Flexible sensor and method of manufacturing the same

Abstract

The embodiment of the application discloses a flexible sensor and a preparation method thereof, and belongs to the technical field of sensors. The flexible sensor comprises a flexible substrate layer, a sensor layer and a reinforcing layer. The sensor layer is formed on a first surface of the flexible substrate layer, and the sensor layer is composed of sensor units. The reinforcing layer is composed of reinforcing units, and the reinforcing units correspond to the positions of the sensor units. The reinforcing units are used for increasing the rigidity of the sensor units. The shape of the flexible sensor matches the surface profile of an object to which the flexible sensor is adapted. In the scheme provided by the embodiment of the application, the rigidity of the sensor units is increased by arranging the reinforcing units, so that the sensor units are prevented from being stretched when the flexible sensor is attached to the surface of the object, and the performance of the flexible sensor after attachment is ensured.

Description

Technical Field

[0001] This application relates to the field of sensor technology, and in particular to a flexible sensor and its fabrication method. Background Technology

[0002] Flexible sensors are sensors made using flexible materials, characterized by their flexibility, stretchability, and high sensitivity. With the development of microelectromechanical systems and flexible electronics, flexible sensors are showing great application potential in fields such as robotics and medicine.

[0003] In related technologies, most flexible sensors are manufactured on a two-dimensional plane. Based on the characteristics of flexible materials being soft and easily deformable, the resulting flexible sensors can be attached to the surface of the product and adapt to the surface contour of the product.

[0004] In the above technical solution, if the surface to which the flexible sensor is attached is a complex curved surface, the sensor unit in the flexible sensor will be stretched during the attachment process, resulting in a decrease in the sensitivity and stability of the flexible sensor. Summary of the Invention

[0005] This application provides a flexible sensor and its fabrication method. During the attachment of the flexible sensor to a complex curved surface, its sensor unit does not undergo tensile deformation, thereby ensuring the sensitivity and stability of the flexible sensor. The technical solution is as follows:

[0006] On one hand, embodiments of this application provide a flexible sensor, which includes:

[0007] Flexible substrate layer, sensor layer, and reinforcement layer;

[0008] The sensor layer is formed on the first surface of the flexible substrate layer, and the sensor layer is composed of sensor units;

[0009] The reinforcement layer is composed of reinforcement units, and the reinforcement units correspond to the positions of the sensor units. The reinforcement units are used to increase the rigidity of the sensor units.

[0010] The shape of the flexible sensor matches the surface contour of the object to which the flexible sensor is adapted.

[0011] On the other hand, embodiments of this application provide an intelligent robot in which a flexible sensor as described above is attached to the robot body with a surface curvature greater than a curvature threshold.

[0012] On the other hand, embodiments of this application provide a method for fabricating a flexible sensor, the method comprising:

[0013] A reinforcement layer is formed on the surface of a flexible sensor, wherein the reinforcement units in the reinforcement layer correspond to the positions of the sensor units in the sensor layer. The sensor layer is formed on the first surface of a flexible substrate layer, and the reinforcement units are used to increase the stiffness of the sensor units.

[0014] The heated flexible sensor is attached to the surface of the adaptable object;

[0015] The flexible sensor is cooled and shaped.

[0016] The technical solution provided in this application may include the following beneficial effects:

[0017] In this embodiment, a reinforcing layer is formed on the surface of the flexible sensor, with the reinforcing units in the reinforcing layer corresponding to the sensor units in the flexible sensor layer. This increases the stiffness of the sensor units, ensuring that the sensor units are not stretched when the flexible sensor is attached to the surface of the adaptable object, thus guaranteeing the sensitivity and stability of the flexible sensor after attachment. Furthermore, the shape of the fabricated flexible sensor matches the surface contour of the adaptable object, eliminating the need for reshaping the flexible sensor when it is subsequently applied to the adaptable object, simplifying the usage process. Attached Figure Description

[0018] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0019] Figure 1 This is a schematic diagram of the structure of a flexible sensor provided in an exemplary embodiment of this application;

[0020] Figure 2 This is a schematic diagram illustrating the working principle of the reinforcement unit provided in an exemplary embodiment of this application;

[0021] Figure 3 This is a flowchart of a method for fabricating a flexible sensor provided in an exemplary embodiment of this application;

[0022] Figure 4 This is an implementation flowchart of the flexible sensor fabrication process provided in an exemplary embodiment of this application;

[0023] Figure 5 This is a schematic diagram of the structure of a flexible sensor provided in another exemplary embodiment of this application;

[0024] Figure 6 This is a flowchart of a method for forming a reinforcing layer in a flexible sensor provided in an exemplary embodiment of this application;

[0025] Figure 7This is a schematic diagram illustrating an embodiment of the attachment shielding member in an exemplary embodiment of this application;

[0026] Figure 8 This is an exemplary embodiment of the present application illustrating the formation of a reinforcing layer using a screen printing process;

[0027] Figure 9 This is an exemplary embodiment of the present application illustrating the formation of a reinforcing layer using a dispensing process;

[0028] Figure 10 This is a schematic diagram of the structure of a flexible sensor provided in another exemplary embodiment of this application;

[0029] Figure 11 This is a schematic diagram illustrating an embodiment of forming a reinforcing layer using a dispensing process, as shown in another exemplary embodiment of this application.

