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CN101464126A - Production method of integrated submissive sensor for measuring curve clearance and force - Google Patents

Production method of integrated submissive sensor for measuring curve clearance and force Download PDF

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CN101464126A
CN101464126A CNA2009100761228A CN200910076122A CN101464126A CN 101464126 A CN101464126 A CN 101464126A CN A2009100761228 A CNA2009100761228 A CN A2009100761228A CN 200910076122 A CN200910076122 A CN 200910076122A CN 101464126 A CN101464126 A CN 101464126A
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conductive polymer
sensitive element
eddy current
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sensor
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CN101464126B (en
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王鹏
丁天怀
胡颖
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Tsinghua University
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Abstract

本发明涉及一种测量曲面间隙和力的集成化柔顺式传感器的制备方法,属于传感器技术领域。分别制备平面电涡流敏感元件和超薄柔顺导电高分子敏感元件:利用定位胶和封装胶,将已经粘贴超薄柔顺导电高分子敏感元件的平面电涡流敏感元件的基底周边涂覆具有热固性的封装胶,利用封装胶将另一层平面电涡流敏感元件粘附在表面,得到集成化柔顺式传感器,粘附时,使上、下两层平面电涡流线圈、内引线和开孔分别相对。本方法制备的传感器,能够同时测量曲面间隙和挤压力;可以贴附在任意形状的表面间进行测量,适合安装在狭小的空间进行测量;能应用在高温、辐射等测量场合;而且测量量程宽,测量精度高。

The invention relates to a preparation method of an integrated flexible sensor for measuring curved surface gap and force, and belongs to the technical field of sensors. Prepare the planar eddy current sensitive element and the ultra-thin compliant conductive polymer sensitive element respectively: use positioning glue and packaging glue to coat the base periphery of the planar eddy current sensitive element pasted with the ultra-thin compliant conductive polymer sensitive element with thermosetting encapsulation Glue, another layer of planar eddy current sensitive element is adhered to the surface with packaging glue to obtain an integrated flexible sensor. When adhering, the upper and lower layers of planar eddy current coils, inner leads and openings are opposite to each other. The sensor prepared by this method can measure the surface gap and extrusion force at the same time; it can be attached to any shape of the surface for measurement, and it is suitable for installation in a narrow space for measurement; it can be used in high temperature, radiation and other measurement occasions; and the measurement range Wide, high measurement accuracy.

Description

一种测量曲面间隙和力的集成化柔顺式传感器的制备方法 Preparation method of an integrated compliant sensor for measuring surface gap and force

技术领域 technical field

本发明涉及一种测量曲面间隙和力的集成化柔顺式传感器的制备方法,属于传感器技术领域。The invention relates to a preparation method of an integrated flexible sensor for measuring curved surface gap and force, and belongs to the technical field of sensors.

背景技术 Background technique

“柔顺传感器”概念的提出可以追溯到上世纪80年代末期,航空航天器中的许多特殊结构给传统刚性传感器的安装带来了很大困难。人们希望传感器具有良好的柔顺性能,不受被测物体形状限制,能够贴附于各种规则或不规则曲面实现正常的传感功能。进入上世纪90年代以后,美国、法国、日本、瑞士和葡萄牙等国家的科学家开始进行柔顺传感器的研究工作,许多新型的传感器材料和结构被应用到这一研究领域之中。The concept of "compliant sensor" can be traced back to the late 1980s. Many special structures in aerospace vehicles have brought great difficulties to the installation of traditional rigid sensors. People hope that the sensor has good flexibility, is not limited by the shape of the object to be measured, and can be attached to various regular or irregular surfaces to achieve normal sensing functions. After entering the 1990s, scientists in the United States, France, Japan, Switzerland, Portugal and other countries began to conduct research on compliant sensors, and many new sensor materials and structures were applied to this research field.

