Encoder Scale Chrome Electroconductive Layer Antistatic Bonding
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Solution Overview
Problem
The manufacturing process of electromagnetic induction linear encoders is complex due to the need for multiple processes to prevent electrostatic charging of the glass substrate, which causes electrical discharge and noise, and requires a separate antistatic electrode for grounding, increasing the number of manufacturing steps.
Innovation Solution
An encoder scale with a chrome electroconductive layer wider than the copper electric conductor, which acts as both an antistatic electrode and a bonding layer, simplifying the manufacturing process by eliminating the need for additional etching steps and allowing easy grounding, thus reducing the number of processes required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate antistatic electrode is added to prevent electrostatic charging, then electrostatic charge is neutralized, but the number of manufacturing processes increases
Solution Approach 1:
The patent combines the antistatic electrode and bonding layer into a single integrated structure. The electroconductive layer serves dual functions: as a bonding layer to attach the copper electric conductor to the glass substrate and as an antistatic electrode to neutralize electrostatic charge. This merging eliminates the need for separate antistatic electrode fabrication steps while maintaining both bonding reliability and electrostatic charge neutralization.
Solution Approach 2:
The electroconductive layer is designed to perform multiple functions simultaneously: it acts as a bonding layer for mechanical attachment, as an antistatic electrode for electrostatic charge neutralization, and as a mask during etching processes. This multi-functionality reduces the overall complexity of the manufacturing process by consolidating multiple requirements into a single layer structure.
2Manufacturing precision
If multiple etching processes are used to form antistatic electrode and electric conductor, then proper patterns are achieved, but manufacturing complexity increases
Solution Approach 1:
The patent applies a resist layer to the electroconductive layer before etching the copper electric conductor. This preliminary resist application creates a mask that protects the electroconductive layer from etching while allowing the copper to be selectively removed. This approach enables precise pattern formation in a single etching process rather than requiring multiple separate etching steps.
3Reliability
If chrome is used as bonding layer, then bonding reliability is improved, but electrostatic charge is generated during roller rotation
Solution Approach 1:
The patent merges the bonding layer and antistatic electrode into a single electroconductive layer. This integrated structure maintains the bonding reliability provided by chrome while simultaneously serving as an antistatic electrode that neutralizes electrostatic charge generated during roller rotation, eliminating the harmful effect rather than adding a separate component to address it.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively neutralizes electrostatic charges on the substrate, simplifies the manufacturing process, and maintains the electric potential at a reference level, reducing the risk of electrical discharge and noise while ensuring reliable bonding between the substrate and electric conductor.
Implementation Method 1
the electroconductive layer with electroconductivity provided to the one surface of the substrate attracts electric charges by the principle of electrostatic induction, which results in electrical neutralization between the substrate and the electroconductive layer
Implementation Method 2
An electric current induced into the induction electrode by a sliding movement of the scale relative to the head is detected by a pick-up coil of the encoder head
Data Source
AI summary
An encoder scale for an electromagnetic induction linear encoder includes a substrate, an electroconductive layer exhibiting electroconductivity and provided to one surface of the substrate, and an electric conductor provided on the electroconductive layer. The electroconductive layer is wider than the electric conductor in a plan view of the substrate and is grounded. The electroconductive layer is formed on the entire one surface of the substrate except a guide surface, and glass is exposed on the guide surface.