Flexible electrode circuit board and method of manufacturing the same

Abstract

The application relates to the technical field of circuit boards, in particular to a flexible electrode circuit board and a preparation method thereof, which comprises an encoder PCB, a driving PCB, a heat insulation medium layer and a rotor code disc; in the application, a power management module provides stable power supply for an MCU, the encoder PCB2 and a driving module when the product is working; the rotor rotates; a magnetic field detection unit on the encoder PCB2 detects the magnetic field change in real time, and angle calculation is completed through an ASIC; position information is fed back to the MCU; the MCU carries out control algorithm calculation according to the encoder feedback signal, and outputs a control signal to a power driving module, so that motor closed-loop control is realized; in the working process of the driving PCB4, heat is generated by MOSFET and other power devices; since the 0.1mm polyimide heat insulation medium layer is arranged between the driving PCB4 and the encoder PCB2, the heat resistance can be effectively increased, and the heat conduction to the encoder PCB2 is slowed down.

Description

Technical Field

[0001] This invention relates to the field of circuit board technology, specifically to a flexible electrode circuit board and its fabrication method. Background Technology

[0002] With the development of humanoid robots, collaborative robots, medical robots, and high-performance servo systems, actuators and encoders are gradually moving towards high integration, lightweighting, and ultra-thinning.

[0003] Existing integrated drive and encoder products typically achieve integration by simply stacking the drive PCB and encoder PCB. However, due to limited axial space, the drive circuit and the encoder detection area are very close, resulting in the detection circuit, control circuit and power circuit being arranged in an interleaved manner, and the heat source, current loop and magnetic field detection area affecting each other. Summary of the Invention

[0004] To address the aforementioned issues, this invention provides an integrated encoder structure that maintains an ultra-thin structure while achieving a reasonable layout of the drive circuit and encoder detection area, reducing thermal impact, and improving long-term stability.

[0005] To address the problems in the prior art, this invention provides a flexible electrode circuit board and its fabrication method, comprising an encoder PCB, a drive PCB, a thermal insulation dielectric layer, and a rotor code disk. The encoder PCB and drive PCB are coaxially stacked and connected by conductive posts. The encoder PC2B adopts a layout that separates the detection area from the device area, with electronic devices concentrated in the outer annular area and the detection area remaining device-free. A low thermal conductivity insulating dielectric layer with a thickness of approximately 0.1 mm is provided between the encoder PCB and the drive PCB and fixed by adhesive bonding.

[0006] Specifically, the heat insulation medium layer is made of polyimide, PPS, LCP or PET insulating film.

[0007] Specifically, the heat insulation medium layer is bonded with high-temperature resistant insulating structural adhesive.

[0008] Specifically, the power driving devices on the driving PCB are concentrated in the same area.

[0009] Specifically, the encoder PCB detection area is set around the center of the output shaft and is kept at a distance from the concentrated area of ​​the devices.

[0010] Specifically, the rotor encoder is equipped with a dust removal structure, which consists of an air collecting duct, a fixed shell, an air vent, an mounting cylinder, a fan, an air outlet box, and a sieve plate. The air collecting duct is installed at the lower end of the rotor encoder.

[0011] Specifically, multiple sets of air outlet boxes are fixedly installed on the air collecting duct, a sieve plate is provided on one side of the air outlet box, a set of fixed shells are fixedly installed at the lower end of the air collecting duct, multiple sets of air vents are opened on the side wall of the fixed shells, a set of mounting cylinders are fixedly installed inside the fixed shells, and a set of fans are provided inside the mounting cylinders.

[0012] Specifically, the lower end of the dust removal structure is provided with a set of connecting structures. The connecting structures include a protective cover, a connecting plate, a limiting post, an arc-shaped block, an extrusion block, an electric push rod, and a fixing block. The protective cover is fixedly installed at the lower end of the fixed shell. A set of connecting plates is fixedly installed on the inner wall of the protective cover. The connecting plates are annular and have multiple sets of limiting grooves on their inner walls. The limiting grooves on the inner wall of the connecting plates and the limiting post are slidably connected.