2001年,美国传感器领域的知名学者Lumelsky教授对柔顺传感器的发展方向提出了大胆的设想。Lumelsky教授认为,敏感表皮将是一种大面积的柔顺传感器阵列,就像人体的皮肤一样,能够覆盖整个测量机构的表面。它具有感知外界环境的能力,能够较为准确地测量挤压力、剪切力、接近距离、光强、温度、湿度和某些气体浓度的变化,从而帮助一些自主控制机构(例如:机器人)在复杂的环境中准确地执行任务。可以预见,柔顺传感器技术将给传感器领域带来一场新的革命,并将带动工业自动化、医疗卫生、航空航天、环境监测、机器人等领域中相关技术的发展。In 2001, Professor Lumelsky, a well-known scholar in the field of sensors in the United States, put forward a bold vision for the development direction of compliant sensors. Professor Lumelsky believes that the sensitive epidermis will be a large-area array of compliant sensors, like the human skin, able to cover the entire surface of the measuring mechanism. It has the ability to perceive the external environment, and can more accurately measure changes in extrusion force, shear force, proximity distance, light intensity, temperature, humidity, and certain gas concentrations, thereby helping some autonomous control mechanisms (such as: robots) Accurately perform tasks in complex environments. It can be predicted that compliant sensor technology will bring a new revolution to the field of sensors, and will drive the development of related technologies in the fields of industrial automation, medical and health, aerospace, environmental monitoring, and robotics.

(1)柔顺式电涡流传感器:在2004年的第16届世界无损检测会议上,法国人C.Gilles-Pascaud展示了一种最新研究的应用于航空领域中表面阻断裂纹检测的传感器阵列探头。该仪器包括一组含有32个敏感单元的电涡流线圈阵列和一个高分辨率的摄像头,能够实现对表面潜在裂纹实时、完整和可靠的检测,并可很好的应用于各种合金材料,裂纹深度的检测精度约为0.2mm。该系统最大的特点就是实现了两种不同检测技术的实时融合,从而提高了对小的表面阻断裂纹的检测能力。由此可见,加工在柔性基底材料上的柔顺式电涡流传感器可以很好地应用于曲面间隙测量和曲面体裂纹检测。(1) Compliant eddy current sensor: At the 16th World Conference on Nondestructive Testing in 2004, Frenchman C.Gilles-Pascaud demonstrated a newly researched sensor array probe used in the detection of surface resistance cracks in the aviation field . The instrument includes a set of eddy current coil arrays containing 32 sensitive units and a high-resolution camera, which can realize real-time, complete and reliable detection of potential surface cracks, and can be well applied to various alloy materials, cracks The depth detection accuracy is about 0.2mm. The biggest feature of this system is that it realizes the real-time fusion of two different detection technologies, thereby improving the detection ability of small surface resistance cracks. It can be seen that the compliant eddy current sensor processed on the flexible substrate material can be well applied to the measurement of the gap between curved surfaces and the detection of cracks on curved surfaces.

(2)导电高分子材料柔顺式力传感器:导电高分子复合材料指近年来常见的导电橡胶、导电塑料、导电涂料、导电胶粘剂和导电薄膜等。导电高分子复合材料分为填充型和化合型两种,前者是将导电颗粒混合入聚合物基体中形成导电通道,是两种以上材料的混合体;而后者只是单一材料,自身具有导电性。功能材料领域的研究发现,填充型导电高分子复合材料具有压阻效应,因此一些研究机构利用其作为敏感元件材料,研制了柔顺力传感器。(2) Conductive polymer material compliant force sensor: Conductive polymer composite materials refer to conductive rubber, conductive plastic, conductive paint, conductive adhesive and conductive film that have been common in recent years. Conductive polymer composite materials are divided into two types: filled type and compound type. The former is a mixture of two or more materials that mixes conductive particles into the polymer matrix to form a conductive channel; while the latter is only a single material with conductivity itself. Research in the field of functional materials has found that filled conductive polymer composites have piezoresistive effects, so some research institutions have used them as sensitive element materials to develop compliant force sensors.