[0030] Figure 12 This is a schematic diagram illustrating an embodiment of the present application in which a reinforcing layer is formed using masking tape;

[0031] Figure 13 This is a schematic diagram of a flexible sensor provided in an exemplary embodiment of this application being attached to the surface of a simulated finger of an intelligent robot. Detailed Implementation

[0032] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of sensors and fabrication methods consistent with some aspects of this application as detailed in the appended claims.

[0033] Artificial intelligence (AI) is the theory, methods, technology, and application systems that use digital computers or machines controlled by digital computers to simulate, extend, and expand human intelligence, perceive the environment, acquire knowledge, and use that knowledge to achieve optimal results. In other words, AI is a comprehensive technology within computer science that attempts to understand the essence of intelligence and produce a new kind of intelligent machine that can react in a way similar to human intelligence. AI studies the design principles and implementation methods of various intelligent machines, enabling them to possess the functions of perception, reasoning, and decision-making.

[0034] Artificial intelligence (AI) is a comprehensive discipline encompassing a wide range of fields, including both hardware and software technologies. Fundamental AI technologies generally include sensors, dedicated AI chips, cloud computing, distributed storage, big data processing, operating / interactive systems, and mechatronics. AI software technologies primarily include computer vision, speech processing, natural language processing, and machine learning / deep learning.

[0035] With the research and advancement of artificial intelligence (AI) technology, AI is being studied and applied in various fields, such as smart homes, smart wearable devices, virtual assistants, smart speakers, autonomous driving, drones, robots, and smart healthcare. It is believed that with the development of technology, AI will be applied in more fields and play an increasingly important role.

[0036] The solutions provided in this application relate to robotics technology based on artificial intelligence. This application provides a flexible sensor and its fabrication method. This flexible sensor can be attached to the outer surface of an AI robot as its skin. By sensing changes in the robot's external surface environment, it converts these minute changes into electrical signals and transmits them to the robot controller. The robot controller then controls the robot to perform corresponding operations based on the received electrical signals.

[0037] In related technologies, most flexible sensors are manufactured on a two-dimensional plane. Based on the softness and deformability of flexible materials, the resulting flexible sensors can be attached to the surface of the product and conform to its contours. However, if the surface to which the flexible sensor is attached is a complex curved surface, the sensor will be stretched during attachment. When the flexible sensor is subjected to lateral stress, both the flexible substrate layer and the sensor units within the sensor layer will deform. Deformation of the flexible substrate layer does not affect sensor performance, but deformation of the sensor units will.

[0038] To prevent performance degradation due to stretching deformation of the sensor unit during attachment to complex curved surfaces, this application employs a reinforcement unit to strengthen the sensor unit. This prevents stretching deformation of the sensor unit during attachment to the surface of the adaptable object, thus protecting the sensor's sensitivity and stability. In this configuration, when the flexible sensor is attached to the complex curved surface of an AI robot, it can acquire data promptly and accurately, ensuring the robot's normal operation.

[0039] Optionally, the flexible sensor in this application can be applied to the outer surface of the torso of an artificial intelligence robot, such as the surface of a robot's robotic arm or a simulated human hand.

[0040] The structure and fabrication method of flexible sensors are described below.

[0041] Please refer to Figure 1 The diagram illustrates a structural schematic of a flexible sensor provided in an exemplary embodiment of this application.

[0042] In this embodiment, the flexible sensor includes a flexible substrate layer 11, a sensor layer 12, and a reinforcing layer 13. The sensor layer 12 is formed on the first surface of the flexible substrate layer 11 and is composed of sensor units 121.

[0043] The flexible substrate layer 11 serves as the carrier for the sensor unit 121 within the sensor layer 12. The flexible substrate layer 11 is made of a flexible thermoplastic material, which is soft and easily deformable. Therefore, the resulting flexible sensor can be attached to the surface of an object and conform to its surface contour.

[0044] The surface of the adaptable object can be the surface of a robotic arm of an AI robot, the surface of a simulated finger, etc., and this embodiment does not limit this. The contour of the fabricated flexible sensor matches the contour of the adaptable object's surface. Therefore, when applying the flexible sensor to the adaptable object, there is no need to reshape or adjust the shape of the flexible sensor.

[0045] Optionally, the flexible substrate 11 may be made of thermoplastic polyurethanes (TPU), polyethylene terephthalate (PET), polyvinyl chloride (PVC), and polypropylene (PP), etc., and this application embodiment does not limit this.

