A biomimetic robot facial composite layer, a composite layer molding method, and a biomimetic head device.

Abstract

This invention discloses a bionic robot facial composite layer, a composite layer molding method, and a bionic head device. It includes a bionic robot head skeleton with skeletal gap spaces and several mechanical transmission mechanisms. A three-dimensional grid layer is embedded within the skeletal gap spaces; a transmission base layer is attached to the three-dimensional grid layer; a dermal layer is attached to the transmission base layer; and sensing components and a conductive film layer are provided on the transmission base layer and / or the dermal layer. This invention employs a layered composite structure and triple-fusion drive, enabling large-stroke movements and subtle facial changes, solving the problem of stiff expressions and significantly improving realism. The three-dimensional grid layer provides elastic support and buffered heat dissipation, reducing driving impact and dermal layer wear, extending service life, and improving operational stability. Integrated sensing and conductive structures enable facial tactile perception and closed-loop control, resulting in more delicate and intelligent interaction. The dermal layer is removable and replaceable, facilitating makeup maintenance and rapid face changes. The technology is mature and easy to mass-produce, offering strong practicality and scalability.

Description

Technical Field

[0001] This invention relates to a bionic robot facial composite layer, a composite layer molding method, and a bionic head device, belonging to the technical field of bionic robots. Background Technology

[0002] Humanoid bionic robots are the core development direction of service robots and intelligent interactive devices. The bionic structure of the face directly determines the realism and human-likeness of the robot's interaction.

[0003] The facial structures of existing bionic robots generally suffer from the following technical defects: Structural aspects: Most of them use a single layer of hard leather to directly cover the metal / plastic transmission frame. There is no buffer filling structure between the frame and the leather, resulting in large mechanical transmission impacts. The leather is prone to wrinkling and cracking and cannot conform to the flexible mechanical properties of human skin. The real-life simulated leather is mostly fixed and bonded, which cannot be disassembled and replaced, and the maintenance cost is extremely high, making it unsuitable for long-term use scenarios.

[0004] In terms of functional integration: Traditional dermal structures only have appearance simulation functions. Sensors, conductive components and dermal structures are separated from each other, which makes it impossible to achieve the coordinated cooperation of force / torque transmission, electrical signal conduction and skin deformation. It also lacks the integrated ability of tactile perception and facial expression feedback.

[0005] In terms of transmission mode: it only uses a single mechanical servo drive, which is rigid and can only achieve large-stroke joint movement. It cannot simulate the subtle micro-movements and flexible expansion of human facial muscles, resulting in stiff expressions and extremely low realism.

[0006] In terms of process technology: the skin is mostly processed by simple cutting and bonding, without integrated molding, foaming and conductive paste printing processes. The built-in components cannot be flexibly integrated with the skin, which can easily lead to problems such as open circuits, detachment and deformation failure, making it difficult to meet the long-term stable operation requirements of bionic robots.

[0007] To address the aforementioned pain points, this invention proposes a technical solution featuring a multi-layer composite skin structure, multi-mode coupling transmission, and integrated molding, filling a gap in existing technologies. Summary of the Invention

[0008] The purpose of this invention is to address the shortcomings of the prior art and, in response to problems such as stiffness in traditional simulated facial expressions, to propose a bionic robot facial composite layer, a composite layer molding method, and a bionic head device.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A bionic robot facial composite layer includes a bionic robot head skeleton, wherein the bionic robot head skeleton has skeleton gap spaces and several mechanical transmission mechanisms, including: A three-dimensional grid layer includes a plurality of three-dimensional grid bodies for embedding within the gap space of the skeleton; The base layer is transferred and attached to the three-dimensional grid layer; The dermal layer is detachably attached to the transfer base layer; The base layer and / or the dermis layer are provided with a sensing component and a conductive film layer. The sensing component includes at least one of a force sensor, a torque sensor, and a strain sensor. The sensing component is electrically connected to the conductive film layer.