美国Tekscan公司从上世纪90年代开始,就一直进行柔顺传感器的研究工作。2003年,该公司推出了一种导电高分子复合材料柔顺力传感器,该传感器面积由十几平方厘米到一平方米不等,厚度为0.15mm。传感器敏感单元由上下两层电极和一层导电高分子复合材料构成,引线长度可达到700mm。采用聚酰亚胺膜将上下两层电极和一层导电高分子复合材料封装成一个传感器整体,保证了柔韧性和可靠性,最小允许弯曲半径达到100mm。Tekscan Corporation of the United States has been conducting research on compliant sensors since the 1990s. In 2003, the company launched a compliant force sensor made of conductive polymer composite material, with an area ranging from a dozen square centimeters to one square meter and a thickness of 0.15mm. The sensitive unit of the sensor is composed of upper and lower layers of electrodes and a layer of conductive polymer composite material, and the length of the lead wire can reach 700mm. The upper and lower layers of electrodes and a layer of conductive polymer composite material are packaged into a sensor as a whole by polyimide film, which ensures flexibility and reliability, and the minimum allowable bending radius reaches 100mm.

总而言之,导电高分子复合材料柔顺力传感器具有柔顺性能好、测力量程和有效面积大,加工工艺比较简单、加工费用较低等优点。All in all, the conductive polymer composite compliant force sensor has the advantages of good compliance, large measuring range and effective area, relatively simple processing technology, and low processing cost.

综上所述,柔顺式电涡流传感器和柔顺式力传感器可以分别很好地测量曲面间隙和曲面间挤压力。但是,随着科技及生产的发展,某些重大设备关键零部件的形状越来越复杂,其加工和装配定位精度要求越来越高,对测量提出的要求也就越高。薄壁回转曲面一类形面的零件被广泛应用于国防及各种日常生活产品中,而这些零件的加工、测量、监控往往因受到空间结构尺寸及被测材料介质等一些特殊条件的限制而增大了难度。当在同一曲面间测量间隙和挤压力时,需要安装两种传感器,安装位置和引线方式经常会受到空间结构的制约而无法实现。In summary, the compliant eddy current sensor and the compliant force sensor can measure the surface gap and the extrusion force between surfaces well, respectively. However, with the development of science and technology and production, the shapes of key parts of some major equipment are becoming more and more complex, and the requirements for processing and assembly positioning accuracy are getting higher and higher, and the requirements for measurement are also higher. Parts with thin-walled surfaces of revolution are widely used in national defense and various daily life products, and the processing, measurement and monitoring of these parts are often limited by special conditions such as the size of the space structure and the medium of the material to be measured. Increased difficulty. When measuring the gap and extrusion force between the same curved surfaces, two kinds of sensors need to be installed, and the installation position and lead wire method are often restricted by the space structure and cannot be realized.

发明内容 Contents of the invention

本发明的目的是提出一种测量曲面间隙和力的集成化柔顺式传感器,克服已有技术的不足,使传感器具有结构纤薄、柔顺性好、量程大、精度高、分辨率高、能够同时测量间隙和挤压力的特点,以适合用于工业生产和人体医疗康复过程中曲面间隙和挤压力的在线检测。The purpose of the present invention is to propose an integrated flexible sensor for measuring the surface gap and force, which overcomes the deficiencies of the prior art, and makes the sensor have a thin structure, good flexibility, large range, high precision, high resolution, and can simultaneously The characteristics of measuring gap and extrusion force are suitable for online detection of curved surface gap and extrusion force in industrial production and human medical rehabilitation.

本发明提出的测量曲面间隙和力的集成化柔顺式传感器的制备方法,包括以下步骤:The preparation method of the integrated compliant sensor for measuring surface gap and force proposed by the present invention comprises the following steps:

(1)制备平面电涡流敏感元件:(1) Preparation of planar eddy current sensitive elements:

(1—1)在聚酰亚胺薄膜基底上按行和列开孔,聚酰亚胺薄膜的厚度为100μm—200μm,开孔的孔径为250—350μm;(1-1) Open holes in rows and columns on the polyimide film substrate, the thickness of the polyimide film is 100 μm-200 μm, and the aperture of the holes is 250-350 μm;