[0046] In addition, the flexible substrate 11 also includes electrodes and wires. One end of the wire is connected to the electrodes of each sensor unit 121, and the other end is connected to the controller of the adapted object. The controller generates corresponding control commands based on the received signals, such as controlling a robot to grasp objects.

[0047] Sensor unit 121 is a component that converts environmental information into electrical signals. By sensing changes in the environmental information of the adapted object, it converts the measured minute changes into electrical signals and transmits them to the adapted object, thereby achieving the purpose of control. Sensor unit 121 is a flexible sensor unit that can adapt to the complex curved surfaces of objects.

[0048] Optionally, the environmental information includes, but is not limited to, at least one of the following: pressure intensity, air humidity, gas concentration, ambient light intensity, etc., which are not limited in this embodiment. Correspondingly, the sensor unit can be a pressure sensor, humidity sensor, gas concentration sensor, photosensor, etc., which are not limited in this embodiment.

[0049] Optionally, the sensor units 121 are arranged in an array on the first surface of the flexible substrate. The number of sensor units 121 depends on the area of ​​the adapted object.

[0050] Optionally, the array can be a rectangular array, a circular array, a triangular array, etc., but this embodiment does not limit this.

[0051] In addition, electrodes are provided on the sensor unit 121, and the electrodes between each flexible sensor unit 121 are connected by wires in the flexible substrate layer 11.

[0052] The aforementioned flexible substrate layer 11 and sensor layer 12 constitute the main structure of the flexible sensor, thereby converting changes in environmental signals around the adapted object into electrical signals. In addition, the flexible sensor also includes a reinforcement layer 13, which is an additional structure of the flexible sensor. The reinforcement layer 13 is composed of reinforcement units 131, and the reinforcement units 131 correspond in position to the sensor unit 121. The reinforcement units 131 are used to increase the stiffness of the sensor unit 121.

[0053] Since the sensor unit 121 is formed on the surface of the flexible substrate 11, deformation of the flexible substrate 11 will cause deformation of the sensor unit 121. While deformation of the flexible substrate 11 does not affect the sensitivity and stability of the flexible sensor, deformation of the sensor unit 121 will reduce its sensitivity and stability. Therefore, the reinforcement unit 131 is used to reinforce the sensor unit 121, increasing its rigidity and preventing deformation during attachment to the surface of the adaptable object, thereby ensuring the performance of the flexible sensor.

[0054] For example, such as Figure 2 As shown, without a reinforcing layer, applying a lateral tensile force to the flexible sensor causes deformation of the flexible substrate 11, which in turn causes deformation of the sensor unit 121, resulting in an increase in the area of ​​the sensor unit 121 under the lateral tensile force. However, with a reinforcing layer, when the same lateral tensile force is applied to the flexible sensor, the sensor unit 121 does not deform under the lateral tensile force because the reinforcing unit 131 increases the rigidity of the sensor unit 121; only the flexible substrate 11 deforms.

[0055] Regarding the positional correspondence between the reinforcement unit 131 and the sensor unit 121, in one possible design, the reinforcement layer 13 is formed on the surface of the flexible sensor, and the reinforcement unit 131 can directly correspond to the position of the sensor unit 121. In another possible design, the reinforcement unit 131 indirectly corresponds to the position of the sensor unit 121, that is, it corresponds to the projection position of the sensor unit 121 onto the second surface of the flexible substrate layer 11.

[0056] Regarding the material of the reinforcement unit 131, since the flexible sensor needs to be attached to the surface of the adaptable object, the material of the reinforcement unit 131 is a flexible material. Based on the function of the reinforcement unit 131, the material of the reinforcement unit 131 is not easily deformed under certain stress, and its stiffness is greater than that of the material of the flexible substrate layer 11.

[0057] Optionally, the material of the reinforcing unit 131 can be UV-curable ink, tape, masking tape, etc., and this application embodiment does not limit this.

[0058] Optionally, the area of ​​the reinforcement unit 131 can be equal to or greater than the area of ​​the sensor unit 121. This application embodiment does not limit this.

[0059] In summary, this embodiment forms a reinforcing layer on the surface of the flexible sensor, with the reinforcing units in the reinforcing layer corresponding to the sensor units in the flexible sensor layer. This increases the stiffness of the sensor units, ensuring that the sensor units are not stretched when the flexible sensor is attached to the surface of the adaptable object, thus guaranteeing the sensitivity and stability of the flexible sensor after attachment. Furthermore, the shape of the fabricated flexible sensor matches the surface contour of the adaptable object, eliminating the need for reshaping the flexible sensor when it is subsequently applied to the adaptable object, simplifying the usage process.

[0060] Furthermore, the fabrication method of the aforementioned flexible sensor will be described.

[0061] Please refer to Figure 3 The diagram illustrates a flowchart of a method for fabricating a flexible sensor according to an exemplary embodiment of this application, which may include the following steps.

[0062] Step 310: A reinforcement layer is formed on the surface of the flexible sensor. The reinforcement units in the reinforcement layer correspond to the positions of the sensor units in the sensor layer. The sensor layer is formed on the first surface of the flexible substrate layer. The reinforcement units are used to increase the stiffness of the sensor units.