[0013] Specifically, the limiting post consists of a steel shaft and a rubber sleeve, with the rubber sleeve fitted onto the outer wall of the steel shaft.

[0014] Specifically, one end of the limiting post is fixedly connected to the outer wall of the arc-shaped block, the upper end of the arc-shaped block is hinged to the protective cover, the multiple sets of arc-shaped blocks are initially conical, the upper end of the extrusion block is conical, the electric push rod is fixedly installed on the upper end of the fixed block, and the fixed block is fixedly installed on the output shaft of the motor.

[0015] The beneficial effects of this invention are: 1. In this invention, a stacked structure of drive PCB and encoder PCB is adopted, which significantly reduces the overall axial dimension while ensuring functional integrity, making it suitable for ultra-thin robot joints and dexterous hand products.

[0016] 2. In this invention, the encoder PCB adopts a functional partition layout, with electronic components concentrated in a local annular area and the detection area maintaining a component-free layout, which makes the magnetic field detection area more uniformly heated and improves measurement stability.

[0017] 3. In this invention, a PI thermal insulation medium layer with a thickness of about 0.1mm is used and fixed by adhesive bonding. This ensures that the overall thickness is extremely small and effectively reduces the heat transfer from the drive PCB to the encoder PCB. The overall structure is simple, with few parts, and easy to assemble, making it suitable for mass production.

[0018] 4. In this invention, the heat source of the drive module is centrally arranged on the opposite side of the driver PCB, which facilitates overall thermal management, improves the long-term reliability of the product, and adopts an integrated upper and lower PCB scheme, which can reduce the number of connecting wires and improve vibration resistance and system reliability.

[0019] 5. In this invention, the airflow generated after the fan starts will be blown out through the air box into the gap on the rotor code disk, avoiding the accumulation of too much dust in the gap, extending the overall service life of the rotor code disk, reducing the number of cleaning times, and reducing the burden on the staff.

[0020] 6. In this invention, after the extrusion block enters the multiple sets of arc-shaped blocks, the arc-shaped blocks will expand, thereby sliding the limiting post into the limiting groove in the connecting plate, so that the rotor code disk as a whole is connected to the output shaft of the motor. Compared with the traditional threaded connection, it can avoid the gap at the threaded connection caused by vibration, which would affect the normal operation of the equipment. Attached Figure Description

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0022] Figure 1 This is a schematic diagram of the overall connection structure of the present invention; Figure 2 This is a schematic diagram of the connection structure of components such as the rotor code disk, encoder PCB, and drive PCB in this invention; Figure 3 In this invention Figure 1 A sectional view; Figure 4 In this invention Figure 2 The front view; Figure 5 This is a schematic diagram of the heat conduction path in this invention; Figure 6 This is a block diagram illustrating the working principle of the present invention; Figure 7 In this invention Figure 3 Enlarged view of point A.

[0023] In the diagram: 1. Rotor code disk; 2. Encoder PCB; 3. Heat insulation medium layer; 4. Drive PCB; 5. Dust removal structure; 510. Air collection duct; 511. Fixing shell; 512. Air vent; 513. Mounting cylinder; 514. Fan; 515. Air outlet box; 516. Screen plate; 6. Connecting structure; 610. Protective cover; 611. Connecting plate; 612. Limiting post; 613. Arc block; 614. Extrusion block; 615. Electric actuator; 616. Fixing plate. Detailed Implementation

[0024] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] Example 1: like Figures 1-7 As shown, a flexible electrode circuit board includes an encoder PCB2, a drive PCB4, a thermal insulation layer 3, and a rotor code disk 1. The encoder PCB2 and drive PCB4 are coaxially stacked and connected by conductive posts. The encoder PCB2 adopts a layout where the detection area and the device area are separated. The electronic devices are concentrated in the outer annular area, while the detection area remains free of devices. A low thermal conductivity insulating thermal insulation layer with a thickness of about 0.1 mm is provided between the encoder PCB2 and the drive PCB4 and is fixed by adhesive. The thermal insulation layer 3 is made of polyimide, PPS, LCP, or PET insulating film and is bonded with high-temperature resistant insulating structural adhesive. The power drive devices on the drive PCB4 are concentrated in the same area. The detection area of ​​the encoder PCB2 is set around the center of the output shaft and is kept separate from the concentrated device area.