[0010] Preferably, it includes a fusion drive system, which includes at least a pneumatic drive mechanism and an EMS electrical stimulation drive mechanism; The air passage of the pneumatic transmission mechanism is embedded in the three-dimensional grid layer and the transmission base layer, and the local flexible deformation of the dermis layer is formed by air pressure drive. The electrode pads of the EMS electrical stimulation transmission mechanism are integrated on the transmission base layer. The dermis is a dielectric flexible body with a force-electric coupling effect. The electrode pads are conductively bonded to the dielectric flexible body through a conductive film layer. The dermis is driven to produce local micro-motion deformation through electrical stimulation.

[0011] Preferably, the honeycomb lattice of the three-dimensional grid is a regular hexagonal, rhombic, or irregular flexible grid structure, with a lattice wall thickness of 0.1mm to 4mm, a porosity of 20% to 95%, and an overall compression resilience of ≥90%.

[0012] Preferably, the transfer base layer and the dermis layer are prepared by membrane pressing or foam molding processes, and the conductive film layer is formed on the layer by printing process.

[0013] Preferably, the dermis layer and the transfer base layer are detachably connected by one or more combinations of magnetic snap fasteners, flexible hook and loop fasteners, and positioning slots.

[0014] Preferably, the conductive film has a tensile deformation rate ≥40% and a film thickness of 1μm~200μm.

[0015] The present invention also proposes a composite layer molding method for molding the composite layer of the bionic robot's face, comprising the following steps: S1 three-dimensional grid layer forming, according to the facial mechanical distribution, the arrangement design is carried out in the skeletal gap space, and the three-dimensional grid body is embedded and fixed according to the arrangement design. S2 delivery layer and dermis preparation, preparation of delivery layer matrix and dermis matrix; The S3 sensing component is assembled with a conductive film layer, and the sensing component and conductive film layer are formed on the base substrate and / or dermal layer substrate to form the base substrate and dermal layer. The S4 composite assembly attaches and fixes the transfer base layer to the three-dimensional grid layer, while the dermal layer is assembled on the transfer base layer.

[0016] Preferably, in step S2, the transfer base substrate and the dermal layer substrate are respectively molded substrates.

[0017] Preferably, in step S3, the conductive film layer is formed by printing and curing conductive paste.

[0018] The present invention also proposes a bionic head device, including the bionic robot face composite layer.

[0019] The beneficial effects of this invention are mainly reflected in: 1. Through a layered design of three-dimensional grid layer, transmission base layer and dermal layer, combined with the triple drive of mechanical transmission, pneumatic transmission and EMS electrical stimulation, it can not only realize large-stroke facial expressions, but also complete subtle expressions such as skin micro-movement and local stretching, thus solving the problem of stiff and unrealistic facial expressions of traditional robots from the root.

[0020] 2. The three-dimensional grid fills the gaps in the skeleton, providing uniform elastic support, effectively buffering the impact of mechanical transmission, and reducing fatigue damage to the skin layer caused by rigid drive; at the same time, the grid structure has the characteristics of high resilience, high breathability, and good heat dissipation, which significantly improves the service life and operational stability of the composite layer.

[0021] 3. By integrating sensing components and conductive film layers into the dermal and subcutaneous layers, facial force and deformation signals can be collected in real time, enabling tactile perception and closed-loop control of facial expressions, thus giving the robot more delicate and intelligent external interaction capabilities.

[0022] 4. The dermal layer adopts a detachable structure such as magnetic, snap, and hook-and-loop fasteners, which can be used for makeup, coloring, and texture creation separately, enabling quick face changing to meet the needs of different appearances, scenes, and character images, reducing maintenance costs and expanding application scenarios.

[0023] 5. The three-dimensional grid layer, the base layer, and the dermis layer can all be prepared using mature processes such as molding, foaming, 3D printing, and conductive printing. The air path, circuit, and sensing points can be pre-set in one piece, simplifying the assembly process and making it suitable for mass production and industrial applications. Attached Figure Description

[0024] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is an exploded structural diagram of a composite layer for the face of a biomimetic robot according to the present invention. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described in the present application can be combined with each other.

