WO2002063261A2 - Electronic pressure sensitive transducer apparatus and method for manufacturing same - Google Patents

Electronic pressure sensitive transducer apparatus and method for manufacturing same Download PDF

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Publication number
WO2002063261A2
WO2002063261A2 PCT/US2002/003675 US0203675W WO02063261A2 WO 2002063261 A2 WO2002063261 A2 WO 2002063261A2 US 0203675 W US0203675 W US 0203675W WO 02063261 A2 WO02063261 A2 WO 02063261A2
Authority
WO
WIPO (PCT)
Prior art keywords
circuit board
printed circuit
traces
pressure sensitive
contact area
Prior art date
Application number
PCT/US2002/003675
Other languages
French (fr)
Other versions
WO2002063261A3 (en
Inventor
Jeffrey R. Baker
Carlos S. Sanchez
Original Assignee
Interlink Electronics, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Interlink Electronics, Inc. filed Critical Interlink Electronics, Inc.
Priority to AU2002243885A priority Critical patent/AU2002243885A1/en
Priority to EP02709401A priority patent/EP1364220A4/en
Priority to JP2002562959A priority patent/JP4261186B2/en
Publication of WO2002063261A2 publication Critical patent/WO2002063261A2/en
Publication of WO2002063261A3 publication Critical patent/WO2002063261A3/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H13/00—Switches having rectilinearly-movable operating part or parts adapted for pushing or pulling in one direction only, e.g. push-button switch
    • H01H13/70—Switches having rectilinearly-movable operating part or parts adapted for pushing or pulling in one direction only, e.g. push-button switch having a plurality of operating members associated with different sets of contacts, e.g. keyboard
    • H01H13/702—Switches having rectilinearly-movable operating part or parts adapted for pushing or pulling in one direction only, e.g. push-button switch having a plurality of operating members associated with different sets of contacts, e.g. keyboard with contacts carried by or formed from layers in a multilayer structure, e.g. membrane switches
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
    • G01L1/00—Measuring force or stress, in general
    • G01L1/20—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
    • G01L1/00—Measuring force or stress, in general
    • G01L1/20—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress
    • G01L1/205—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress using distributed sensing elements
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/11—Printed elements for providing electric connections to or between printed circuits
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2201/00—Contacts
    • H01H2201/022—Material
    • H01H2201/032—Conductive polymer; Rubber
    • H01H2201/036—Variable resistance
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2203/00—Form of contacts
    • H01H2203/02—Interspersed fingers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2239/00—Miscellaneous
    • H01H2239/01—Miscellaneous combined with other elements on the same substrate
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/0266—Marks, test patterns or identification means
    • H05K1/0268—Marks, test patterns or identification means for electrical inspection or testing
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/14—Structural association of two or more printed circuits
    • H05K1/141—One or more single auxiliary printed circuits mounted on a main printed circuit, e.g. modules, adapters
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/16—Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
    • H05K1/167—Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor incorporating printed resistors
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/03—Conductive materials
    • H05K2201/0332—Structure of the conductor
    • H05K2201/0335—Layered conductors or foils
    • H05K2201/035—Paste overlayer, i.e. conductive paste or solder paste over conductive layer
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/09—Shape and layout
    • H05K2201/09209—Shape and layout details of conductors
    • H05K2201/09654—Shape and layout details of conductors covering at least two types of conductors provided for in H05K2201/09218 - H05K2201/095
    • H05K2201/09663—Divided layout, i.e. conductors divided in two or more parts
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10007—Types of components
    • H05K2201/10151—Sensor
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/20—Details of printed circuits not provided for in H05K2201/01 - H05K2201/10
    • H05K2201/2036—Permanent spacer or stand-off in a printed circuit or printed circuit assembly
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/02—Details related to mechanical or acoustic processing, e.g. drilling, punching, cutting, using ultrasound
    • H05K2203/0278—Flat pressure, e.g. for connecting terminals with anisotropic conductive adhesive
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/22—Secondary treatment of printed circuits
    • H05K3/24—Reinforcing the conductive pattern
    • H05K3/245—Reinforcing conductive patterns made by printing techniques or by other techniques for applying conductive pastes, inks or powders; Reinforcing other conductive patterns by such techniques
    • H05K3/247—Finish coating of conductors by using conductive pastes, inks or powders
    • H05K3/249—Finish coating of conductors by using conductive pastes, inks or powders comprising carbon particles as main constituent
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/303—Surface mounted components, e.g. affixing before soldering, aligning means, spacing means
    • H05K3/305—Affixing by adhesive
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/36—Assembling printed circuits with other printed circuits
    • H05K3/361—Assembling flexible printed circuits with other printed circuits
    • H05K3/365—Assembling flexible printed circuits with other printed circuits by abutting, i.e. without alloying process
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49007—Indicating transducer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/49128—Assembling formed circuit to base
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
    • Y10T29/49146—Assembling to base an electrical component, e.g., capacitor, etc. with encapsulating, e.g., potting, etc.

Definitions

  • the Present invention relates to transducer systems for sensing pressure.
  • Pressure sensitive transducers generate a signal indicative of the amount of pressure applied to a flexible membrane. Such transducers may also generate a signal based on the location of pressure applied to the flexible membrane. Such pressure sensitive transducers provide inputs for a wide variety of applications such as remote controls, game controllers, mouse pads, tactile sensors, and the like. Pressure sensitive transducers are typically coupled with electronics that condition and amplify pressure signals.
  • FSRs force sensing resisters
  • Various FSRs have been disclosed, such as those described in commonly assigned U.S. Patent Nos. 4,314,227; 4,314,228; and 4,489,302; each of which is hereby incorporated by reference in its entirety.
  • an FSR is composed of three parts, a rigid base, a spacer, and a resistive membrane.
  • Conductive traces are typically arranged in separated interdigitated sets on the base. These traces may be configured in a single zone or in multiple zones to allow, for example, pointing devices as described in commonly assigned U.S. Patent Nos.
  • the flexible resistive membrane is spaced apart from the base layer by a spacer, which is typically a ring of material around the outer edge of the conductive traces.
  • the spacer is also typically coated with adhesive to hold the device together.
