Sandwich Probe Arm with Resilient Foil Hinge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing probe arms are highly sensitive and require careful handling, with spring hinges being intricate and difficult to manufacture, making them challenging to produce and handle robustly.
Innovation Solution
A probe arm composed of at least two layers, with a thin, resilient metal foil as a hinge layer and stiffer material layers forming a sandwich structure, allowing for precise setting of spring properties and robust handling, and an efficient manufacturing process using laser-cut cover body blanks and laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-material probe arm with weakened section is used, then the spring hinge can be integrated, but the probe arm becomes highly sensitive and difficult to handle
Solution Approach 1:
The probe arm uses a composite structure with at least two different materials: a resilient material (e.g., spring steel) for the hinge section and a stiffer material (e.g., tool steel, ceramic, or plastic) for the enclosing layers. This material differentiation allows the hinge to provide necessary flexibility while the stiffer enclosing layers protect the sensitive internal structure, making the overall device more robust for handling.
2Manufacturing precision
If intricate spring hinges are used to achieve desired measuring force, then measurement precision is improved, but manufacturing difficulty increases
Solution Approach 1:
The probe arm is segmented into distinct functional zones: resilient hinge sections for flexibility and stiffer enclosing layers for structural integrity. This segmentation allows each part to be optimized independently - the hinge section can be precisely controlled for measuring force while the enclosing layers can be manufactured separately and assembled, simplifying the overall manufacturing process.
Solution Approach 2:
The invention allows adjustment of physical parameters such as foil thickness (10-100 μm), material selection, and hinge geometry to precisely control the spring properties and measuring force. These parameter changes enable customization of the hinge characteristics without requiring intricate manufacturing processes.
3Manufacturing precision
If thin resilient foil is used for the hinge layer, then spring properties can be precisely controlled, but manufacturing robustness decreases
Solution Approach 1:
The thin resilient foil (10-100 μm) is sandwiched between stiffer enclosing layers, creating a composite structure where the thin foil provides precise spring properties while the enclosing layers provide mechanical strength and impact resistance. This composite approach allows the thin foil to function effectively without being vulnerable to damage.
Solution Approach 2:
The stiffer enclosing layers act as protective cushions for the thin resilient foil before any impact occurs. These enclosing layers prevent the thin foil from being damaged during handling and transport, while still allowing the foil to flex within its elastic range for precise measuring force control.
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 results in probe arms that are insensitive to impact, easy to produce in large quantities, and maintain precise spring properties, enabling robust handling and efficient mass production.
Implementation Method 1
At least one of the layers, preferably the middle layer, has a physical property that allows it to be used as a bearing or hinge. This layer is preferably designed as a thin, resilient foil, according to the invention as a metal foil
Implementation Method 2
The foil and the elements attached to it are preferably permanently connected to one another, for example by gluing, welding, laser welding, plasma welding or other suitable means
Implementation Method 3
an efficient manufacturing process using laser-cut cover body blanks and laser welding
Data Source
Figure 1~3
Figure 4
Figure 5
AI summary
Reference is made to a sandwich design for the production of sensing arms (6), and preferably stiff covering elements (22, 23) are placed onto a central, resilient foil (21) for this purpose. At least one of the covering elements (22, 23) can have at least locally defined magnetic properties in order to cooperate, for example, with a sensor coil (11). The covering elements (22, 23) are [covered] with a foil (21) in a manner essentially following the contour thereof, and specifically except for small, preferably slot-like cutouts (32 to 35) where the foil (21) is exposed in order to form spring hinges.