SENSORY ARRAY FOR USE WITH ARTIFICIAL SKIN AND ARTIFICIAL SKIN WITH SENSORY ARRAY, USEFUL IN ROBOTICS
20210307170 · 2021-09-30
Inventors
Cpc classification
H05K1/142
ELECTRICITY
H05K2201/058
ELECTRICITY
H05K1/189
ELECTRICITY
H05K2201/042
ELECTRICITY
H05K1/147
ELECTRICITY
International classification
Abstract
A flexible modular skin sensor array can cover any surface of a robot. The skin sensor array includes a flexible mesh and a set of modular sensor panels that attached to the mesh. The skin sensor array underlies or is molded inside a skin membrane (e.g., silicone), and can flex and stretch with the skin. Each modular sensor panel has a communications chip and one or more sensors. A master controller provides communications with the modular sensor panels through a shared bus. Modular sensor panels can fail without affecting the network. The flexible mesh and modular sensor panels may be made of flexible PCB, to accommodate movement of the skin. A set of convoluted bridges connect locations at which the modular sensor panels attach, allowing for flexing and stretching without tearing of the flexible mesh. The redundancy allows some of the connection leads to fail without affecting communications.
Claims
1. A flexible sensor array, comprising: a flexible mesh, the flexible mesh comprising a plurality of islands and a plurality of bridges, wherein each respective bridge flexibly physically couples between a respective pair of islands and each respective island is flexibly physically coupled to at least two other islands via respective bridges, and wherein each respective island includes a respective coupler; a plurality of electrically conductive paths, each respective electrically conductive path having at least two nodes, wherein each respective bridge carries at least a portion of at least one respective electrically conductive path with the nodes of the respective electrically conductive path located at respective ones of the pair of islands that are flexibly physically coupled by the respective bridge; and a plurality of modular panels, each respective modular panel comprising a substrate, at least one sensor carried by the substrate, at least one integrated circuit, and a complementary coupler that is complementary to the respective couplers of the islands to at least physically couple the modular panel to a respective island with at least one electrical connection between the respective node at the island and the at least one sensor of the respective modular panel.
2. The flexible sensor array of claim 1 wherein each respective bridge comprises at least one dielectric layer, and wherein each respective electrically conductive path is a flexible electrically conductive trace carried by at least one bridge.
3. The flexible sensor array of claim 2 wherein each respective bridge has a plurality of flexures.
4. The flexible sensor array of claim 2 wherein each respective bridge comprises a plurality of layers of a dielectric having a serpentine profile.
5. The flexible sensor array of claim 1 wherein each of the modular panels is removably physically coupled to a respective one of the islands by a respective coupler.
6. The flexible sensor array of claim 1 wherein the substrate of each of the modular panels is a flexible substrate, and wherein the flexible substrate of each of the modular panels is bendable about at least one axis but is not stretchable.
7. The flexible sensor array of claim 1 wherein the substrate of each of the modular panels is a flexible substrate, and wherein the at least one electrical connection between the respective node at the island and the at least one sensor of the respective modular panel is an indirect electrical connection between the respective node and a contact of the at least one sensor via at least one electrically conductive path carried by the substrate of the modular panel.
8. The flexible sensor array of claim 1 wherein the substrate of each of the modular panels is a flexible substrate, and wherein the at least one electrical connection between the respective node at the island and the at least one sensor of the respective modular panel is a direct electrical connection between the respective node and a contact of the at least one sensor.
9. The flexible sensor array of claim 1 wherein the sensors include at least one of: a force sensor, a capacitive sensor, an inertial measurement sensor, or a temperature sensor.
10. The flexible sensor array of claim 1, further comprising: at least one processor communicatively coupled to the respective integrated circuit of each respective modular panel by a set of the electrically conductive paths.
11. The flexible sensor array of claim 1 wherein the islands are tiled in a repeating pattern.
12. The flexible sensor array of claim 1 wherein the flexible sensor array underlies a pliable resilient electrically insulating material.
13. The flexible sensor array of claim 1 wherein the flexible sensor array is embedded in at least one pliable resilient electrically insulating membrane to form an artificial skin.