  • the flexible top membrane may be made of a polymer coated on its inner face with semi-conductive or resistive ink, giving the FSR force sensing properties. This ink is described in commonly owned U.S. Patent Nos. 5,296,837 and 5,302,936, each of which is hereby incorporated by reference in its entirety.
  • the FSR must be connected to sensing and conditioning electronics in order to effectively operate.
  • One way this may be accomplished is by connecting the FSR to a printed circuit board containing the electronics with a multi-conductor cable.
  • Another way of connecting the FSR to support electronics is to adhere the FSR base directly to the circuit board containing the electronics. Electrical connection may be made between traces on the FSR and corresponding traces on the printed circuit board using z-tape, which only conducts in a direction perpendicular to the tape surface. While either method is effective, both have unnecessary manufacturing steps and require unnecessary components, thus increasing the cost of a pressure sensitive transducer system as well as increasing the likelihood of system failure. What is needed is a pressure sensitive transducer and a method for making such a transducer that requires fewer components and fewer manufacturing steps without sacrificing transducer performance.
  • the present invention decreases the cost and complexity of an electronic pressure sensitive transducer by constructing such a transducer directly on a printed circuit board containing support electronics.
  • An electronic pressure sensitive transducer producing an electrical signal indicative of applied pressure includes a printed circuit board accepting a plurality of electronic elements for processing the transducer electrical signal. Conductive traces are formed on the printed circuit board to define a contact area. A flexible substrate having an inner surface is positioned over the contact area. An adhesive spacer substantially surrounds the contact area. The adhesive spacer attaches the flexible substrate to the printed circuit board. At least one resistive layer is deposited on the flexible substrate inner surface. The resistive layer contacts at least two of the traces in response to pressure applied to the flexible substrate to produce the electrical signal indicative of applied pressure.
  • At least one resistive layer is made with resistive ink.
  • a pedestal is formed on the printed circuit board substantially around the contact area.
  • the pedestal receives the adhesive spacer for attaching the flexible substrate.
  • the pedestal increases the space between resistive layers on the substrate and conductive traces on the printed circuit board.
  • the pedestal may be formed by coating traces on the printed circuit board with a non-conductive material such as soldermask.
  • the conductive traces include a plurality of sets of traces. Each set of traces is interconnected within a zone of the contact area. An interconnected set of contact traces extends into each zone. At least one of the interconnected set of traces may be connected to the electronic elements for processing the transducer signal via a through-hole in the printed circuit board. The through-hole may be within the contact area.
  • conductive traces are arranged in sets of interconnected traces. At least two sets of traces are interdigitated.
  • conductive traces comprise copper traces covered with an oxidation preventing conductive material.
  • conductive traces comprise screen printed carbon ink.
  • a method of forming an electronic pressure sensitive transducer on a printed circuit board is also provided.
  • the printed circuit board accepts electronic components for producing signals generated by the pressure sensitive transducer.
  • a plurality of conductive traces are formed on the printed circuit board to form a contact area.
  • At least one resistive layer is deposited on an inner side of a flexible substrate.
  • the flexible substrate is assembled on the printed circuit board such that the flexible substrate resistive layer is facing the printed circuit board conductive traces.
  • the flexible substrate is held to the printed circuit board by an adhesive substantially surrounding at least a portion of the contact area.
  • a transducer system is also provided.
  • the system includes a printed circuit board having a plurality of conductive traces. At least two of these traces define contact areas.
  • the printed circuit board is constructed to accept electronic elements for processing electrical signals produced by a plurality of transducers. Each of these signals is indicative of pressure applied to at least one of the transducers.
  • the system also includes at least one flexible substrate having an inner surface facing each contact area. At least one adhesive spacer substantially surrounds each contact layer to attach at least one flexible substrate to the printed circuit board. At least one resistive layer is deposited on a flexible substrate inner surface. Each resistive layer contacts at least two of the traces in response to pressure applied to the flexible substrate to produce an electrical signal indicative of applied pressure.
  • the contact areas, at least one flexible substrate, at least one adhesive spacer and at least one resistive layer form the plurality of transducers, each transducer constructed on the printed circuit board.
  • a method of forming an electronic pressure sensitive transducer on a printed circuit board supporting electronic elements is also provided.
  • a portion of conductive material on a printed circuit board is selectively removed to define traces in a contact area, traces connecting the electronic elements to the contact area, and at least a portion of a pedestal.
  • FIGURE 1 is an exploded cross-sectional view illustrating a conceptualized pressure sensitive transducer according to an embodiment of the present invention
  • FIGURE 2 is a top view of a printed circuit board illustrating a four- zone contact area according to an embodiment of the present invention
  • FIGURE 3 is a top view of a printed circuit board illustrating carbon traces according to an embodiment of the present invention
  • FIGURE 4 is a top view of a pressure sensitive transducer constructed using the printed circuit board of Figure 2 or 3 according to an embodiment of the present invention
  • FIGURE 5 is an exploded view illustrating conceptualized multiple single-zone FSRs in a pressure sensitive transducer according to an embodiment of the present invention.
  • FIGURE 6 is a top view of a printed circuit board implementing multiple single-zone FSRs in a pressure sensitive transducer according to an embodiment of the present invention.
  • FIG. 1 an exploded cross-sectional view illustrating a conceptualized pressure sensitive transducer according to an embodiment of the present invention is shown.
  • An electronic pressure sensitive transducer shown generally by 20, produces an electrical signal indicative of applied pressure.
  • Pressure transducer 20 includes printed circuit board 22 accepting a plurality of electronic elements, not shown for clarity, for processing the transducer electrical signal.
  • Conductive traces 24 are formed on printed circuit board 22 to define contact area 26.
  • Flexible substrate 28 has inner surface 30 which faces contact area 26 when pressure transducer 20 is assembled.
  • At least one resistive layer 32 is deposited on inner surface 30.
  • Adhesive spacer 34 substantially surrounds contact area 26. Adhesive spacer 34 attaches flexible substrate 28 to printed circuit board 22. When assembled, resistive layer 32 contacts at least two traces 24 in response to pressure applied to flexible substrate 28 to produce electrical signals indicative of applied pressure.
  • Flexible substrate 28 with resistive layer 32 together with traces 24 on printed circuit board 22 implement a force sensing resistor (FSR), shown generally by 36.
