Piezoelectric Force Sensor With Insulating Adhesive
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Solution Overview
Problem
Existing force detection devices in industrial robots face issues with mechanical stress resistance, signal accuracy, and short circuit risks due to the use of Ag paste connections and require labor-intensive positioning methods during manufacturing.
Innovation Solution
A sensor device with a piezoelectric element and conductive paste connection, where the adhesive has insulating properties and includes inorganic fillers to enhance stability and prevent short circuits, and a lid to airtightly seal the force detection element, improving mechanical strength and detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Ag paste is used as connection electrode to connect laminated body and terminal, then electrical connection is achieved, but short circuit risk increases due to paste dripping onto Kovar base portion
Solution Approach 1:
An insulating adhesive is introduced as an intermediary substance between the conductive Ag paste connection electrode and the Kovar base portion. This adhesive layer prevents direct contact between the conductive paste and the metallic base, eliminating the short circuit risk while maintaining the electrical connection function of the paste between the laminated body and terminal.
Solution Approach 2:
The connection structure is segmented into distinct functional layers: the Ag paste provides electrical connection, the insulating adhesive provides isolation and positioning, and the Kovar base provides structural support. This segmentation allows each component to perform its specific function without interfering negatively with others.
2Manufacturing precision
If positioning jig is used to position laminated body in recess portion during manufacturing, then positioning accuracy is improved, but manufacturing complexity and labor increase
Solution Approach 1:
The insulating adhesive serves a dual function: it provides electrical insulation and simultaneously acts as a self-positioning mechanism. The adhesive's viscosity and curing characteristics enable the laminated body to be positioned and fixed in the correct location without requiring external positioning jigs, allowing the manufacturing process to be self-sufficient.
Solution Approach 2:
The insulating adhesive performs multiple functions simultaneously: electrical insulation, mechanical bonding, positioning, and gap filling. This multi-functionality eliminates the need for separate positioning jigs and simplifies the manufacturing process while maintaining positioning accuracy.
3Object-affected harmful factors
If adhesive with insulating properties is used between force detecting element and bottom surface, then short circuit prevention is improved, but mechanical bonding strength may be reduced
Solution Approach 1:
The adhesive is formulated as a composite material combining insulating polymers with reinforcing fillers such as glass fibers, ceramic particles, or metal oxides. This composite structure provides both electrical insulation properties and enhanced mechanical bonding strength, resolving the contradiction between insulation and strength requirements.
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 enhances the stability and accuracy of force detection, reduces mechanical stress resistance, and prevents short circuits, allowing for precise and reliable force measurement in industrial robots.
Implementation Method 1
a force detecting element which is provided in the recess, and includes at least one piezoelectric element that outputs a signal in accordance with an external force
Implementation Method 2
at least one conductive paste which electrically connects the electrode and the terminal to each other
Implementation Method 3
an adhesive which is provided between the force detecting element and a bottom surface of the recess
Data Source
AI summary
A sensor device includes: a base having a recess; a force detecting element which is provided in the recess, and includes at least one piezoelectric element that outputs a signal in accordance with an external force; an adhesive which is provided between the force detecting element and a bottom surface of the recess; at least one electrode provided in the force detecting element; at least one terminal provided in the base; and at least one conductive paste which electrically connects the electrode and the terminal to each other, in which the conductive paste has a part that overlaps the adhesive when viewed from a direction in which the force detecting element and the bottom surface overlap each other, and in which the force detecting element overlaps the bottom surface when viewed from the direction in which the force detecting element and the bottom surface overlap each other.