting contact with the second sensor part at the inner and outer rims, including the first sensor part in direct, abutting contact with the second sensor part at a circumferential region of direct interface having a minimum radius that is greater than a maximum radius of the first electrode plates relative to the longitudinal axis; wherein the respective first electrode plate of each of the capacitive sensing components is movable relative to the corresponding respective second electrode plate to establish a variable gap therebetween. - View Dependent Claims (11, 12, 13)
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Specification