[0027] This invention provides a biomimetic robot facial composite layer, such as... Figure 1 As shown, the robot includes a bionic head skeleton 1, which has a skeleton gap space 2 and several mechanical transmission mechanisms 3, including: The three-dimensional grid layer 4 includes a plurality of three-dimensional grid bodies 40 for embedding within the gap space of the skeleton.

[0028] The base layer 5 is transferred and attached to the three-dimensional grid layer.

[0029] The dermal layer 6 is detachably attached to the transfer base layer 5.

[0030] The base layer 5 and / or the dermis layer 6 are provided with a sensing component 7 and a conductive film layer 8. The sensing component includes at least one of a force sensor, a torque sensor, and a strain sensor. The sensing component is electrically connected to the conductive film layer.

[0031] Detailed implementation process and principle explanation: Reference Figure 1 As shown, the present invention adopts a multi-level composite flexible support structure: First, a three-dimensional grid body 40 is embedded in the gap space 2 of the skeleton. By utilizing the porous elastic structure of the grid itself, four functions are achieved: elastic support, buffering and shock absorption, uniform force transmission, heat dissipation and ventilation.

[0032] After the three-dimensional grid 40 is filled, a continuous, smooth support surface with a certain rigidity and resilience is formed on the outside of the skeleton, providing a stable and reliable adhesion base for the transfer base layer 5. The two can be bonded and fixed by environmentally friendly silicone, hot melt adhesive, flexible double-sided tape, etc.

[0033] The base layer 5 serves as an intermediate force and electricity transmission medium, receiving the drive signal from the mechanical transmission mechanism 3 and uniformly transmitting the driving force to the dermal layer 6. On the other hand, it serves as a carrier for the sensing components 7 and the conductive film layer 8, realizing the acquisition of force, torque, and strain signals and the conduction of electrical signals, so that the facial composite layer has the ability to perform drive execution, perception feedback, and circuit interconnection.

[0034] The dermal layer 6 is detachably attached to the outside of the transfer base layer 5, serving as the appearance layer of the bionic robot. It can simulate the texture, pattern, and skin tone of human skin and can be post-processed such as makeup, spraying, and texture transfer. The detachable structural design allows for rapid replacement of the dermal layer, meeting the needs of different character images, different scene displays, and repair and replacement.

[0035] The sensing components 7 integrated in the base layer 5 and the dermis layer 6 work together with the conductive film layer 8 to form a flexible facial sensing network: when the robot's face is touched, pressed, or stroked by the outside world, the sensing components can collect pressure, deformation, and torque information in real time and transmit it to the control system through the conductive film layer; when the robot makes an expression, the sensing components can monitor the deformation state of the skin layer in real time, forming a closed-loop feedback, making the facial expressions more delicate and closer to human micro-expressions.

[0036] In one specific embodiment, a fusion drive system 9 is included, which includes at least a pneumatic drive mechanism 91 and an EMS electrical stimulation drive mechanism 92.

[0037] The air passage of the pneumatic transmission mechanism 91 is embedded in the three-dimensional grid layer and the transmission base layer, and the local flexible deformation of the dermis layer is formed by air pressure drive. The electrode pads of the EMS electrical stimulation transmission mechanism are integrated on the transmission base layer 5. The dermis is a dielectric flexible body with a force-electric coupling effect. The electrode pads are conductively bonded to the dielectric flexible body through a conductive film layer. The dermis is driven to produce local micro-motion deformation through electrical stimulation.

[0038] Specifically, the air passage of the pneumatic transmission mechanism 91 is embedded inside the three-dimensional grid layer 4 and the transmission base layer 5. The air passage is prepared by methods such as micro-tube pre-embedding, in-mold molding, laser drilling, and 3D printing of flow channels. The air passage is distributed along the direction of facial muscles, corresponding to key expression areas such as cheeks, corners of the mouth, nostrils, and eyelids.

[0039] During operation, the air pressure changes in the air passage are controlled by an external air pump or a miniature valve island, causing the corresponding dermal layer to undergo flexible deformations such as swelling, contraction, lifting, and relaxation, thus enabling delicate movements such as smiling, pursing lips, puffing out cheeks, and subtle breathing movements.