(1—2)在聚酰亚胺薄膜基底的正反两个表面以及上述开孔的表面上分别镀复铜箔,铜箔的厚度为15μm—20μm;(1-2) Copper foil is respectively plated on the front and back surfaces of the polyimide film substrate and the surface of the above-mentioned opening, and the thickness of the copper foil is 15 μm-20 μm;

(1—3)对上述反面铜箔进行光刻,以上述开孔为中心形成电涡流线圈,在每个电涡流线圈的一侧形成内引线,对上述正面铜箔进行光刻,在上述开孔之间形成外引线;(1-3) Photolithography is carried out on the above-mentioned reverse copper foil, an eddy current coil is formed centering on the above-mentioned opening, an inner lead is formed on one side of each eddy-current coil, the above-mentioned front copper foil is photo-etched, and an electric current coil is formed on the above-mentioned opening. Outer leads are formed between the holes;

(2)制备超薄柔顺导电高分子敏感元件:(2) Preparation of ultra-thin and flexible conductive polymer sensitive elements:

(2—1)将粒径小于1微米的导电炭黑粉末、粒径为10—50纳米的二氧化硅分散剂粉末和液态单组份硅橡胶在浓度为95%以上的丙酮有机溶剂中混合,混合时各成分的体积百分比浓度为:单组份硅橡胶:导电炭黑粉末:二氧化硅分散剂粉末:丙酮有机溶剂=100:10—15:1—3:300—500;(2-1) Mix the conductive carbon black powder with a particle size of less than 1 micron, the silicon dioxide dispersant powder with a particle size of 10-50 nanometers, and the liquid one-component silicone rubber in an acetone organic solvent with a concentration of more than 95%. , the volume percent concentration of each composition when mixing is: single-component silicone rubber: conductive carbon black powder: silicon dioxide dispersant powder: acetone organic solvent=100:10—15:1—3:300—500;

(2—2)在超声振荡下进行机械搅拌,搅拌环境温度为40-60℃,搅拌时间为2-4小时,得到凝胶状态混合体;(2-2) Perform mechanical stirring under ultrasonic vibration, the temperature of the stirring environment is 40-60° C., and the stirring time is 2-4 hours to obtain a gel state mixture;

(2—3)将占上述混合体总体积量的3—5%的顺丁橡胶颗粒加入到该混合体中,继续机械搅拌20-30分钟,使丙酮挥发;(2-3) Add 3-5% butadiene rubber particles accounting for the total volume of the mixture into the mixture, continue mechanical stirring for 20-30 minutes, and volatilize the acetone;

(2—4)将上述丙酮挥发后的混合体滴入旋转平台,旋涂成型,得到厚度为70—100微米的导电高分子膜;(2-4) dripping the above-mentioned acetone volatilized mixture into the rotating platform, and spin-coating to obtain a conductive polymer film with a thickness of 70-100 microns;

(2—5)将占上述导电高分子膜总体积1%的正硅酸乙脂交联剂和占上述导电高分子膜总体积2%的二月桂酸二丁基锡催化剂混合成溶液,将该混合溶液涂在上述导电高分子膜的表面,使导电高分子膜硫化,硫化时间为24小时以上,得到超薄柔顺导电高分子敏感元件;(2-5) the tetraethyl orthosilicate crosslinking agent accounting for 1% of the total volume of the above-mentioned conductive polymer film and the dibutyltin dilaurate catalyst accounting for 2% of the total volume of the above-mentioned conductive polymer film are mixed into a solution, and the mixed The solution is coated on the surface of the conductive polymer film to vulcanize the conductive polymer film, and the vulcanization time is more than 24 hours to obtain an ultra-thin and flexible conductive polymer sensitive element;

(3)集成化柔顺式传感器的封装:(3) Packaging of integrated flexible sensors:

(3—1)在上述平面电涡流敏感元件的每相邻两列电涡流线圈之间涂覆一层定位胶;(3-1) Coating a layer of positioning glue between every adjacent two rows of eddy current coils of the above-mentioned planar eddy current sensitive element;

