Force Sensor Adhesive Layer Control
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Solution Overview
Problem
Existing methods for producing force sensors in large series struggle with reproducibility, as variations in the thickness of the sealing adhesive layer between the deformation measuring device and the test body lead to inconsistent signal measurements under stress.
Innovation Solution
A method involving the use of a reactive viscous adhesive, applied between the deformation measuring device and the test body, with a calibration step to ensure a consistent adhesive thickness by applying pressure until a specific distance is reached, followed by heat or UV activation for rapid solidification, ensuring uniform signal response across force sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a reactive viscous adhesive is applied between the deformation measuring device and the test body, then the signal measurement consistency is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies a reactive viscous adhesive to the receiving surface before mounting the deformation measuring device. This preliminary action ensures that the adhesive is in place and ready to be activated immediately after mounting, eliminating gaps or inconsistencies in the sealing layer thickness that would affect signal measurement consistency.
Solution Approach 2:
The patent utilizes the chemical reaction parameters of the reactive viscous adhesive (such as curing time, reaction temperature, and viscosity changes during curing) to achieve consistent sealing. By controlling these parameters, the adhesive transforms from a viscous state to a solidified state with uniform thickness, ensuring reproducible signal measurements across multiple force sensors.
2Manufacturing precision
If pressure is applied to the deformation measuring device to control adhesive thickness, then the manufacturing precision is improved, but the production time increases
Solution Approach 1:
The calibration device is prepared in advance with the deformation measuring device positioned at the correct height. This preliminary positioning ensures that when pressure is applied during assembly, the adhesive layer achieves the target thickness immediately, eliminating the need for time-consuming adjustments or iterations.
Solution Approach 2:
The patent replaces complex mechanical thickness control mechanisms with a simpler approach: applying controlled pressure while using a calibration device that defines the target geometry. The reactive viscous adhesive's flow characteristics under pressure, combined with the calibration device's geometric constraints, automatically achieve uniform thickness without complex mechanical adjustment systems.
3Reliability
If a rigid connection is used to seal the deformation measuring device, then the reliability is improved, but the adaptability to variations in adhesive thickness decreases
Solution Approach 1:
The patent employs a reactive viscous adhesive that undergoes parameter changes during curing - transitioning from a viscous, compliant state to a solidified, rigid state. During the assembly process, the viscous state allows the adhesive to conform to thickness variations and provide a reliable seal. After curing, the rigid state ensures consistent mechanical connection and signal measurement reliability.
Solution Approach 2:
The calibration device is used to pre-establish the correct geometric relationship between the deformation measuring device and the receiving surface before final assembly. This preliminary action ensures that when the reactive viscous adhesive is applied and pressure is applied, the adhesive fills the precise gap required for reliable sealing, accommodating thickness variations while ensuring consistent connection quality.
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
This approach allows for the mass production of force sensors with identical precision and signal consistency under stress, as the controlled adhesive thickness eliminates variations in signal measurement, enabling high reproducibility across the series.
Implementation Method 1
a reactive viscous adhesive is applied to said receiving surface of said test body, and said deformation measuring device is carried on said viscous adhesive applied so as to trap a layer of said viscous reactive adhesive between said device for measuring deformation and said receiving surface of said test body
Implementation Method 2
The basic principle that governs the operation of the strain gauge is the change in conductivity of a material depending on the mechanical stress it experiences. In this case, the deformation of the printed circuit leads to a variation in the conductivity of the material of the track
Data Source
Figure 1~2b
Figure 3~5
Figure 6~7
AI summary
The invention relates to a method for manufacturing a force sensor and a facility for implementing same. The method includes the following steps: a) providing a deformation measurement apparatus (22) and a proof body (10); b) providing a reactive viscous adhesive; and c) applying said reactive viscous adhesive (14) to said proof body (10); d) placing said deformation measurement apparatus (22) on said viscous apparatus applied such as to trap a layer of said reactive viscous adhesive (50); then applying pressure to said deformation measurement apparatus (22) in order to bring same to a given distance from said proof body (10); and e) causing said reactive viscous adhesive of said layer (50) to react in order to sealingly secure said deformation measurement apparatus (22) to said receiving surface (12) of said proof body (10).