[0026] In this embodiment, both encoder PCB2 and drive PCB4 use FR-4 circuit boards with an overall ring structure. The encoder PCB2 has a magnetic field detection area in the center. The ASIC, communication interface, power filter, and peripheral components are concentrated in the ring area outside the PCB coil. The encoder PCB2 and drive PCB4 have pre-reserved pads for mounting holes for conductive posts at corresponding positions. The drive PCB2 is located below the encoder PCB4. The conductive posts ensure that the two PCBs are positioned, coaxially mounted, and connected. A 0.1mm polyimide insulating film is bonded between the encoder PCB2 and drive PCB4 as a heat insulation medium and fixed with high-temperature epoxy glue. The rotor code disk 1 maintains the designed air gap with the encoder PCB2. The rotor code disk 1 rotates to achieve absolute position detection. This invention does not rely on a metal shielding shell, but achieves thermal impact control through the functional partitioning of the encoder PCB2 and the ultra-thin heat insulation medium, meeting the requirements of high precision and high reliability for ultra-thin integrated drive and encoder products. When the product is working, the power management module provides stable power to the MCU, encoder PCB2, and drive module. As the rotor rotates, the magnetic field detection unit on encoder PCB2 detects changes in the magnetic field in real time and performs angle calculations through ASIC, feeding the position information back to the MCU. The MCU calculates the control algorithm based on the encoder feedback signal and outputs control signals to the power drive module to achieve closed-loop control of the motor. During the operation of drive PCB4, power devices such as MOSFETs generate heat. Since a 0.1mm polyimide thermal insulation layer is set between drive PCB4 and encoder PCB2, it can effectively increase thermal resistance and slow down the conduction of heat to encoder PCB2. At the same time, since encoder PCB2 adopts a centralized layout of devices and there are no heat-generating devices around the detection area, the detection area always maintains a relatively stable temperature environment, reducing temperature drift and improving the long-term working accuracy of the encoder.

[0027] Example 2: Example 2 is a further improvement on Example 1.

[0028] like Figures 1-7 As shown, the rotor encoder 1 is provided with a dust removal structure 5, which consists of an air collecting duct 510, a fixed shell 511, an air vent 512, an mounting cylinder 513, a fan 514, an air outlet box 515, and a sieve plate 516. The air collecting duct 510 is installed at the lower end of the rotor encoder 1. Multiple sets of air outlet boxes 515 are fixedly installed on the air collecting duct 510. A sieve plate 516 is provided on one side of the air outlet box 515. A set of fixed shells 511 is fixedly installed at the lower end of the air collecting duct 510. Multiple sets of air vents 512 are opened on the side wall of the fixed shell 511. A set of mounting cylinders 513 is fixedly installed inside the fixed shell 511. A set of fans 514 is provided inside the mounting cylinder 513.

[0029] As shown above, after each use of the equipment, the fan 514 is turned on. At this time, the fan 514 blows the airflow through the air collection tube 510 into the interior of the air outlet box 515, and then blows it through the sieve plate 516 into the gaps of the equipment. The airflow will blow away the dust, thereby reducing the amount of dust residue in the gaps, extending the overall service life of the rotor encoder 1, reducing the number of cleanings, and reducing the burden on the staff. The vent 512 allows the airflow to enter the interior of the fixed shell 511, thereby forming a circulation system with the air outlet box 515.

[0030] Furthermore, the lower end of the dust removal structure 5 is provided with a set of connecting structures 6. The connecting structure 6 includes a protective cover 610, a connecting plate 611, a limiting post 612, an arc-shaped block 613, a squeezing block 614, an electric push rod 615, and a fixing block 616. The protective cover 610 is fixedly installed at the lower end of the fixed shell 511. A set of connecting plates 611 is fixedly installed on the inner wall of the protective cover 610. The connecting plates 611 are annular and have multiple sets of limiting grooves on their inner walls. The limiting grooves on the inner wall of the connecting plates 611 and the limiting post 612 are slidably connected.

