Strain Body Anisotropic Conductive Film Connection
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Solution Overview
Problem
The challenge in developing six-axis force sensors for robot arms is the difficulty in maintaining reliable electric connections between electrode terminals and lead wires due to the narrow pitch required for downsized and high-performance strain bodies, leading to unreliable signal detection.
Innovation Solution
A strain body design featuring a central portion, outer peripheral portion, connecting portions with strain sensors, reference resistors forming bridge circuits, an electrode for signal detection, and an anisotropic conductive film for reliable connection between the electrode and lead wire, ensuring stable electric connections and improved detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the strain body is downsized to achieve higher performance, then the detection capability and response speed are improved, but the pitch between electrode terminals becomes narrower making reliable electric connection difficult
Solution Approach 1:
The patent introduces a flexible printed circuit board (FPC) as an intermediary component between the electrode terminals on the strain body and the external lead wires. The FPC provides a stable mounting surface with sufficient area for reliable soldering connections, while maintaining the compact size of the strain body through its flexible nature. This mediator resolves the contradiction by decoupling the size constraints of the strain body from the connection reliability requirements.
Solution Approach 2:
The patent utilizes the flexibility and three-dimensional conformability of the FPC to resolve the spatial constraints. By allowing the circuit board to bend and conform to the compact strain body geometry, it provides adequate space for electrode terminals and connection points without increasing the overall footprint. This dimensional flexibility enables reliable connections in a downsized configuration.
2Ease of manufacture
If the position of electrode terminal and lead wire terminal are slightly shifted, then manufacturing tolerance is relaxed, but normal detection signal cannot be taken to the outside
Solution Approach 1:
The FPC acts as a tolerant intermediary that can accommodate positional shifts between electrode terminals and lead wire connections through its flexibility. The flexible nature allows for adjustment and compensation of misalignments during assembly, ensuring reliable electrical connection even when terminal positions are not perfectly aligned, thus maintaining both manufacturing ease and signal detection capability.
3Volume of moving object
If strain sensors are placed in limited space, then device size is reduced, but connection reliability between electrode and lead wire deteriorates
Solution Approach 1:
The patent employs a flexible printed circuit board as a thin film structure that provides adequate surface area for reliable connections while maintaining a compact form factor. The flexibility of this thin film allows it to conform to the limited space requirements while providing sufficient room for electrode terminals and lead wire connections, thus resolving the contradiction between miniaturization and connection reliability.
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 design enhances the reliability and detection accuracy of six-axis force sensors by maintaining reliable electric connections and reducing the influence of temperature errors and external noise, while allowing for high-density and accurate placement of strain sensors in limited spaces.
Implementation Method 1
an anisotropic conductive film provided between the electrode and the lead wire to make electric connection between a terminal of the electrode and a terminal of the lead wire
Implementation Method 2
deformation of a strain sensor (strain gauge) provided on the strain body is converted into an electric signal and detected
Implementation Method 3
reference resistors provided on a main surface of the central portion, and constructing a bridge circuit with the strain sensors
Data Source
AI summary
A strain body according to an embodiment includes a central portion, an outer peripheral portion, connecting portions, strain sensors provided on main surfaces of the connecting portions, reference resistors provided on a main surface of the central portion, and constructing a bridge circuit with the strain sensors, an electrode for taking a detection signal of the bridge circuit, a lead wire making electric connection between the electrode and the outside, and an anisotropic conductive film provided between the electrode and the lead wire to make electric connection between a terminal of the electrode and a terminal of the lead wire.