  • FSR 36 force sensing resistor
  • SOB sensor on board
  • Conductive traces 24 on printed circuit board 22 may be formed by any suitable means known in the art.
  • traces 24 may be formed by depositing conductive material on printed circuit board 22 then selectively removing a portion of the conductive material to define traces 24.
  • Dimensions for conductive traces 24 depend on the dimensions of FSR 36, material and construction for flexible substrate 28, material and construction for resistive layers 32, and the like. Typical line thicknesses for conductive traces 24 range between 0.010 inches (0.25 mm) and 0.060 inches (1.5 mm).
  • Typical line spacing between conductive traces 24 ranges between 0.010 inches (0.25 mm) and 0.060 inches (1.5 mm). Positional tolerance of FSR 36 on printed circuit board 22 varies as well, with +0.015 inches ( ⁇ 0.4 mm) typical.
  • Two sets of interconnected traces 24 may be used to form a single zone within contact area 26. Multiple zones within contact area 26 permit location of pressure on flexible substrate 28 to be determined. Multiple zones may be obtained by using a plurality of sets of interconnected traces 24 and one interconnected set of common traces 24 extending into each zone. Alternatively, each zone may be defined by two or more separate sets of traces 24. Preferably, the sets of traces 24 in each zone are interdigitated.
  • Flexible substrate 28 may be constructed from any suitably flexible material such as, for example, Mylar.
  • the thickness of substrate 28 varies depending on the application and dimensions of FSR 36.
  • Preparing substrate 28 for resistive layers 32 entails cutting material for substrate 28 into sheets or other shapes suitable for printing or other methods of depositing resistive layers 32.
  • resistive layers 32 are deposited on substrate 28 by conventional means such as, for example, by screen printing resistive ink onto substrate 28. Resistive layers 32 may be printed over the entire substrate 28 or only over that portion which will cover operative traces 24 on printed circuit board 22. Resistive layers 32 may also be deposited such that several distinct regions are formed over that portion of substrate 28 which will cover operative traces 24 on printed circuit board 22.
  • Adhesive 34 is used to attach flexible substrate 28 to printed circuit board 22. Adhesive 34 also provides spacing between resistive layers 32 on substrate 28 and traces 24 on printed circuit board 22. Adhesive 34 may be applied to printed circuit board 22, to flexible substrate 28, or to both as suits manufacturability of FSR 36. Adhesive 34 may be applied to either surface in a conventional manner such as, for example, by depositing a bead of adhesive 34 around some or all of the perimeter of contact area 26. In a preferred embodiment, adhesive layer 34 comprises an adhesive ink screen printed onto substrate 28. Adhesive inks that may be used include product numbers SP-7533 from 3M or ML25184 from Acheson Industries, Inc. of Port Huron, Michigan. If adhesive 34 is applied to substrate 28 in advance of final assembly, a protective release liner may be cut or positioned over adhesive 34 to prevent inadvertent adhesion to other surfaces or airborne materials.
  • Substrate 28 may be formed into strips and kiss cut, or partially cut, into the desired final shape. Individual substrates 28 may then be easily separated by hand or machine immediately prior to assembly onto printed circuit board 22. Preferably, this final assembly step occurs after electronic components have been mounted on printed circuit board 22 to prevent heat damage to substrate 28 from soldering operations.
  • a pedestal shown generally by 38, may be formed on printed circuit board 22 in regions where substrate 28 is adhered to printed circuit board 22.
  • Pedestal 38 increases the distance that substrate 28 must be depressed prior to contact between resistive layer 22 and traces 24 on printed circuit board 22.
  • Pedestal 38 may be formed in a variety of manners. First, printed circuit board 22 may be manufactured with additional thickness to form pedestal 38. Second, one or more layers of conductive traces 40 may be built on printed circuit board 22 to form pedestal 38. Pedestal 38 is then covered with a non-conducting material 42, such as soldermask, to prevent inadvertent short circuits between traces 40 and resistive layer 32.
  • a non-conducting material 42 such as soldermask
  • pedestal 38 a polymer thick film may be deposited on printed circuit board 22 to form pedestal 38.
  • a sheet of material may be adhered to printed circuit board 22 to form pedestal 38.
  • pedestal 38 many constructions for pedestal 38 are possible.
  • Printed circuit board 22 includes traces 24 within contact area 26 forming four zones, each shown generally by 50.
  • Each zone 50 includes one set of traces 24 interconnected by line 52 which extends out of contact area 26 to through-hole 54.
  • Through-hole 54 permits traces 24 to be connected to electronics mounted on the bottom side of circuit board 22 by soldering processes known in the art.
  • Traces 52 may also connect traces 24 to electronic elements on the same side of printed circuit board 22 as traces 24.
  • Each zone 50 may also share a common set of interconnected traces joined to electronics on the back side of circuit board 22 via through-hole 56 in the center of contact area 26.
  • Traces 24 may be formed by any means which presents a conductive surface to resistive layer 32. Since air typically fills the gap between printed circuit board 22 and flexible substrate 28, traces 30 should resist corrosion. Traces 24 may be constructed, for example, by plating or coating copper traces with an oxidation preventing conductive material such as gold, silver, solder, carbon ink, and the like. Alternatively, traces 24 may be constructed by screen printing carbon, silver, or other conductive inks onto printed circuit board 22.
  • Traces 24 and at least a portion of pedestal 38 may be fabricated at the same time and of the same materials. This may result in traces 24 and the base of pedestal 38 extending the same height above board 22.
  • the height of pedestal 38 may be increased by the addition of solder mask or similar material and adhesive spacer 34. This typically will result in a distance between traces 24 and flexible substrate 28 sufficient to prevent inadvertent contact between resistive layer 32 and conductive traces 24. Simultaneous cofabrication of pedestal 38 and traces 24 together with the remainder of circuit board 22 results in very low incremental cost to circuit board 22.
  • Printed circuit board 22 includes screen printed carbon ink traces 24 within contact area 26 forming four zones 50. Due to the high resistivity of screen printed carbon ink, traces 24 are printed over copper pads 60 located just outside of contact area 26. Copper traces 62 connect pads 60 to through holes 54 or to electrical components on the same side of printed circuit board 22 as traces 24.