14. The flexible sensor array of claim 1 wherein the plurality of islands and the plurality of bridges are parts of a unitary, single piece substrate.
15. A flexible sensor array comprising: a flexible mesh comprising a plurality of sensor panel coupling areas, a plurality of electrically conductive elements each coupling a sensor panel coupling area to at least another sensor panel coupling area, a plurality of sensor panels, each sensor panel comprising: a set of sensors, the set of sensors comprising at least one of a force sensor, a capacitive sensor, an inertial measurement unit, or a temperature sensor, an integrated circuit that electrically couples to the set of sensors, and a mesh coupling mechanism that mechanically and electrically couples the sensor panel to a sensor panel coupling area on the flexible mesh, and an electronic controller or processor that electrically couples to the plurality of sensor panel coupling areas and communicates with the integrated circuit devices on the plurality of sensor panels.
16. The flexible sensor array of claim 15 wherein the plurality of sensor panel coupling areas are tiled on the flexible mesh in a triangular, a hexagonal, a rectangular or other regular tiling, and wherein each of the plurality of sensor panels has a geometric shape that matches the regular tiling of the sensor panel coupling areas.
17. The flexible sensor array of claim 15 wherein the flexible mesh comprises a set of sensor panel coupling areas to each of which at least one other one of the sensor panel coupling areas is fixed and a set of panel interconnects which flexibly couple adjacent sensor panel coupling areas.
18. The flexible sensor array of claim 17 wherein the set of sensor panel coupling areas and the set of panel interconnects are composed of a flexible printed circuit board material, and the plurality of electrically conductive elements are a set of printed circuitry on the flexible printed circuit board material.
19. The flexible sensor array of claim 15, further comprising: an artificial skin composed of a soft insulating material covering the flexible mesh and the plurality of sensor panels on at least one side.
20. The flexible sensor array of claim 15, further comprising: an artificial skin composed of a soft insulating material in which the flexible mesh and the plurality of sensor panels are imbedded.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn are not intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings.
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DETAILED DESCRIPTION
[0018] In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations and embodiments. However, one skilled in the relevant art will recognize that the implementations and embodiments may be practiced without one or more of these specific details, or with other methods, components, structures, materials, etc. In other instances, well-known structures associated with skin-like sensor arrays (e.g., piezoelectric sensors, force sensitive materials, flexible PCB manufacturing, asynchronous electronic communication protocols) operable to provide human skin-like touch precision have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments.
[0019] Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is, as “including, but not limited to.”
[0020] Reference throughout this specification to “in one implementation” or “in an implementation” or “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the implementation or embodiment is included in at least one implementation or at least one embodiment. Thus, the appearances of the phrases “in one implementation” or “in an implementation” or “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same implementation or embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0021] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
[0022] As used in this specification and the appended claims, “flexible”, “flexibly” and similar, refers to the ability of a material to bend, flex, twist, or otherwise deform to a functionally significant amount with little or no plastic deformation in at least one axis when a load is applied.
[0023] As used in this specification and the appended claims, “stretchable”, “stretchability”, “stretchably”, and similar, refers to the ability of a material to elongate to a functionally significant amount with little or no plastic deformation in at least one axis when a load is applied.
[0024] The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
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[0027] The modular sensor panel 102 may also comprise one or more integrated circuits 210, each of the integrated circuits 210 may be coupled or attached to a respective location on the printed circuit board 202.
[0028] The printed circuit board 202 may take the form of a flexible printed circuit board, that bends or flexes without plastic deformation or destruction under an applied force, the applied force being a force that is anticipated to be applied during normal use, for instance the amount of force applied by a human finger pressing on the printed circuit board 202. In some implementations, the printed circuit board 202 may even take the form of a printed circuit board that stretches under an applied force (e.g., tension). For example, printed circuit board 202 may take the form of a printed circuit board with relatively few layers or that has a small thickness as compared to a lateral (e.g., length, width) dimension, to provide for the flexibility of the modular sensor panel 102. Additionally or alternatively, the sensor areas 204 may take the form of distinct islands, and the printed circuit board 202 of the modular sensor panel 200 may also include a plurality of sensor bridges 208 that couple the sensor areas 204 together, further enhancing the flexibility of the modular sensor panel 102.