(3—2)将上述制备的超薄柔顺导电高分子敏感元件剪成条状,将剪成条状的超薄柔顺导电高分子敏感元件粘贴在上述定位胶上;(3-2) Cut the ultra-thin and compliant conductive polymer sensitive element prepared above into strips, and paste the ultra-thin and compliant conductive polymer sensitive element cut into strips on the above-mentioned positioning glue;

(3—3)在上述已经粘贴超薄柔顺导电高分子敏感元件的平面电涡流敏感元件的基底周边涂覆具有热固性的封装胶,利用封装胶将另一层平面电涡流敏感元件粘附在表面,得到集成化柔顺式传感器,粘附时,使上、下两层平面电涡流线圈、内引线和开孔分别相对。(3-3) Coat the periphery of the substrate of the above-mentioned planar eddy current sensitive element pasted with ultra-thin and flexible conductive polymer sensitive element with thermosetting encapsulation glue, and use the encapsulation glue to adhere another layer of planar eddy current sensitive element to the surface , to obtain an integrated flexible sensor, when adhering, the upper and lower layers of planar eddy current coils, inner leads and openings are respectively opposite.

本发明提出的测量曲面间隙和力的集成化柔顺式传感器的制备方法,其优点是:The preparation method of the integrated compliant sensor for measuring surface gap and force proposed by the present invention has the advantages of:

1、本发明制备的集成化柔顺式传感器的集成化敏感元件,将超薄平面电涡流线圈和导电高分子力敏感元件集成在同一柔性基底材料上,能够同时测量曲面间隙和挤压力。1. The integrated sensitive element of the integrated flexible sensor prepared by the present invention integrates the ultra-thin planar eddy current coil and the conductive polymer force sensitive element on the same flexible substrate material, and can simultaneously measure the surface gap and extrusion force.

2、本发明制备的集成化柔顺式传感器中的导电高分子力敏感元件,采用了新型的材料设计和加工工艺,具有大的量程,以及高的力敏精度和分辨率。2. The conductive polymer force sensitive element in the integrated flexible sensor prepared by the present invention adopts a new material design and processing technology, has a large measuring range, and high force-sensing precision and resolution.

3、本发明制备的集成化柔顺式传感器中的超薄平面电涡流线圈及其引出电缆具有良好的柔顺性。因此,传感器可以贴附在任意形状的表面间进行测量。而传统的电涡流传感器无法安装在曲面上进行测量。3. The ultra-thin planar eddy current coil and its lead-out cables in the integrated flexible sensor prepared by the present invention have good flexibility. Therefore, the sensor can be attached to any shape of surface for measurement. However, traditional eddy current sensors cannot be installed on curved surfaces for measurement.

4、本发明制备的的集成化柔性传感器可进行大面积范围内的快速测量。由于采用了印刷电路板工艺,集成化传感器阵列可以分布在很大的面积范围内(400mm×700mm甚至更大),从而实现大面积范围的测量。而其它工艺,如MEMS等微细加工工艺,就无法制作大面积范围的柔性传感器阵列,因此也难以实现大面积范围内的测量。如果利用单个传感器进行大面积范围的测量,则需要利用机械装置控制传感器或被测目标按规律动作,这必然影响测量的速度和精度。而在本发明中,利用多路选通开关,对传感器阵列实现快速循环扫描。扫描一个通道仅需20毫秒。4. The integrated flexible sensor prepared by the present invention can perform rapid measurement in a large area. Due to the use of printed circuit board technology, the integrated sensor array can be distributed in a large area (400mm×700mm or even larger), thereby realizing the measurement of a large area. However, other processes, such as MEMS and other microfabrication processes, cannot fabricate large-area flexible sensor arrays, so it is also difficult to achieve large-area measurement. If a single sensor is used to measure a large area, it is necessary to use a mechanical device to control the sensor or the measured target to move regularly, which will inevitably affect the speed and accuracy of the measurement. However, in the present invention, a multiplex switch is used to realize fast cycle scanning of the sensor array. Scanning a channel takes only 20 milliseconds.