[0031] As described above, when installing the rotor encoder 1 as a whole, first align the pressing block 614 with the ring formed by multiple sets of arc blocks 613, and then start the electric push rod 615. At this time, the electric push rod 615 will drive the pressing block 614 to extend, thereby pressing the multiple sets of arc blocks 613. When the arc blocks 613 are pressed, the arc blocks 613 begin to move, and the ring formed by them will gradually expand. During the movement of the arc blocks 613, they will push the limiting post 612 into the limiting groove in the inner wall of the connecting plate 611 to form a limit, thereby completing the installation of the rotor encoder 1. Compared with the traditional threaded connection, it can avoid the gap at the threaded connection caused by vibration, which would affect the normal operation of the equipment.

[0032] Furthermore, the limiting post 612 is composed of a steel shaft and a rubber sleeve, with the rubber sleeve fitted onto the outer wall of the steel shaft.

[0033] As shown above, the rubber sleeve is elastic, so that during the irregular extension of the limiting post 612, it will be firmly pressed against the limiting groove of the connecting plate 611. While not blocking the movement of the limiting post 612, it can also increase the limiting effect, and the steel shaft provides support for the rubber sleeve.

[0034] Furthermore, one end of the limiting post 612 is fixedly connected to the outer wall of the arc-shaped block 613, the upper end of the arc-shaped block 613 is hinged to the protective cover 610, the multiple sets of arc-shaped blocks 613 initially present a conical shape, the upper end of the extrusion block 614 presents a conical shape, the electric push rod 615 is fixedly installed on the upper end of the fixing block 616, and the fixing block 616 is fixedly installed on the output shaft of the motor.

[0035] As shown above, the limiting post 612 provides a stable installation environment for the arc-shaped block 613, and the initial state of the multiple sets of arc-shaped blocks 613 is conical, while the upper end of the extrusion block 614 is conical, allowing the extrusion block 614 to move along the inner wall of the arc-shaped block 613, thereby increasing the opening formed by the multiple sets of arc-shaped blocks 613.

[0036] Operation Description: During product operation, the power management module provides stable power to the MCU, encoder PCB2, and drive module. As the rotor rotates, the magnetic field detection unit on encoder PCB2 detects changes in the magnetic field in real time and performs angle calculations via ASIC, feeding the position information back to the MCU. The MCU calculates the control algorithm based on the encoder feedback signal and outputs control signals to the power drive module to achieve closed-loop motor control. During the operation of drive PCB4, power devices such as MOSFETs generate heat. Because a 0.1mm polyimide thermal insulation layer is placed between drive PCB4 and encoder PCB2, thermal resistance is effectively increased, slowing heat conduction to encoder PCB2. Simultaneously, due to the centralized device layout on encoder PCB2, there are no heat-generating devices around the detection area, thus maintaining a relatively stable temperature environment in the detection area, reducing temperature drift, and improving the long-term operating accuracy of the encoder. After each use, fan 514 is started, at which time fan 514 will direct airflow through the air collector 510. The airflow is blown into the interior of the air outlet box 515, and then blown through the sieve plate 516 into the gaps of the equipment. The airflow will blow away the dust, thereby reducing the amount of dust residue in the gaps, extending the overall service life of the rotor encoder 1, reducing the number of cleanings, and reducing the burden on the staff. The vent 512 allows the airflow to enter the interior of the fixed shell 511, thus forming a circulation system with the air outlet box 515. When installing the rotor encoder 1 as a whole, first align the pressing block 614 with the ring formed by multiple sets of arc-shaped blocks 613, and then start the electric... The push rod 615 drives the extrusion block 614 to extend, thereby extruding multiple sets of arc-shaped blocks 613. When the arc-shaped blocks 613 are extruded, they begin to move, and the opening they form gradually expands. During the movement of the arc-shaped blocks 613, they push the limiting post 612 into the limiting groove in the inner wall of the connecting plate 611 to form a limit, thereby completing the installation of the rotor encoder 1. Compared with the traditional threaded connection, it can avoid the gap at the threaded connection caused by vibration, which would affect the normal operation of the equipment.