  • FIG 4 a top view of a pressure sensitive transducer constructed using the printed circuit board of Figures 2 or 3 according to an embodiment of the present invention is shown.
  • Flexible substrate 28 is shown adhered to pedestal 38 on printed circuit board 22. This results in FSR 36 directly constructed on printed circuit board 22.
  • Each contact area 26 includes two sets of interdigitated contacts 24.
  • Spacer 38 in this example a thin plastic sheet coated with adhesive on both sides, is adhered to printed circuit board 22. Spacer 38 includes an opening for each contact area 26.
  • Flexible substrate 28 is then adhered to spacer 38.
  • the entire inner surface 30 of flexible substrate 28 may be coated with one or more resistive layers 32. Alternatively, separate disconnected resistive layers 32 corresponding with each contact area 26 may be formed on flexible substrate 28.
  • Printed circuit board 22 includes six contact areas 26 with traces 24 formed by screen printing carbon ink onto printed circuit board 22. Copper pedestal 38 surrounds contact areas 26. Pedestal 38 may have a wide variety of shapes, but typically mirrors the outline of flexible substrate 28, not shown for clarity. Soldermask 42 covers much of circuit board 22 while leaving contact areas 26 exposed to contact resistive layer 32 on flexible substrate 28.
  • Printed circuit board 22 also contains electronic components, shown generally by 70, soldered to printed circuit board 22 for receiving electrical signals from traces 24 indicative of pressure applied to the FSRs.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Parts Printed On Printed Circuit Boards (AREA)
  • Measuring Fluid Pressure (AREA)

Abstract

The cost and complexity of an electronic pressure sensitive transducer (20) are decreased by constructing such a transducer directly on a printed circuit board (22) containing support electronics. Conductive traces (24) are formed on the printed circuit board (22) to define a contact area (26). A flexible substrate (28) having an inner surface is positioned over the contact area (26). An adhesive spacer (34), substantially surrounding the contact area (26), attaches the flexible substrate to the printed circuit board (22). At least one resistive layer (32) is deposited on the flexible substrate (28) inner surface. In use, the resistive layer (32) contacts at least two conductive traces (24) in response to pressure applied to the flexible substrate to produce an electrical signal indicative of applied pressure.

Description

ELECTRONIC PRESSURE SENSITIVE TRANSDUCER APPARATUS AND METHOD FOR MANUFACTURING SAME
BACKGROUND OF THE INVENTION
1. Field of the Invention
The Present invention relates to transducer systems for sensing pressure.
2. Background Art
Pressure sensitive transducers generate a signal indicative of the amount of pressure applied to a flexible membrane. Such transducers may also generate a signal based on the location of pressure applied to the flexible membrane. Such pressure sensitive transducers provide inputs for a wide variety of applications such as remote controls, game controllers, mouse pads, tactile sensors, and the like. Pressure sensitive transducers are typically coupled with electronics that condition and amplify pressure signals.
Various constructions for pressure sensitive transducers are possible. One type includes one or more force sensing resisters (FSRs). Various FSRs have been disclosed, such as those described in commonly assigned U.S. Patent Nos. 4,314,227; 4,314,228; and 4,489,302; each of which is hereby incorporated by reference in its entirety. Typically, an FSR is composed of three parts, a rigid base, a spacer, and a resistive membrane. Conductive traces are typically arranged in separated interdigitated sets on the base. These traces may be configured in a single zone or in multiple zones to allow, for example, pointing devices as described in commonly assigned U.S. Patent Nos. 5,659,334 and 5,828,363, each of which is hereby incorporated by reference in its entirety. The flexible resistive membrane is spaced apart from the base layer by a spacer, which is typically a ring of material around the outer edge of the conductive traces. The spacer is also typically coated with adhesive to hold the device together. The flexible top membrane may be made of a polymer coated on its inner face with semi-conductive or resistive ink, giving the FSR force sensing properties. This ink is described in commonly owned U.S. Patent Nos. 5,296,837 and 5,302,936, each of which is hereby incorporated by reference in its entirety.
In most practical applications, the FSR must be connected to sensing and conditioning electronics in order to effectively operate. One way this may be accomplished is by connecting the FSR to a printed circuit board containing the electronics with a multi-conductor cable. Another way of connecting the FSR to support electronics is to adhere the FSR base directly to the circuit board containing the electronics. Electrical connection may be made between traces on the FSR and corresponding traces on the printed circuit board using z-tape, which only conducts in a direction perpendicular to the tape surface. While either method is effective, both have unnecessary manufacturing steps and require unnecessary components, thus increasing the cost of a pressure sensitive transducer system as well as increasing the likelihood of system failure. What is needed is a pressure sensitive transducer and a method for making such a transducer that requires fewer components and fewer manufacturing steps without sacrificing transducer performance.
SUMMARY OF THE INVENTION
The present invention decreases the cost and complexity of an electronic pressure sensitive transducer by constructing such a transducer directly on a printed circuit board containing support electronics.
An electronic pressure sensitive transducer producing an electrical signal indicative of applied pressure is provided. The transducer includes a printed circuit board accepting a plurality of electronic elements for processing the transducer electrical signal. Conductive traces are formed on the printed circuit board to define a contact area. A flexible substrate having an inner surface is positioned over the contact area. An adhesive spacer substantially surrounds the contact area. The adhesive spacer attaches the flexible substrate to the printed circuit board. At least one resistive layer is deposited on the flexible substrate inner surface. The resistive layer contacts at least two of the traces in response to pressure applied to the flexible substrate to produce the electrical signal indicative of applied pressure.
In an embodiment of the present invention, at least one resistive layer is made with resistive ink.
In another embodiment of the present invention, a pedestal is formed on the printed circuit board substantially around the contact area. The pedestal receives the adhesive spacer for attaching the flexible substrate. The pedestal increases the space between resistive layers on the substrate and conductive traces on the printed circuit board. The pedestal may be formed by coating traces on the printed circuit board with a non-conductive material such as soldermask.
In yet another embodiment of the present invention, the conductive traces include a plurality of sets of traces. Each set of traces is interconnected within a zone of the contact area. An interconnected set of contact traces extends into each zone. At least one of the interconnected set of traces may be connected to the electronic elements for processing the transducer signal via a through-hole in the printed circuit board. The through-hole may be within the contact area.