[0040] Pneumatic drive has advantages such as good flexibility, low impact, low noise, and multi-point independent control, making it particularly suitable for large-area, low-intensity facial expressions.

[0041] The electrode pads of the EMS electrical stimulation transmission mechanism 92 are integrated on the transmission base layer 5. The electrode pads are fixed by printing, embedding, bonding and other methods, and are reliably connected to the conductive film layer 8.

[0042] The dermis layer 6 uses a dielectric flexible material with electromechanical coupling effect, such as dielectric elastomer, flexible ion gel, conductive silicone composite material, etc., which can produce controllable micro-deformation under the action of an electric field.

[0043] The electrode sheet is closely attached to the dielectric flexible body through the conductive film layer 8. When a pulsed electrical signal is applied, the dielectric flexible body will locally contract or stretch, driving the dermis to produce micro-level micro-movements, such as slight trembling of the eyelids, slight raising of the corners of the mouth, slight tightening and loosening of the facial skin, which greatly improves the realism of the expression.

[0044] The traditional mechanical transmission mechanism 3 is mainly responsible for large-stroke, high-rigidity motion output, such as turning the head, opening the mouth, and blinking sharply; the pneumatic transmission mechanism 91 is responsible for large-area, flexible, and expressive facial expressions; and the EMS electrical stimulation transmission mechanism 92 is responsible for micro-deformation, high-frequency, and high-precision skin micro-movements. The three work together to achieve full-dimensional simulation from macroscopic movements to microscopic expressions, solving the problems of stiff expressions and lack of detail caused by single mechanical drives.

[0045] In one specific embodiment, the honeycomb lattice of the three-dimensional grid is a regular hexagonal, rhombic, or irregular flexible grid structure with a lattice wall thickness of 0.1mm to 4mm, a porosity of 20% to 95%, and an overall compression resilience of ≥90%. It can quickly recover its shape after repeated compression and deformation, avoiding collapse after long-term use.

[0046] In one specific embodiment, the three-dimensional grid is made of TPU, TPE, flexible silicone or foamed polypropylene material, and is formed into a regular hexagonal honeycomb structure through processes such as injection molding foam, 3D printing, and compression molding foam.

[0047] For example, TPU material with a wall thickness of 0.8mm and a porosity of 75% can be used. It is bonded to the hollow part of the transmission frame with environmentally friendly silicone. With a compression rebound rate of 92%, it can effectively buffer the impact of mechanical transmission, convert rigid rotation into flexible thrust, and reduce skin wear and abnormal noise.

[0048] In one specific embodiment, the base layer and the dermis layer are prepared by membrane pressing or foam molding processes, respectively, and a conductive film layer is formed on the layer by printing process.

[0049] During the molding process, the following can be pre-set: sensor component embedding groove, conductive film wiring groove, electrode plate mounting position, air passage pre-embedded cavity, positioning buckle or magnetic mounting position, to achieve integrated molding of structure, circuit, air passage and sensing, which greatly improves assembly accuracy and structural stability.

[0050] In one specific embodiment, the dermis layer and the transfer base layer are detachably connected by one or more combinations of magnetic snap fasteners, flexible hook and loop fasteners, and positioning slots.

[0051] The dermal layer and the transfer base layer are detachably connected using one or more combinations of magnetic snaps, flexible hooks and loops, positioning slots, and edge-sealing snaps. The connection points are discreetly located in non-exposed areas such as the hairline, behind the ears, and jawline, without affecting the appearance. The dermal layer can be used independently for facial makeup, texture creation, coloring, and hair implantation. By quickly replacing the dermal layer, the robot can perform multiple functions such as face replacement, clothing change, makeup change, and age / gender change, reducing maintenance and customization costs.

[0052] In one specific embodiment, the tensile deformation rate of the conductive film is ≥40%, and the film thickness is 1μm~200μm.