[0063] The reinforcement layer consists of reinforcement units, which increase the stiffness of the sensor unit. The purpose of these units is to prevent deformation of the flexible substrate layer from causing deformation of the sensor unit on its surface during the attachment of the flexible sensor to the surface of the adaptable object, thus affecting the sensor's sensitivity and stability. Therefore, the reinforcement units and sensor units are positioned correspondingly. The flexible substrate layer needs to undergo stretching deformation during attachment to the surface of the adaptable object to match its contours. Therefore, the area outside the corresponding sensor unit position in the flexible sensor does not include reinforcement units.

[0064] Regarding the method of forming a reinforcing layer on the surface of a flexible sensor, in one possible implementation, the reinforcing layer is formed on the surface of the flexible sensor by a screen printing process.

[0065] In another possible implementation, a reinforcing layer is formed on the surface of the flexible sensor using a dispensing process.

[0066] In another possible implementation, a reinforcing material is applied to the corresponding location of the sensor unit in the flexible sensor to form a reinforcing layer.

[0067] Step 320: Attach the heated flexible sensor to the surface of the adaptable object.

[0068] Because the flexible substrate layer of the flexible sensor is made of flexible thermoplastic material, which is soft and stretchable, it is easily deformed at a certain temperature and can maintain a certain shape after cooling. Therefore, the reinforced flexible sensor is heated so that the flexible sensor can match the surface contour of the object.

[0069] In one possible implementation, a flexible sensor and an adapter are placed on a machine platform, with the adapter positioned below the flexible sensor. The flexible sensor is then heated and brought close to the surface of the adapter, causing the flexible sensor to adhere to the surface of the adapter.

[0070] In this embodiment, the heating temperature range is 100–300°C. Different flexible substrate materials require different heating temperatures.

[0071] Optionally, when the flexible base layer is made of thermoplastic polyurethane elastic rubber, the heating temperature is 80°C.

[0072] Optionally, when the flexible substrate material is polyethylene terephthalate, the heating temperature range is 260–280°C;

[0073] Optionally, when the flexible substrate is made of polyvinyl chloride, the heating temperature range is 160–210°C;

[0074] Optionally, when the flexible substrate is made of polypropylene, the heating temperature is 155°C.

[0075] It should be noted that this embodiment is only used to illustrate the materials used to make the flexible substrate layer. In other possible implementations, developers may adjust the heating temperature within a specified heating range according to different materials. This embodiment does not constitute a limitation in this regard.

[0076] During the process of attaching the heated flexible sensor to the surface of the adaptable object, the flexible sensor will undergo tensile deformation. Since the reinforcement unit reinforces the sensor unit, the sensor unit will not deform during the stretching process. Only the flexible base layer deforms. The deformation of the flexible base layer will not affect the sensitivity and stability of the flexible sensor, thus ensuring both the adaptability of the flexible sensor shape to the object's surface contour and the performance of the flexible sensor.

[0077] Step 330: Cool and shape the flexible sensor.

[0078] Based on the material properties of the flexible substrate, after the heated flexible sensor is attached to the surface of the adaptable object, the flexible sensor needs to be cooled and shaped for a certain period of time to prevent the shape of the flexible sensor from collapsing.

[0079] In one possible implementation, during the separation of the flexible sensor from the adapter object, after a specified cooling and shaping time, the cooled and shaped flexible sensor is separated from the surface of the adapter object to obtain a flexible sensor that conforms to the surface contour of the adapter object.

[0080] In another possible implementation, when the flexible sensor and the adapter are fabricated together, after a specified cooling and shaping time, the flexible sensor is directly attached to the surface of the adapter, and its shape is consistent with the contour of the adapter surface.

[0081] Optionally, the cooling and shaping time can be 1 hour, 2 hours, etc., depending on the material of the flexible substrate layer of the flexible sensor. This application embodiment does not limit this.

[0082] Furthermore, before attaching the heated flexible sensor to the surface of the adapter object, the relative position of the flexible sensor and the adapter object needs to be adjusted to prevent the flexible sensor from deviating from its preset position during the attachment process. In one possible implementation, a first positioning mark and a second positioning mark are respectively provided on the surfaces of the flexible sensor and the adapter object. After placing the flexible sensor and the adapter object on the machine, the relative positions of the first and second positioning marks are observed. If the first and second positioning marks are aligned, no adjustment of the relative position of the flexible sensor and the adapter object is required. If the first and second positioning marks are not aligned, the relative position between the flexible sensor and the adapter object needs to be adjusted.

[0083] Regarding the method of adjusting the relative position of the flexible sensor and the adapter, in one possible implementation, the relative position of the flexible sensor or the adapter can be manually adjusted until the first positioning mark and the second positioning mark are aligned.