In still another embodiment of the present invention, conductive traces are arranged in sets of interconnected traces. At least two sets of traces are interdigitated.
In a further embodiment of the present invention, conductive traces comprise copper traces covered with an oxidation preventing conductive material.
In a still further embodiment of the present invention, conductive traces comprise screen printed carbon ink. A method of forming an electronic pressure sensitive transducer on a printed circuit board is also provided. The printed circuit board accepts electronic components for producing signals generated by the pressure sensitive transducer. A plurality of conductive traces are formed on the printed circuit board to form a contact area. At least one resistive layer is deposited on an inner side of a flexible substrate. The flexible substrate is assembled on the printed circuit board such that the flexible substrate resistive layer is facing the printed circuit board conductive traces. The flexible substrate is held to the printed circuit board by an adhesive substantially surrounding at least a portion of the contact area.
A transducer system is also provided. The system includes a printed circuit board having a plurality of conductive traces. At least two of these traces define contact areas. The printed circuit board is constructed to accept electronic elements for processing electrical signals produced by a plurality of transducers. Each of these signals is indicative of pressure applied to at least one of the transducers. The system also includes at least one flexible substrate having an inner surface facing each contact area. At least one adhesive spacer substantially surrounds each contact layer to attach at least one flexible substrate to the printed circuit board. At least one resistive layer is deposited on a flexible substrate inner surface. Each resistive layer contacts at least two of the traces in response to pressure applied to the flexible substrate to produce an electrical signal indicative of applied pressure. The contact areas, at least one flexible substrate, at least one adhesive spacer and at least one resistive layer form the plurality of transducers, each transducer constructed on the printed circuit board.
A method of forming an electronic pressure sensitive transducer on a printed circuit board supporting electronic elements is also provided. A portion of conductive material on a printed circuit board is selectively removed to define traces in a contact area, traces connecting the electronic elements to the contact area, and at least a portion of a pedestal.
The above objects and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is an exploded cross-sectional view illustrating a conceptualized pressure sensitive transducer according to an embodiment of the present invention;
FIGURE 2 is a top view of a printed circuit board illustrating a four- zone contact area according to an embodiment of the present invention;
FIGURE 3 is a top view of a printed circuit board illustrating carbon traces according to an embodiment of the present invention;
FIGURE 4 is a top view of a pressure sensitive transducer constructed using the printed circuit board of Figure 2 or 3 according to an embodiment of the present invention;
FIGURE 5 is an exploded view illustrating conceptualized multiple single-zone FSRs in a pressure sensitive transducer according to an embodiment of the present invention; and
FIGURE 6 is a top view of a printed circuit board implementing multiple single-zone FSRs in a pressure sensitive transducer according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
Referring to Figure 1 , an exploded cross-sectional view illustrating a conceptualized pressure sensitive transducer according to an embodiment of the present invention is shown. An electronic pressure sensitive transducer, shown generally by 20, produces an electrical signal indicative of applied pressure. Pressure transducer 20 includes printed circuit board 22 accepting a plurality of electronic elements, not shown for clarity, for processing the transducer electrical signal. Conductive traces 24 are formed on printed circuit board 22 to define contact area 26. Flexible substrate 28 has inner surface 30 which faces contact area 26 when pressure transducer 20 is assembled. At least one resistive layer 32 is deposited on inner surface 30. Adhesive spacer 34 substantially surrounds contact area 26. Adhesive spacer 34 attaches flexible substrate 28 to printed circuit board 22. When assembled, resistive layer 32 contacts at least two traces 24 in response to pressure applied to flexible substrate 28 to produce electrical signals indicative of applied pressure.
Flexible substrate 28 with resistive layer 32 together with traces 24 on printed circuit board 22 implement a force sensing resistor (FSR), shown generally by 36. Integrating FSR 36 directly onto printed circuit board 22 creates a pressure sensor transducer which may be referred to as "sensor on board" (SOB). Such a construction eliminates some of the materials and manufacturing steps previously required to manufacture a pressure sensitive transducer.
Virtually any printed circuit board 22 can be adapted to receive FSR 36 according to the present invention, providing that sufficient surface space is available for FSR 36. This includes both rigid and flexible circuit boards. Conductive traces 24 on printed circuit board 22 may be formed by any suitable means known in the art. For example, traces 24 may be formed by depositing conductive material on printed circuit board 22 then selectively removing a portion of the conductive material to define traces 24. Dimensions for conductive traces 24 depend on the dimensions of FSR 36, material and construction for flexible substrate 28, material and construction for resistive layers 32, and the like. Typical line thicknesses for conductive traces 24 range between 0.010 inches (0.25 mm) and 0.060 inches (1.5 mm). Typical line spacing between conductive traces 24 ranges between 0.010 inches (0.25 mm) and 0.060 inches (1.5 mm). Positional tolerance of FSR 36 on printed circuit board 22 varies as well, with +0.015 inches (±0.4 mm) typical. Two sets of interconnected traces 24 may be used to form a single zone within contact area 26. Multiple zones within contact area 26 permit location of pressure on flexible substrate 28 to be determined. Multiple zones may be obtained by using a plurality of sets of interconnected traces 24 and one interconnected set of common traces 24 extending into each zone. Alternatively, each zone may be defined by two or more separate sets of traces 24. Preferably, the sets of traces 24 in each zone are interdigitated.
Flexible substrate 28 may be constructed from any suitably flexible material such as, for example, Mylar. The thickness of substrate 28 varies depending on the application and dimensions of FSR 36. Preparing substrate 28 for resistive layers 32 entails cutting material for substrate 28 into sheets or other shapes suitable for printing or other methods of depositing resistive layers 32.
One or more resistive layers 32 are deposited on substrate 28 by conventional means such as, for example, by screen printing resistive ink onto substrate 28. Resistive layers 32 may be printed over the entire substrate 28 or only over that portion which will cover operative traces 24 on printed circuit board 22. Resistive layers 32 may also be deposited such that several distinct regions are formed over that portion of substrate 28 which will cover operative traces 24 on printed circuit board 22.