[0053] Materials such as silver nanoparticle conductive adhesive, carbon nanotube conductive paste, and liquid metal flexible conductive ink can be selected. The conductive film layer deforms with the skin's stretching, bending, and twisting, yet still maintains stable conductivity, exhibiting excellent fatigue resistance, temperature resistance, and aging resistance, meeting the needs of long-term, high-frequency facial expressions.

[0054] This invention also proposes a composite layer molding method for molding the composite layer of the bionic robot's face, comprising the following steps: The first step is to form a three-dimensional grid layer, design the arrangement of the grid within the skeletal gaps based on the facial biomechanical distribution, and then embed and fix the three-dimensional grid body according to the arrangement design.

[0055] Based on the anatomical structure and mechanical distribution of the face, topology optimization is performed on the skeletal gap space to determine the arrangement density, aperture type, wall thickness and position of the three-dimensional grid.

[0056] A bionic head skeleton model is obtained through 3D scanning, and a three-dimensional grid structure that matches the gap space of the skeleton is precisely designed and manufactured. The three-dimensional grid structure is embedded and fixed in the gap space to form a continuous, elastic, and breathable intermediate support layer.

[0057] Next is the preparation of the delivery base layer and the dermis layer, specifically the preparation of the delivery base layer matrix and the dermis layer matrix.

[0058] Based on the biomimetic facial shape, a curved structure was designed to connect the basal layer and the dermis.

[0059] The transfer base layer and dermal layer are prepared by means of membrane pressing, foaming, casting or 3D printing, respectively, to ensure that the surface texture is delicate, the thickness is uniform and the flexibility is moderate.

[0060] Next, the sensing components and conductive film layers are assembled. The sensing components and conductive film layers are formed on the base layer substrate and / or dermal layer substrate to form the base layer and dermal layer.

[0061] On the base substrate and / or dermal layer substrate: a conductive film layer is printed / deposited; the sensing components and electrode sheets are bonded, welded, or pressed together; air passages are pre-embedded or air interfaces are reserved. This enables the single-layer substrate to simultaneously possess structural support, force transmission, sensing, conductivity, and pneumatic drive functions.

[0062] Finally, the composite assembly involves attaching and fixing the transfer base layer onto the three-dimensional grid layer, while the dermal layer is assembled onto the transfer base layer.

[0063] The transfer base layer is bonded / fixed to the outside of the three-dimensional grid layer, ensuring a smooth, flat fit without voids or wrinkles. The genuine leather layer is then assembled onto the transfer base layer using magnetic, snap-fit, or hook-and-loop fasteners, enabling rapid positioning and detachable connection. This ultimately forms a biomimetic robot face composite layer that integrates support, cushioning, actuation, sensing, conductivity, breathability, and replaceability.

[0064] A bionic head device comprising a bionic robotic face composite layer.

[0065] This bionic head device can be widely used in: service robot reception and guidance; health and wellness companion robots and emotional companion robots; film and television props, bionic dolls, and intelligent humanoid displays; medical rehabilitation facial expression training models; human-computer interaction experiments and AI emotional interaction research. All bionic head devices that employ the multi-layered composite flexible facial structure, multi-mode fusion drive, and detachable epidermis of this invention fall within the protection scope of this invention.

[0066] As described above, the layered design of the three-dimensional grid layer, the transmission base layer, and the dermis layer, combined with the triple-drive system of mechanical transmission, pneumatic transmission, and EMS electrical stimulation, enables both large-stroke facial expressions and subtle expressions such as skin micro-movements and localized stretching. This fundamentally solves the problem of stiff and unnatural facial expressions in traditional robots. The three-dimensional grid fills the gaps in the skeleton, providing uniform elastic support and effectively buffering the impact of mechanical transmission, reducing fatigue damage to the dermis caused by rigid drives. Simultaneously, the grid structure features high resilience, high breathability, and good heat dissipation, significantly improving the lifespan and operational stability of the composite layer. Integrating sensing components and conductive film layers in the transmission base layer and dermis layer allows for real-time acquisition of facial force and deformation signals, enabling tactile perception and closed-loop control of facial expressions, giving the robot more delicate and intelligent external interaction capabilities. The dermis layer uses detachable structures such as magnetic, snap-on, and Velcro, allowing for separate makeup, coloring, and texture creation, enabling rapid face changing to meet different appearance, scene, and character image needs, reducing maintenance costs and expanding application scenarios. The three-dimensional grid layer, the base layer, and the dermis layer can all be prepared using mature processes such as molding, foaming, 3D printing, and conductive printing. The air path, circuit, and sensing points can be pre-set in one piece, simplifying the assembly process and making it suitable for mass production and industrial applications.