[0084] In another possible implementation, the flexible sensor and the adapter are placed behind the machine tool, which automatically adjusts the relative positions of the flexible sensor and the adapter using a cursor positioning method based on the first positioning mark and the second positioning mark.

[0085] Furthermore, if air may be present between the flexible sensor and the surface of the adapter during the attachment process, the resulting flexible sensor may form bulges, causing a mismatch between the sensor's shape and the adapter's surface contour, which could subsequently affect its performance. To improve the matching degree between the flexible sensor and the adapter, vacuum suction forming technology can be used to remove the air between them during the attachment process.

[0086] During the process of attaching the heated flexible sensor to the surface of the adaptable object, the air between the flexible sensor and the surface of the adaptable object is extracted to create a vacuum state. This creates a pressure difference, which allows the flexible sensor to completely adhere to the surface of the adaptable object and form a shape that matches the contour of the surface of the adaptable object.

[0087] For example, Figure 4 This is a flowchart illustrating an exemplary embodiment of the flexible sensor fabrication process provided in this application. An array of sensor units 42 is formed on the flexible substrate layer 43 of the flexible sensor 41. A reinforcing material is attached to the second surface of the flexible substrate layer 43 at a position corresponding to the sensor unit 42, forming a reinforcing unit 44 to reinforce the sensor unit 42. Further, the flexible sensor 41 and the adapter object 45 are placed on a machine tool. By aligning the first positioning mark on the flexible sensor 41 and the second positioning mark on the adapter object 45, their relative positions are adjusted to a preset position, fixing the flexible sensor 41 and the adapter object 45. Further, the flexible sensor 41 is heated to a temperature selected according to the material of the flexible substrate layer, and then attached to the surface of the adapter object 45. During the attachment process, air is extracted between the surfaces of the flexible sensor 41 and the adapter object 45 using vacuum suction forming technology, creating a vacuum state and a pressure difference, allowing the flexible sensor 41 to be completely attached to the surface of the adapter object 45. Furthermore, after a period of cooling and shaping, a flexible sensor 41 that conforms to the surface contour of the adapted object is obtained.

[0088] In summary, this embodiment forms a reinforcing layer on the surface of the flexible sensor, with the reinforcing units in the reinforcing layer corresponding to the sensor units in the flexible sensor layer. This increases the stiffness of the sensor units, ensuring that the sensor units are not stretched when the flexible sensor is attached to the surface of the adaptable object, thus guaranteeing the sensitivity and stability of the flexible sensor after attachment. Furthermore, the shape of the fabricated flexible sensor matches the surface contour of the adaptable object, eliminating the need for reshaping the flexible sensor when it is subsequently applied to the adaptable object, simplifying the usage process.

[0089] In the embodiments of this application, the location of the reinforcing layer on the surface of the flexible sensor can include two types: 1. The reinforcing layer is formed on the second surface of the flexible substrate layer, with the first surface corresponding to the second surface; 2. The reinforcing layer is formed on the sensor surface. The locations and preparation methods of these two types of reinforcing layers are described below.

[0090] Please refer to Figure 5 This illustration shows a schematic diagram of a flexible sensor provided in another exemplary embodiment of this application. In this flexible sensor, a reinforcing layer 13 is formed on the second surface of a flexible substrate layer 11, with the second surface opposite to the first surface. The flexible substrate layer 11 is located between the sensor layer 12 and the reinforcing layer 13. In this embodiment, the reinforcing unit 131 is located at the projection position of the sensor unit 121 on the second surface of the flexible substrate layer 11, and does not directly contact the sensor unit 121, thus avoiding any impact on the sensitivity of the sensor unit 121. This design is suitable for various types of flexible sensors.

[0091] In addition, the reinforcement unit 131 does not reinforce the flexible substrate 11, so the area outside the area corresponding to the sensor unit 121 on the second surface of the flexible substrate 11 does not contain the reinforcement unit.

[0092] Furthermore, the method for forming the reinforcing layer in the aforementioned flexible sensor is described.

[0093] Please refer to Figure 6 The illustration shows a flowchart of a method for forming a reinforcing layer in a flexible sensor according to an exemplary embodiment of this application. The method includes:

[0094] Step 310A: Attach the shielding member to the second surface of the flexible substrate. After attaching the shielding member, the exposed area of ​​the second surface corresponds to the position of the sensor unit.

[0095] In this embodiment, since the area outside the sensor unit region on the second surface of the flexible substrate does not contain reinforcement units, a shielding element needs to be covered on the second surface of the flexible substrate during the reinforcement layer fabrication process. The function of the shielding element is to prevent the reinforcement layer from forming on the surface of the flexible substrate, thus avoiding affecting the tensile deformation of the flexible substrate during the process of attaching it to the surface of the adapted object.

[0096] Regarding the position of the masking component, it covers the area outside the sensor unit's corresponding region on the second surface of the flexible substrate, exposing the area where the sensor unit is located. Therefore, the masking component needs to be cut out, with the cutout area corresponding to the number, size, and arrangement of the sensor units. Furthermore, to ensure the masking component completely covers the flexible sensor, its area is larger than the area of ​​the flexible sensor. One side of the masking component is adhesive, allowing it to be attached to the surface of the flexible substrate.