Adhesive 34 is used to attach flexible substrate 28 to printed circuit board 22. Adhesive 34 also provides spacing between resistive layers 32 on substrate 28 and traces 24 on printed circuit board 22. Adhesive 34 may be applied to printed circuit board 22, to flexible substrate 28, or to both as suits manufacturability of FSR 36. Adhesive 34 may be applied to either surface in a conventional manner such as, for example, by depositing a bead of adhesive 34 around some or all of the perimeter of contact area 26. In a preferred embodiment, adhesive layer 34 comprises an adhesive ink screen printed onto substrate 28. Adhesive inks that may be used include product numbers SP-7533 from 3M or ML25184 from Acheson Industries, Inc. of Port Huron, Michigan. If adhesive 34 is applied to substrate 28 in advance of final assembly, a protective release liner may be cut or positioned over adhesive 34 to prevent inadvertent adhesion to other surfaces or airborne materials.
Substrate 28 may be formed into strips and kiss cut, or partially cut, into the desired final shape. Individual substrates 28 may then be easily separated by hand or machine immediately prior to assembly onto printed circuit board 22. Preferably, this final assembly step occurs after electronic components have been mounted on printed circuit board 22 to prevent heat damage to substrate 28 from soldering operations.
If additional space is required between printed circuit board 22 and substrate 28, a pedestal, shown generally by 38, may be formed on printed circuit board 22 in regions where substrate 28 is adhered to printed circuit board 22. Pedestal 38 increases the distance that substrate 28 must be depressed prior to contact between resistive layer 22 and traces 24 on printed circuit board 22. Pedestal 38 may be formed in a variety of manners. First, printed circuit board 22 may be manufactured with additional thickness to form pedestal 38. Second, one or more layers of conductive traces 40 may be built on printed circuit board 22 to form pedestal 38. Pedestal 38 is then covered with a non-conducting material 42, such as soldermask, to prevent inadvertent short circuits between traces 40 and resistive layer 32. Third, a polymer thick film may be deposited on printed circuit board 22 to form pedestal 38. Fourth, a sheet of material may be adhered to printed circuit board 22 to form pedestal 38. As will be recognized by one of ordinary skill in the art, many constructions for pedestal 38 are possible.
Referring now to Figure 2, a top view of a printed circuit board illustrating a four-zone contact area according to an embodiment of the present invention is shown. Printed circuit board 22 includes traces 24 within contact area 26 forming four zones, each shown generally by 50. Each zone 50 includes one set of traces 24 interconnected by line 52 which extends out of contact area 26 to through-hole 54. Through-hole 54 permits traces 24 to be connected to electronics mounted on the bottom side of circuit board 22 by soldering processes known in the art. Traces 52 may also connect traces 24 to electronic elements on the same side of printed circuit board 22 as traces 24. Each zone 50 may also share a common set of interconnected traces joined to electronics on the back side of circuit board 22 via through-hole 56 in the center of contact area 26.
Traces 24 may be formed by any means which presents a conductive surface to resistive layer 32. Since air typically fills the gap between printed circuit board 22 and flexible substrate 28, traces 30 should resist corrosion. Traces 24 may be constructed, for example, by plating or coating copper traces with an oxidation preventing conductive material such as gold, silver, solder, carbon ink, and the like. Alternatively, traces 24 may be constructed by screen printing carbon, silver, or other conductive inks onto printed circuit board 22.
Traces 24 and at least a portion of pedestal 38 may be fabricated at the same time and of the same materials. This may result in traces 24 and the base of pedestal 38 extending the same height above board 22. The height of pedestal 38 may be increased by the addition of solder mask or similar material and adhesive spacer 34. This typically will result in a distance between traces 24 and flexible substrate 28 sufficient to prevent inadvertent contact between resistive layer 32 and conductive traces 24. Simultaneous cofabrication of pedestal 38 and traces 24 together with the remainder of circuit board 22 results in very low incremental cost to circuit board 22.
Referring now to Figure 3, a top view of a printed circuit board with carbon ink traces according to an embodiment of the present invention is shown. Printed circuit board 22 includes screen printed carbon ink traces 24 within contact area 26 forming four zones 50. Due to the high resistivity of screen printed carbon ink, traces 24 are printed over copper pads 60 located just outside of contact area 26. Copper traces 62 connect pads 60 to through holes 54 or to electrical components on the same side of printed circuit board 22 as traces 24.
Referring now to Figure 4, a top view of a pressure sensitive transducer constructed using the printed circuit board of Figures 2 or 3 according to an embodiment of the present invention is shown. Flexible substrate 28 is shown adhered to pedestal 38 on printed circuit board 22. This results in FSR 36 directly constructed on printed circuit board 22.
Referring now to Figure 5, an exploded view illustrating multiple single-zone FSRs in a pressure sensitive transducer according to an embodiment of the present invention is shown. Six FSRs are shown. Each contact area 26 includes two sets of interdigitated contacts 24. Spacer 38, in this example a thin plastic sheet coated with adhesive on both sides, is adhered to printed circuit board 22. Spacer 38 includes an opening for each contact area 26. Flexible substrate 28 is then adhered to spacer 38. The entire inner surface 30 of flexible substrate 28 may be coated with one or more resistive layers 32. Alternatively, separate disconnected resistive layers 32 corresponding with each contact area 26 may be formed on flexible substrate 28.
Referring now to Figure 6, a top view of a printed circuit board implementing multiple single-zone FSRs in a pressure sensitive transducer according to an embodiment of the present invention is shown. Printed circuit board 22 includes six contact areas 26 with traces 24 formed by screen printing carbon ink onto printed circuit board 22. Copper pedestal 38 surrounds contact areas 26. Pedestal 38 may have a wide variety of shapes, but typically mirrors the outline of flexible substrate 28, not shown for clarity. Soldermask 42 covers much of circuit board 22 while leaving contact areas 26 exposed to contact resistive layer 32 on flexible substrate 28. Printed circuit board 22 also contains electronic components, shown generally by 70, soldered to printed circuit board 22 for receiving electrical signals from traces 24 indicative of pressure applied to the FSRs.
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.