5、本发明制备的集成化柔顺式传感器具有超薄的特性。集成化传感器阵列及其引出电缆的厚度最小可做到0.3mm,适合安装在狭小的空间中进行测量。5. The integrated flexible sensor prepared by the present invention has ultra-thin characteristics. The minimum thickness of the integrated sensor array and its outgoing cables can be 0.3mm, which is suitable for installation in a small space for measurement.

6、本发明制备的集成化柔顺式传感器可以形成密排电缆。传感器阵列的引线汇集到一起,形成密排长电缆,使结构更加紧凑。由于采用循环扫描的测量方法,任意时刻,电缆中只有一组线中有信号传输,因此,电缆所传输信号互不干扰。6. The integrated flexible sensor prepared by the present invention can form a close-packed cable. The leads of the sensor array are brought together to form a densely packed long cable, making the structure more compact. Due to the measurement method of circular scanning, at any time, only one group of lines in the cable has signal transmission, so the signals transmitted by the cable do not interfere with each other.

7、本发明制备的集成化柔顺式传感器相对传统的间隙测量和力测量传感器,能适用于很多测量场合,如曲面测量、大面积范围内快速测量、狭小空间中的测量等。基底材料如采用聚合材料聚酰亚胺,则该传感器阵列还能应用在高温(300—400℃)、辐射等测量场合。7. Compared with traditional gap measurement and force measurement sensors, the integrated flexible sensor prepared by the present invention can be applied to many measurement occasions, such as curved surface measurement, rapid measurement in a large area, and measurement in a narrow space. If the base material is polyimide, the sensor array can also be used in high temperature (300-400° C.), radiation and other measurement occasions.

8、本发明制备的的集成化柔性传感器,厚度仅为0.3mm;柔顺性能好,最小弯曲半径可达到200mm;传感器阵列面积可订做,范围为400~700mm2;测力的量程:0~2MPa;测力的精度:1%FS;测力的分辨率:0.2%FS;测量间隙的分辨率:1μm;测量间隙的灵敏度:100Hz/μm;测量间隙的精度:±1%FS;测量间隙的量程:0~5mm。8. The integrated flexible sensor prepared by the present invention has a thickness of only 0.3mm; good compliance performance, and the minimum bending radius can reach 200mm; the sensor array area can be customized, and the range is 400-700mm 2 ; the measuring range of force: 0~ 2MPa; force measurement accuracy: 1% FS; force measurement resolution: 0.2% FS; measurement gap resolution: 1μm; measurement gap sensitivity: 100Hz/μm; measurement gap accuracy: ±1% FS; measurement gap Measuring range: 0~5mm.

附图说明 Description of drawings

图1是本发明制备集成化柔顺式传感器过程中传感器封装前的正向平面图。Fig. 1 is a front plan view of the sensor before packaging in the process of preparing the integrated flexible sensor of the present invention.

图2是图1所示的封装前传感器的反向平面图。FIG. 2 is a reverse plan view of the front-of-package sensor shown in FIG. 1 .

图3是封装后图1所示的传感器的A-A剖视图。Fig. 3 is an A-A sectional view of the sensor shown in Fig. 1 after packaging.

图4是封装后图1所示的传感器的B-B剖视图。Fig. 4 is a B-B sectional view of the sensor shown in Fig. 1 after packaging.

图1—图3中,1是基底,2是外引线,3是内引线,4是开孔,5是超薄导电高分子材料敏感元件,6是定位胶,7是电涡流线圈,8是密封胶。In Figure 1-Figure 3, 1 is the base, 2 is the outer lead, 3 is the inner lead, 4 is the opening, 5 is the ultra-thin conductive polymer material sensitive element, 6 is the positioning glue, 7 is the eddy current coil, 8 is the sealant.