[0037] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the present invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of protection claimed by the present invention.

Claims

1. A flexible electrode circuit board and its fabrication method, comprising an encoder PCB (2), a drive PCB (4), a heat insulation dielectric layer (3), and a rotor code disk (1), characterized in that: The encoder PCB (2) and the drive PCB (4) are mounted on a coaxial stack and connected by a conductive post. The encoder PC (2)B adopts a layout that separates the detection area from the device area. The electronic devices are concentrated in the outer ring area, while the detection area is kept without any devices. A low thermal conductivity insulating medium layer with a thickness of about 0.1 mm is provided between the encoder PCB (2) and the drive PCB (4), and is fixed by adhesive bonding.

2. The flexible electrode circuit board and its fabrication method according to claim 1, characterized in that: The heat insulation medium layer (3) is made of polyimide, PPS, LCP or PET insulating film.

3. The flexible electrode circuit board and its fabrication method according to claim 2, characterized in that: The heat insulation medium layer (3) is bonded with high-temperature resistant insulating structural adhesive.

4. The flexible electrode circuit board and its fabrication method according to claim 1, characterized in that: The power drive devices on the drive PCB (4) are concentrated in the same area.

5. The flexible electrode circuit board and its fabrication method according to claim 4, characterized in that: The encoder PCB (2) detection area is set around the center of the output shaft and is kept apart from the concentrated area of ​​the device.

6. A flexible electrode circuit board according to claim 6, characterized in that: The rotor encoder (1) is provided with a dust removal structure (5), which consists of an air collecting duct (510), a fixed shell (511), an air vent (512), an installation cylinder (513), a fan (514), an air outlet box (515), and a sieve plate (516). The air collecting duct (510) is installed at the lower end of the rotor encoder (1).

7. A flexible electrode circuit board according to claim 4, characterized in that: Multiple sets of air outlet boxes (515) are fixedly installed on the air collection duct (510). A sieve plate (516) is provided on one side of the air outlet box (515). A set of fixed shells (511) is fixedly installed at the lower end of the air collection duct (510). Multiple sets of air vents (512) are opened on the side wall of the fixed shell (511).

8. A flexible electrode circuit board according to claim 6, characterized in that: A set of mounting cylinders (513) are fixedly installed inside the fixed housing (511), and a set of fans (514) are provided inside the mounting cylinders (513).

9. A flexible electrode circuit board according to claim 6, characterized in that: The lower end of the dust removal structure (5) is provided with a set of connecting structures (6). The connecting structure (6) includes a protective cover (610), a connecting plate (611), a limiting post (612), an arc block (613), a squeezing block (614), an electric push rod (615), and a fixing block (616). The protective cover (610) is fixedly installed at the lower end of the fixed shell (511).

10. A flexible electrode circuit board according to claim 9, characterized in that: A set of connecting discs (611) is fixedly installed on the inner wall of the protective cover (610). The connecting discs (611) are circular and have multiple sets of limiting grooves on their inner walls. The limiting grooves on the inner wall of the connecting discs (611) are slidably connected to the limiting posts (612).

11. A flexible electrode circuit board according to claim 10, characterized in that: The limiting post (612) consists of a steel shaft and a rubber sleeve, with the rubber sleeve fitted onto the outer wall of the steel shaft.

12. A flexible electrode circuit board according to claim 11, characterized in that: One end of the limiting post (612) is fixedly connected to the outer wall of the arc block (613), the upper end of the arc block (613) is hinged to the protective cover (610), and the multiple sets of arc blocks (613) initially present a conical shape.

13. A flexible electrode circuit board according to claim 9, characterized in that: The upper end of the extrusion block (614) is conical, the electric push rod (615) is fixedly installed on the upper end of the fixing block (616), and the fixing block (616) is fixedly installed on the output shaft of the motor.

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