[0097] Optionally, the masking material can be masking tape, adhesive tape, etc., but this embodiment does not limit it.

[0098] For example, such as Figure 7 As shown, the masking element is masking tape, one side of which is adhesive. First, the masking tape 71 is cut with a laser, and the number, size, and position of the cut-out areas 72 correspond to the sensor units 74 of the flexible sensor 73. Then, the laser-cut masking tape 71 is pasted onto the second surface of the flexible substrate layer 75 of the flexible sensor 73 to obtain the covered flexible sensor.

[0099] Step 310B: Using screen printing or dispensing processes, the reinforcing material is covered over the exposed areas of the second surface.

[0100] In one possible implementation, a screen printing process is used to cover the exposed area of ​​the second surface of the flexible substrate with reinforcing material. Screen printing utilizes the principle that ink can pass through the mesh openings of the image portion of a screen printing plate, while ink cannot pass through the openings in the non-image portion. During printing, ink is poured into one end of the screen printing plate, and a squeegee applies pressure to the ink area while moving at a constant speed towards the other end. As it moves, the ink is squeezed from the mesh openings of the image portion onto the substrate. In this embodiment, the flexible substrate of the flexible sensor corresponds to the substrate, and the masking element corresponds to the image portion. The masking element has cutout areas corresponding to the number, size, and position of the sensor units. The masking element covers the second surface of the flexible substrate, and the reinforcing material is placed at one end of the masking element. A squeegee applies pressure to the reinforcing material while moving at a constant speed towards the other end of the flexible sensor. As it moves, the reinforcing material is squeezed from the exposed area of ​​the masking element onto the second surface of the flexible sensor, forming units of the same size and area corresponding to the sensor unit positions. In addition, the shielding also prevents the reinforcement layer from forming on the second surface of the flexible substrate, which affects the deformation that occurs during the attachment of the adapted object.

[0101] For example, Figure 8 A side view after the masking tape 71 has been applied to the flexible sensor. On the second surface of the flexible substrate 75, the area corresponding to the sensor unit 74 (i.e., the cutout area 72 of the masking tape 71) is exposed, while the area outside the area corresponding to the sensor unit 74 is covered by the masking tape 71. Further, UV-curable ink 81 is placed on the masking tape 71, and a squeegee 82 is used to press the UV-curable ink 81, slowly moving it from one side of the flexible sensor to the other, filling the cutout area 72 with reinforcing material.

[0102] In another possible implementation, a dispensing process is used to cover the reinforcing material onto the second surface of the flexible substrate. The dispensing process involves using a dispensing device to apply the reinforcing material to the exposed area of ​​the second surface. In this embodiment, the reinforcing material is placed in the dispensing device, which is then aligned with the exposed area of ​​the second surface, and the reinforcing material is applied manually or automatically to the exposed area of ​​the second surface.

[0103] For example, during the dispensing process, to prevent the reinforcing material from dripping onto the second surface of the flexible substrate, masking tape needs to be attached to the second surface of the flexible substrate. The method for attaching the masking tape is as described above and will not be repeated here. For example, Figure 9 Side view after applying masking tape 71 to the flexible sensor. The reinforcing material UV-curable ink 81 is loaded into the dispensing device 91, which is positioned over the cutout area 72 on the second surface of the flexible substrate. The reinforcing material is then dispensed into the cutout area 72. The area of ​​the dispensed reinforcing material is the same as the area of ​​the cutout area.

[0104] Step 310C: Separate the shielding element from the second surface and cure the reinforcing material to form a reinforcing unit.

[0105] After the reinforcement material is applied to the exposed area of ​​the second surface, it needs to be cured.

[0106] In one possible implementation, the material is cured by light irradiation. Optionally, the light irradiation can be ultraviolet light irradiation, ordinary light irradiation, etc., and this embodiment is not limited to this.

[0107] In another possible implementation, the material is cured by natural placement. Optionally, the natural placement time can be 1 hour, 2 hours, etc., and the natural placement time can be adjusted according to the characteristics of the material to be cured. This embodiment does not limit this.

[0108] It should be noted that this embodiment is only used to illustrate the curing method described above. In other possible implementations, developers may adjust the curing method according to the characteristics of different curing materials. This embodiment does not constitute a limitation in this regard.

[0109] For example, such as Figure 8 or Figure 9 The reinforcing material is cured by irradiation with ultraviolet light. After the reinforcing material is cured, the masking tape 71 is separated from the second surface of the flexible base layer 75 to obtain the final reinforcing unit 83.