具体实施方式 Detailed ways

本发明提出的测量曲面间隙和力的集成化柔顺式传感器的制备方法,制备过程中传感器封装前的正向平面图如图1所示,包括以下步骤:The preparation method of the integrated compliant sensor for measuring the surface gap and force proposed by the present invention, the front plan view of the sensor before packaging during the preparation process is shown in Figure 1, including the following steps:

(1)制备平面电涡流敏感元件:(1) Preparation of planar eddy current sensitive elements:

(1—1)在聚酰亚胺薄膜基底1上按行和列开孔4,聚酰亚胺薄膜的厚度为100μm—200μm,开孔的孔径为250—350μm;(1-1) On the polyimide film substrate 1, holes 4 are opened in rows and columns, the thickness of the polyimide film is 100 μm-200 μm, and the aperture of the holes is 250-350 μm;

(1—2)在聚酰亚胺薄膜基底的正反两个表面以及上述开孔的表面上分别镀复铜箔,铜箔的厚度为15μm—20μm;(1-2) Copper foil is respectively plated on the front and back surfaces of the polyimide film substrate and the surface of the above-mentioned opening, and the thickness of the copper foil is 15 μm-20 μm;

(1—3)对上述反面铜箔进行光刻,以上述开孔4为中心形成电涡流线圈7,在每个电涡流线圈7的一侧形成内引线3,对上述正面铜箔进行光刻,在上述开孔4之间形成外引线2,如图2所示;(1-3) The above-mentioned reverse copper foil is carried out photoetching, the eddy current coil 7 is formed centering on the above-mentioned opening 4, and the inner lead 3 is formed on one side of each eddy current coil 7, and the above-mentioned front copper foil is photo-etched. , forming an outer lead 2 between the above-mentioned openings 4, as shown in FIG. 2 ;

(2)制备超薄柔顺导电高分子敏感元件:(2) Preparation of ultra-thin and flexible conductive polymer sensitive elements:

(2—1)将粒径小于1微米的导电炭黑粉末、粒径为10—50纳米的二氧化硅分散剂粉末和液态单组份硅橡胶在浓度为95%以上的丙酮有机溶剂中混合,混合时各成分的体积百分比浓度为:单组份硅橡胶:导电炭黑粉末:二氧化硅分散剂粉末:丙酮有机溶剂=100:10—15:1—3:300—500;(2-1) Mix the conductive carbon black powder with a particle size of less than 1 micron, the silicon dioxide dispersant powder with a particle size of 10-50 nanometers, and the liquid one-component silicone rubber in an acetone organic solvent with a concentration of more than 95%. , the volume percent concentration of each composition when mixing is: single-component silicone rubber: conductive carbon black powder: silicon dioxide dispersant powder: acetone organic solvent=100:10—15:1—3:300—500;

(2—2)在超声振荡下进行机械搅拌,搅拌环境温度为40-60℃,搅拌时间为2-4小时,得到凝胶状态混合体;(2-2) Perform mechanical stirring under ultrasonic vibration, the temperature of the stirring environment is 40-60° C., and the stirring time is 2-4 hours to obtain a gel state mixture;

(2—3)将占上述混合体总体积量的3—5%的顺丁橡胶颗粒加入到该混合体中,继续机械搅拌20-30分钟,使丙酮挥发;(2-3) Add 3-5% butadiene rubber particles accounting for the total volume of the mixture into the mixture, continue mechanical stirring for 20-30 minutes, and volatilize the acetone;

(2—4)将上述丙酮挥发后的混合体滴入旋转平台,旋涂成型,得到厚度为70—100微米的导电高分子膜;(2-4) dripping the above-mentioned acetone volatilized mixture into the rotating platform, and spin-coating to obtain a conductive polymer film with a thickness of 70-100 microns;

(2—5)将占上述导电高分子膜总体积1%的正硅酸乙脂交联剂和占上述导电高分子膜总体积2%的二月桂酸二丁基锡催化剂混合成溶液,将该混合溶液涂在上述导电高分子膜的表面,使导电高分子膜硫化,硫化时间为24小时以上,得到超薄柔顺导电高分子敏感元件;(2-5) the tetraethyl orthosilicate crosslinking agent accounting for 1% of the total volume of the above-mentioned conductive polymer film and the dibutyltin dilaurate catalyst accounting for 2% of the total volume of the above-mentioned conductive polymer film are mixed into a solution, and the mixed The solution is coated on the surface of the conductive polymer film to vulcanize the conductive polymer film, and the vulcanization time is more than 24 hours to obtain an ultra-thin and flexible conductive polymer sensitive element;