[0029] Alternatively, the printed circuit board 202 may take the form of a rigid printed circuit board that does not bend or flex under an applied force, the applied force being a force anticipated to be applied during normal use, for instance the amount of force applied by a human finger pressing on the printed circuit board 202.
[0030] The printed circuit board 202 may comprise one or more layers of electrically insulative materials, for example Kapton or other polyimide layers which may enhance flexibility. The printed circuit board 202 may include one or more printed circuit traces and/or vias of electrically conductive materials, for example copper, beryllium copper, cupro-nickel, nickel, or silver epoxy. The printed circuit traces may be carried on an outer surface and/or on an inner layer of the printed circuit board 202. Vias may extend between opposed outer surfaces and/or between inner layers, and/or between an outer surface and an inner layer of the printed circuit board 202. Printed circuit traces and vias may carry signals and/or electrical power.
[0031] The integrated circuits 210 are physically coupled to the circuit board 202 and communicatively (e.g., signals, power) coupled to the plurality of sensors 206 through electrically conductive paths (e.g., electrically conductive traces) on the circuit board 202. Other implementations may have a fewer or greater number of integrated circuits 210 than illustration, and are operable to process, compress, and/or communicate the information generated or sensed or output by the sensors 206.
[0032] As best illustrated in
[0033] As best illustrated in
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[0035] The printed circuit board 402 may, for example, take the form of a printed circuit board with relatively few layers or that has a small thickness as compared to a lateral (e.g., length, width) dimension, to provide flexibility. The flexible printed circuit board 402 may comprise a set of islands 404 coupled together by a set of bridges 406. Each bridge 406 couples together two islands 404, each island 404 coupled at a respective end of the bridge 406. As best illustrated in
[0036] As illustrated in
[0037] The printed circuit board 402 may comprise one or more layers of electrically insulative materials, for example Kapton or other polyimide layers which may enhance flexibility. The printed circuit board 402 may include one or more printed circuit traces and/or vias of electrically conductive materials, for example copper, beryllium copper, cupro-nickel, nickel, or silver epoxy. The printed circuit traces may be carried on an outer surface and/or on an inner layer of the printed circuit board 402. Vias may extend between opposed outer surfaces and/or between inner layers, and/or between an outer surface and an inner layer of the printed circuit board 402. Printed circuit traces and vias may carry signals and/or electrical power.
[0038] Other implementations may have more or fewer islands and bridges in other tilings, such as square, rectangular, rhombic, hexagonal, or other, or in a non-tiling pattern. Other implementations may also have bridges and islands be separate structures coupled together through a set of mechanical and electrical couplers.
[0039] As also illustrated in
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[0041] Each bridge 503 comprises a set of electrically conductive paths (e.g., electrically conductive circuit traces) 504 which in this implementation is a set of printed circuitry or conductive traces printed or otherwise formed on one or more layers of the flexible circuit board material. Each set of electrically conductive paths 504 is electrically coupled to a common electrical coupler or connector 506 such that each set of electrically conductive paths 504 is communicatively (e.g., electrically) coupled to every other set of electrically conductive paths 504 and the sets of electrically conductive paths form a common bus shared by the entire system.
[0042] Each island 502 comprises an electrical plug 508 that can receive an electrical coupler from a sensor module, for example as that shown in
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[0046] The artificial skin 800 may optionally include a shell panel 808. The shell panel 808 includes structures that allow the artificial skin 800 to be attached to a portion of a robot, for example attached to a limb of a robot, for instance as shown in an example illustrated implementation. In some implementations the shell panel 808 may be a plastic panel with attachment features (e.g., holes, pins). A cut-away portion of the pliable, resilient, electrically insulating material 802 is indicated by broken-line 810. The sensors carried by the modular sensor panels 806 can detect and respond to pressure applied through the pliable, resilient, electrically insulating material 802 and relay corresponding sensor information to a processor of the flexible sensor array 100 (
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[0050] This application incorporates by reference the teachings of U.S. patent application 63/001,755 in its entirety. The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.