[0110] Please refer to Figure 10 This illustration shows a schematic diagram of the structure of a flexible sensor provided in another exemplary embodiment of this application. In this flexible sensor, a reinforcing layer 13 is formed on the surface of a sensor layer 12, and the sensor layer 12 is formed on the surface of a flexible substrate layer 11, with the sensor layer 12 located between the reinforcing layer 13 and the flexible substrate layer 11. The reinforcing unit 131 in the reinforcing layer corresponds to the position of the sensor unit 121 in the sensor layer.

[0111] It should also be noted that, due to the operating characteristics of the sensor unit, the formation of a hardening unit on the surface of a specific type of sensor unit may affect its performance. For example, when a hardening unit is formed on the surface of a photosensitive sensor unit, it will affect the light reception intensity of the photosensitive sensor unit, thus affecting its performance; however, when a hardening unit is formed on the surface of a pressure sensor unit, it will not affect its performance. Therefore, when forming a hardening layer on the surface of a flexible sensor, the formation location of the hardening layer needs to be selected based on the operating characteristics of the sensor unit. For example, when the sensor unit is a photosensitive sensor unit, the hardening layer can only be formed on the second surface of the flexible substrate layer; when the sensor unit is a pressure sensor unit, the hardening layer can be formed on either the second surface of the flexible substrate layer or the surface of the sensor unit.

[0112] Furthermore, the method for forming the aforementioned flexible sensor reinforcement layer is described.

[0113] In this embodiment, a dispensing process is used to cover the surface of the sensor unit with reinforcing material, and then the reinforcing material is cured to form a reinforcing unit.

[0114] Figure 11 This is a schematic diagram illustrating an embodiment of forming a reinforcing layer using a dispensing process, as shown in another exemplary embodiment of this application.

[0115] Before the dispensing process, masking tape 71 is cut out according to the number, size, and position of the sensor units. The cut masking tape 71 is then placed over the first surface of the flexible substrate 75 to prevent the reinforcing material from dripping onto the first surface of the flexible substrate during the dispensing process. UV-curable ink 81 is loaded into the dispensing device 91, which positions the sensor units 74 and evenly dispenses the UV-curable ink 81 onto the surface of the sensor units 74. The area of ​​the ink dispensed is the same as the area of ​​the sensor unit. The reinforcing material is then cured by UV light. Finally, the masking tape 71 is separated from the first surface of the flexible substrate 75 to obtain the final reinforced unit 83.

[0116] Additionally, it should be noted that the reinforcing materials for the aforementioned reinforcement units can also be adhesive tape, masking tape, etc. However, when adhesive tape or masking tape is used as a reinforcing material, it must not deform at temperatures exceeding 300℃. The process for preparing the reinforcing layer using materials such as adhesive tape and masking tape differs from the process for preparing the reinforcing layer using UV-cured ink, which will be described below.

[0117] For example, such as Figure 12 As shown, sensor unit 1201 is formed on the first surface of flexible substrate 1202. When a reinforcing layer needs to be formed on the second surface of flexible substrate 1202, masking tape 1203 is attached to the second surface of flexible substrate 1202. Then, according to the number, size, and position of sensor units 1201 in the flexible sensor, the area where the reinforcing unit 1204 is located is etched onto the masking tape 1203. After etching, the masking tape 1203 is separated from the surface of flexible substrate 1202. On the second surface of flexible substrate 1202, only the area where the reinforcing unit 1204 is located has masking tape attached. This method of forming reinforcing material on the surface of flexible sensor is simple in processing and simplifies the fabrication process of flexible sensor.

[0118] In summary, in this embodiment, by forming a reinforcing layer on the surface of the flexible sensor, the reinforcing units in the reinforcing layer correspond to the positions of the sensor units in the flexible sensor layer. This increases the stiffness of the sensor units by means of the reinforcing units, ensuring that the sensor units are not stretched when the flexible sensor is attached to the surface of the adaptable object, thus ensuring the sensitivity and stability of the flexible sensor after attachment.

[0119] In this application, the flexible sensor prepared by the aforementioned method is suitable for the surface of objects with a surface curvature greater than the curvature threshold.

[0120] Optionally, the curvature threshold can be 0.5, 1, 3, etc., and this application embodiment does not limit it.

[0121] Optionally, the shape of the object's surface can be cylindrical, saddle-shaped, etc., and this application embodiment does not limit this.

[0122] Optionally, the applicable object surface can be the simulated finger surface of an intelligent robot, the concave-convex torso surface of an intelligent robot, etc., and this application embodiment does not limit this.

[0123] For example, please refer to Figure 13 The illustration shows a schematic diagram of a flexible sensor provided in an exemplary embodiment of this application attached to the surface of a simulated finger of an intelligent robot.

[0124] In this embodiment, after preparing a flexible sensor 1301 that matches the surface contour of the simulated finger in the robotic arm 1302 using the aforementioned preparation method, the flexible sensor 1301 is attached to the surface of the simulated finger. When the robotic arm 1302 grasps an object, the sensor unit of the flexible sensor 1301 senses the pressure change, converts the pressure change signal into an electrical signal, and transmits it to the control end of the robotic arm 1302. After receiving the electrical signal, the control end controls the simulated finger to close according to the pressure value represented by the electrical signal, thereby increasing the gripping force and completing the object grasping.