[0067] The term "comprising" or any other similar term is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus / device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent in such process, method, article, or apparatus / device.

[0068] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A bionic robot facial composite layer, comprising a bionic robot head skeleton, wherein the bionic robot head skeleton has skeleton gap spaces and several mechanical transmission mechanisms, characterized in that... include: A three-dimensional grid layer includes a plurality of three-dimensional grid bodies for embedding within the gap space of the skeleton; The base layer is transferred and attached to the three-dimensional grid layer; The dermal layer is detachably attached to the transfer base layer; The base layer and / or the dermis layer are provided with a sensing component and a conductive film layer. The sensing component includes at least one of a force sensor, a torque sensor, and a strain sensor. The sensing component is electrically connected to the conductive film layer.

2. The bionic robot facial composite layer according to claim 1, characterized in that: The system includes a fusion drive system, which includes at least a pneumatic drive mechanism and an EMS electrical stimulation drive mechanism. The air passage of the pneumatic transmission mechanism is embedded in the three-dimensional grid layer and the transmission base layer, and the local flexible deformation of the dermis layer is formed by air pressure drive. The electrode pads of the EMS electrical stimulation transmission mechanism are integrated on the transmission base layer. The dermis is a dielectric flexible body with a force-electric coupling effect. The electrode pads are conductively bonded to the dielectric flexible body through a conductive film layer. The dermis is driven to produce local micro-motion deformation through electrical stimulation.

3. The bionic robot facial composite layer according to claim 1, characterized in that: The honeycomb lattice of the three-dimensional grid is a regular hexagonal, rhomboid or irregular flexible grid structure with a lattice wall thickness of 0.1mm to 4mm, a porosity of 20% to 95%, and an overall compression resilience of ≥90%.

4. The bionic robot facial composite layer according to claim 1, characterized in that: The conductive base layer and the dermis layer are prepared by membrane pressing or foam molding processes, respectively, and the conductive film layer is formed on the layer by printing process.

5. The bionic robot facial composite layer according to claim 1, characterized in that: The dermis layer and the transfer base layer are detachably connected by one or more combinations of magnetic snap fasteners, flexible hook and loop fasteners, and positioning slots.

6. The bionic robot facial composite layer according to claim 1, characterized in that: The conductive film has a tensile deformation rate of ≥40% and a film thickness of 1μm~200μm.

7. A composite layer molding method for molding the bionic robot facial composite layer according to any one of claims 1 to 6, characterized in that... Includes the following steps: S1 three-dimensional grid layer forming, according to the facial mechanical distribution, the arrangement design is carried out in the skeletal gap space, and the three-dimensional grid body is embedded and fixed according to the arrangement design. S2 delivery layer and dermis preparation, preparation of delivery layer matrix and dermis matrix; The S3 sensing component is assembled with a conductive film layer, and the sensing component and conductive film layer are formed on the base substrate and / or dermal layer substrate to form the base substrate and dermal layer. The S4 composite assembly attaches and fixes the transfer base layer to the three-dimensional grid layer, while the dermal layer is assembled on the transfer base layer.

8. The composite layer forming method according to claim 7, characterized in that: In step S2, the transfer base substrate and the dermal layer substrate are respectively molded substrates.

9. The composite layer forming method according to claim 7, characterized in that: In step S3, the conductive film layer is formed by printing and curing conductive paste.

10. A bionic head device, characterized in that: Includes the bionic robot face composite layer described in any one of claims 1 to 5.

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