Claims

WHAT IS CLAIMED IS:
1. An electronic pressure sensitive transducer producing an electrical signal indicative of applied pressure, the transducer comprising: a printed circuit board accepting a plurality of electronic elements for processing the transducer electrical signal; a plurality of conductive traces formed on the printed circuit board to define a contact area; a flexible substrate having an inner surface positioned over the contact area; an adhesive spacer substantially surrounding the contact area, the adhesive spacer attaching the flexible substrate to the printed circuit board; and at least one resistive layer deposited on the flexible substrate inner surface, the resistive layer contacting at least two of the traces in response to pressure applied to the flexible substrate to produce the electrical signal indicative of applied pressure.
2. An electronic pressure sensitive transducer as in claim 1 wherein at least one resistive layer comprises resistive ink.
3. An electronic pressure sensitive transducer as in claim 1 further comprising a pedestal formed on the printed circuit board substantially around the contact area, the pedestal receiving the adhesive spacer.
4. An electronic pressure sensitive transducer as in claim 3 wherein the pedestal comprises conductive traces covered with a non-conductive material.
5. An electronic pressure sensitive transducer as in claim 1 wherein the plurality of conductive traces comprise: a plurality of sets of traces, each set of traces interconnected within a zone of the contact area; and an interconnected set of common traces extending into each zone.
6. An electronic pressure sensitive transducer as in claim 5 wherein at least one interconnected set of traces is connected to the electronic elements for processing the transducer electrical signal via a through-hole in the printed circuit board.
7. An electronic pressure sensitive transducer as in claim 6 wherein the through-hole is within the contact area.
8. An electronic pressure sensitive transducer as in claim 1 wherein conductive traces are arranged in interconnected sets, with at least two sets of traces interdigitated.
9. An electronic pressure sensitive transducer as in claim 1 wherein conductive traces comprise copper traces covered with an oxidation preventing conductive material.
10. An electronic pressure sensitive transducer as in claim 1 wherein conductive traces comprise screen printed carbon ink.
11. A method of forming an electronic pressure sensitive transducer on a printed circuit board, the printed circuit board accepting a plurality of electronic components for processing signals generated by the pressure sensitive transducer, the method comprising: forming a plurality of conductive traces on the printed circuit board to form a contact area; depositing at least one resistive layer on an inner side of a flexible substrate; and assembling the flexible substrate on the printed circuit board such that the flexible substrate resistive layer is facing the printed circuit board conductive traces, the flexible substrate held to the printed circuit board by an adhesive substantially surrounding at least a portion of the contact area.
12. A method of forming an electronic pressure sensitive transducer on a printed circuit board as in claim 11 wherein at least one resistive layer comprises resistive ink.
13. A method of forming an electronic pressure sensitive transducer on a printed circuit board as in claim 11 wherein assembling comprises screen printing the adhesive on at least one of the flexible substrate and the printed circuit board.
14. A method of forming an electronic pressure sensitive transducer on a printed circuit board as in claim 11 further comprising forming a pedestal on the printed circuit board substantially around the contact area, the adhesive contacting the pedestal when assembled.
15. A method of forming an electronic pressure sensitive transducer on a printed circuit board as in claim 14 wherein forming a pedestal comprises forming traces on the printed circuit board in the shape of the pedestal and covering the pedestal traces with a non-conducting material.
16. A method of forming an electronic pressure sensitive transducer on a printed circuit board as in claim 15 wherein the traces forming the pedestal are formed in the same process as the traces forming the contact area.
17. A method of forming an electronic pressure sensitive transducer on a printed circuit board as in claim 11 wherein the plurality of conductive traces are formed as a plurality of sets of zonal traces, each set of zonal traces interconnected within a zone of the contact area, and as an interconnected set of common traces extending into each zone.
18. A method of forming an electronic pressure sensitive transducer on a printed circuit board as in claim 11 wherein the plurality of conductive traces are formed in interconnected sets, with at least two sets of interconnected traces interdigitated within the contact area.
19. A method of forming an electronic pressure sensitive transducer on a printed circuit board as in claim 11 wherein forming a plurality of conductive traces comprises depositing an oxidation preventing conductive material over copper traces.
20. A method of forming an electronic pressure sensitive transducer on a printed circuit board as in claim 11 wherein forming a plurality of conductive traces comprises screen printing a carbon ink.
21. A printed circuit board electronic pressure sensitive transducer assembly comprising: a printed circuit board accepting a plurality of electronic elements for processing pressure transducer electrical signals; a plurality of conductive traces formed on the printed circuit board to define a contact area; a flexible substrate having an inner surface positioned over the contact area; an adhesive spacer substantially surrounding the contact area, the adhesive spacer attaching the flexible substrate to the printed circuit board; and at least one resistive layer comprising a resistive ink deposited on the flexible substrate inner surface, the resistive layer contacting at least two of the contact area conductive traces in response to pressure applied to the flexible substrate.
22. A printed circuit board electronic pressure sensitive transducer assembly as in claim 21 further comprising a pedestal formed on the printed circuit board, the pedestal substantially surrounding the contact area, the pedestal receiving the adhesive spacer.
23. A printed circuit board electronic pressure sensitive transducer assembly as in claim 22 wherein the pedestal comprises a conductive material coated with a non-conductive material, the conductive material formed on the printed circuit board.
24. A printed circuit board electronic pressure sensitive transducer assembly as in claim 21 wherein the plurality of conductive traces comprise: a plurality of sets of traces, each set of traces interconnected within a zone of the contact area; and an interconnected set of common traces extending into each zone.
25. A printed circuit board electronic pressure sensitive transducer assembly as in claim 24 wherein at least one interconnected set of traces is connected to the electronic elements for processing the transducer electrical signal via a through-hole in the printed circuit board.
26. A printed circuit board electronic pressure sensitive transducer assembly as in claim 25 wherein the through-hole is within the contact area.
27. A printed circuit board electronic pressure sensitive transducer assembly as in claim 21 wherein conductive traces are arranged in interconnected sets, with at least two sets of traces interdigitated.
28. An electronic pressure sensitive transducer as in claim 21 wherein the adhesive spacer comprises adhesive ink.
29. A printed circuit board electronic pressure sensitive transducer assembly as in claim 21 wherein conductive traces comprise copper traces covered with an oxidation preventing conductive material.
30. A printed circuit board electronic pressure sensitive transducer assembly as in claim 21 wherein conductive traces comprise screen printed carbon ink.