[0125] It should be noted that this embodiment is only used to illustrate the application of the flexible sensor to the outer surface of the simulated finger of an intelligent robot. In other possible implementations, developers may also attach the flexible sensor to the surface of different adaptable objects, and this embodiment does not constitute a limitation.

[0126] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the embodiments disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. The specification and embodiments are to be considered exemplary only, and the true scope and spirit of this application are indicated by the following claims.

[0127] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A flexible sensor, characterized in that, The flexible sensor includes: Flexible substrate layer, sensor layer, and reinforcement layer; The sensor layer is formed on the first surface of the flexible substrate layer, and the sensor layer is composed of sensor units; The reinforcing layer is composed of reinforcing units, and the reinforcing units correspond to the positions of the sensor units. The reinforcing units are made of flexible materials, and their stiffness is greater than that of the flexible substrate layer after heating. The reinforcing units are used to increase the stiffness of the sensor units, and the areas outside the corresponding areas of the sensor units do not contain the reinforcing units. The flexible substrate layer is made of flexible thermoplastic materials, including at least one of thermoplastic polyurethane elastic rubber (TPU), polyethylene terephthalate (PET), polyvinyl chloride (PVC), and polypropylene (PP). The reinforcing layer is made of at least one of ultraviolet-curable ink, adhesive tape, and masking tape. The shape of the flexible sensor matches the surface contour of the object to which it is adapted. The shape of the flexible sensor is formed by heating and attaching it to the surface of the adaptable object, followed by cooling and shaping. The process of attaching the flexible sensor to the surface of the adaptable object involves vacuum suction forming to remove air between the two.

2. The flexible sensor according to claim 1, characterized in that, The reinforcing layer is formed on the second surface of the flexible substrate layer, the second surface being opposite to the first surface, and the flexible substrate layer being located between the sensor layer and the reinforcing layer.

3. The flexible sensor according to claim 2, characterized in that, On the second surface of the flexible substrate layer.

4. The flexible sensor according to claim 1, characterized in that, The reinforcement layer is formed on the surface of the sensor layer.

5. The flexible sensor according to claim 4, characterized in that, On the first surface of the flexible substrate layer.

6. The flexible sensor according to any one of claims 1 to 5, characterized in that, The processing technology of the reinforcement unit includes at least one of screen printing and dispensing.

7. The flexible sensor according to any one of claims 1 to 5, characterized in that, The sensor unit is a flexible sensor unit.

8. An intelligent robot, characterized in that, The intelligent robot has a flexible sensor attached to its torso, which has a surface curvature greater than a curvature threshold, as described in any one of claims 1 to 7.

9. A method for fabricating a flexible sensor, characterized in that, The method includes: A reinforcement layer is formed on the surface of a flexible sensor. Reinforcement units in the reinforcement layer correspond to the sensor units in the sensor layer. The sensor layer is formed on the first surface of a flexible substrate. The reinforcement units are made of a flexible material. After heating, the stiffness of the reinforcement units is greater than the stiffness of the flexible substrate after heating. The reinforcement units are used to increase the stiffness of the sensor units. Areas outside the corresponding region of the sensor units do not contain the reinforcement units. The flexible substrate is made of a flexible thermoplastic material, including at least one of thermoplastic polyurethane elastic rubber (TPU), polyethylene terephthalate (PET), polyvinyl chloride (PVC), and polypropylene (PP). The reinforcement layer is made of at least one of ultraviolet-curable ink, adhesive tape, and masking tape. The heated flexible sensor is attached to the surface of the adaptable object; A vacuum is drawn between the flexible sensor and the surface of the object; The flexible sensor is cooled and shaped.

10. The method according to claim 9, characterized in that, The process of forming a reinforcing layer on the surface of the flexible sensor includes: The reinforcing layer is formed on a second surface of the flexible substrate layer, the second surface being opposite to the first surface, and the flexible substrate layer being located between the sensor layer and the reinforcing layer.

11. The method according to claim 10, characterized in that, The formation of the reinforcing layer on the second surface of the flexible substrate includes: The shielding element is attached to the second surface. After the shielding element is attached, the exposed area of ​​the second surface corresponds to the position of the sensor unit. The reinforcing material is applied to the exposed area of ​​the second surface using screen printing or dispensing techniques. The shielding element is separated from the second surface, and the reinforcing material is cured to form the reinforcing unit.

12. The method according to claim 9, characterized in that, The process of forming a reinforcing layer on the surface of the flexible sensor includes: A dispensing process is used to cover the surface of the sensor unit with reinforcing material; The reinforcing material is cured to form the reinforcing unit.

13. The method according to any one of claims 9 to 12, characterized in that, Before attaching the heated flexible sensor to the surface of the adaptable object, the method further includes: Align the first positioning mark on the flexible sensor with the second positioning mark on the surface of the object.

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