31. A printed circuit board electronic pressure sensitive transducer assembly comprising: a printed circuit board accepting a plurality of electronic elements for processing pressure transducer electrical signals; a plurality of conductive traces formed on the printed circuit board to define a contact area; a pedestal substantially surrounding the contact area, the pedestal forming a flat area higher than the conductive traces; a flexible substrate having an inner surface positioned over the contact area; an adhesive spacer substantially surrounding the contact area, the adhesive spacer attaching the flexible substrate to the pedestal; and at least one resistive layer deposited on the flexible substrate inner surface, the resistive layer contacting at least two of the contact area conductive traces in response to pressure applied to the flexible substrate.
32. A printed circuit board electronic pressure sensitive transducer assembly as in claim 31 wherein the pedestal is formed by depositing a non- conductive layer over a conductive layer, the conductive layer formed on the printed circuit board.
33. An electronic pressure sensitive" transducer as in claim 31 wherein at least one resistive layer comprises resistive ink.
34. An electronic pressure sensitive transducer as in claim 31 wherein the adhesive spacer comprises adhesive ink.
35. A printed circuit board electronic pressure sensitive transducer assembly as in claim 31 wherein the plurality of conductive traces comprise: a plurality of sets of traces, each set of traces interconnected within a zone of the contact area; and an interconnected set of common traces extending into each zone.
36. A printed circuit board electronic pressure sensitive transducer assembly as in claim 35 wherein at least one interconnected set of traces is connected to the electronic elements for processing the transducer electrical signal via a through-hole in the printed circuit board.
37. A printed circuit board electronic pressure sensitive transducer assembly as in claim 36 wherein the through-hole is within the contact area.
38. A printed circuit board electronic pressure sensitive transducer assembly as in claim 31 wherein conductive traces are arranged in interconnected sets, with at least two sets of traces interdigitated.
39. A printed circuit board electronic pressure sensitive transducer assembly as in claim 31 wherein conductive traces comprise copper traces coated with an oxidation preventing conductive material.
40. A printed circuit board electronic pressure sensitive transducer assembly as in claim 31 wherein conductive traces comprise screen printed carbon ink.
41. A method of forming a printed circuit board electronic pressure sensitive transducer assembly comprising: forming on the printed circuit board a plurality of conductive traces to form a contact area; forming on the printed circuit board a plurality of conductive traces connecting the contact area with conductive pads for receiving electronic elements, the electronic elements processing pressure transducer signals; soldering the electronic elements to the printed circuit board conductive pads; printing a resistive layer on a flexible substrate; printing an adhesive layer over a portion of the resistive layer; and assembling the flexible substrate on the printed circuit board by contacting the adhesive with the printed circuit board such that the resistive layer faces the contact area.
42. A method of forming a printed circuit board electronic pressure sensitive transducer assembly as in claim 41 further comprising forming a raised pedestal on the printed circuit board substantially surrounding the contact area, the pedestal contacting the adhesive layer.
43. A method of forming a printed circuit board electronic pressure sensitive transducer assembly as in claim 42 wherein the pedestal is formed by forming conductive material on the printed circuit board and depositing non- conductive material on the conductive material.
44. A method of forming a printed circuit board electronic pressure sensitive transducer assembly as in claim 43 wherein the traces forming the pedestal are formed in the same process as the traces forming the contact area.
45. A transducer system comprising: a printed circuit board having a plurality of conductive traces, at least two of the traces defining each of a plurality of contact areas, the printed circuit board accepting electronic elements for processing electrical signals produced by a plurality of transducers, each signal indicative of pressure applied to at least one of the transducers; at least one flexible substrate having an imier surface, one flexible substrate inner surface facing each contact area; at least one adhesive spacer substantially surrounding each contact layer, each adhesive spacer attaching at least one flexible substrate to the printed circuit board; and at least one resistive layer deposited on the at least one flexible substrate inner surface, each resistive layer contacting at least two of the traces in response to pressure applied to the at least one flexible substrate to produce the electrical signal indicative of the applied pressure; wherein the plurality of contact areas, the at least one flexible substrate, the at least one adhesive spacer and the at least one resistive layer form the plurality of transducers, each transducer constructed on the printed circuit board.
46. A transducer system as in claim 45 wherein the at least one flexible substrate is a single substrate.
47. A transducer system as in claim 45 wherein the at least one adhesive spacer is a single adhesive spacer.
48. A transducer system as in claim 45 further comprising at least one pedestal formed on the printed circuit board substantially around at least one contact areas, the pedestal receiving at least one adhesive spacer.
49. A transducer system as in claim 48 wherein the at least one pedestal is a single pedestal formed substantially around all of the plurality of contact areas.
50. A transducer system as in claim 48 wherein the at least one pedestal comprises conductive traces covered with a non-conductive material.
ι
51. A transducer system as m claim 45 wherem conductive traces defining at least one contact area comprise copper traces covered with an oxidation preventing conductive material.
52. A transducer system as in claim 45 wherein conductive traces defining at least one contact area comprise screen printed carbon ink.
53. A method of forming an electronic pressure sensitive transducer on a printed circuit board supporting electronic elements, the transducer having a flexible substrate with at least one resistive layer on an inner side of the flexible substrate facing the printed circuit board, the resistive layer contacting conductive traces in a contact area on the printed circuit board when pressure is applied to an outer side of the flexible substrate, the transducer further having a pedestal formed substantially around the contact area, the printed circuit board further having conductive traces connecting the electronic elements to the contact area, the method comprising: depositing conductive material on the printed circuit board; and selectively removing a portion of the deposited conductive material to define the traces in the contact area, the traces connecting the electronic elements to the contact area, and at least a portion of the pedestal.
PCT/US2002/003675 2001-02-08 2002-02-07 Electronic pressure sensitive transducer apparatus and method for manufacturing same WO2002063261A2 (en)

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US6909354B2 (en) 2005-06-21
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JP4261186B2 (en) 2009-04-30
US7213323B2 (en) 2007-05-08
US20020104369A1 (en) 2002-08-08
JP2004525360A (en) 2004-08-19
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WO2002063261A3 (en) 2002-10-17
US20050156705A1 (en) 2005-07-21

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