(3)集成化柔顺式传感器的封装:(3) Packaging of integrated flexible sensors:

(3—1)在上述平面电涡流敏感元件的每相邻两列电涡流线圈之间涂覆一层定位胶6;(3-1) Coating a layer of positioning glue 6 between every adjacent two rows of eddy current coils of the above-mentioned planar eddy current sensitive element;

(3—2)将上述制备的超薄柔顺导电高分子敏感元件剪成条状,将剪成条状的超薄柔顺导电高分子敏感元件粘贴在上述定位胶上;(3-2) Cut the ultra-thin and compliant conductive polymer sensitive element prepared above into strips, and paste the ultra-thin and compliant conductive polymer sensitive element cut into strips on the above-mentioned positioning glue;

(3—3)在上述已经粘贴超薄柔顺导电高分子敏感元件的平面电涡流敏感元件的基底周边涂覆具有热固性的封装胶,利用封装胶将另一层平面电涡流敏感元件粘附在表面,得到集成化柔顺式传感器,粘附时,使上、下两层平面电涡流线圈、内引线和开孔分别相对。(3-3) Coat the periphery of the substrate of the above-mentioned planar eddy current sensitive element pasted with ultra-thin and flexible conductive polymer sensitive element with thermosetting encapsulation glue, and use the encapsulation glue to adhere another layer of planar eddy current sensitive element to the surface , to obtain an integrated flexible sensor, when adhering, the upper and lower layers of planar eddy current coils, inner leads and openings are respectively opposite.

上述方法中,制备超薄柔顺导电高分子敏感元件的两个实施例配方为:In the above method, the formulations of two examples for preparing ultra-thin and flexible conductive polymer sensitive elements are:

混合时各成分的体积百分比浓度为:单组份硅橡胶:导电炭黑粉末:二氧化硅分散剂粉末:丙酮有机溶剂=100:12:2:350;The volume percent concentration of each composition during mixing is: single-component silicone rubber: conductive carbon black powder: silicon dioxide dispersant powder: acetone organic solvent=100:12:2:350;

或者混合时各成分的体积百分比浓度为:单组份硅橡胶:导电炭黑粉末:二氧化硅分散剂粉末:丙酮有机溶剂=100:14:2.5:400。Or the volume percent concentration of each component during mixing is: single-component silicone rubber: conductive carbon black powder: silicon dioxide dispersant powder: acetone organic solvent=100:14:2.5:400.

本发明制备的集成化柔顺式传感器,由封装成一体的上下电极层及压于其间的导电高分子力敏感元件阵列构成,如图3和图4所示。The integrated flexible sensor prepared by the present invention is composed of upper and lower electrode layers packaged into one body and an array of conductive polymer force sensitive elements pressed therebetween, as shown in Fig. 3 and Fig. 4 .

本发明制备的集成化柔顺式传感器采用具有压阻效应的导电高分子材料作为测量应力的敏感元件,该材料以导电炭黑粉末作为导电相、以硅橡胶作为绝缘相,按优化比例混合,采用了超声振荡、有机溶剂溶解、加热搅拌、纳米分散和弹性体共混等混合技术。The integrated flexible sensor prepared by the present invention adopts a conductive polymer material with piezoresistive effect as a sensitive element for measuring stress. The material uses conductive carbon black powder as a conductive phase and silicone rubber as an insulating phase, and is mixed according to an optimized ratio. Mixing techniques such as ultrasonic oscillation, organic solvent dissolution, heating and stirring, nano-dispersion and elastomer blending have been introduced.

本发明制备的集成化柔顺式传感器中使用的导电高分子力敏感元件电极层是利用柔性印刷电路板工艺在薄膜基底上制作而成,其中上、下电极采用了超薄平面电涡流线圈替代传统的平板电极。上、下电极可以分别单独采用超薄平面电涡流线圈,也可以同时采用超薄平面电涡流线圈。由此,上、下电极形成单层或双层电涡流检测结构。超薄平面电涡流线圈与导电高分子力敏感元件集成在一起,共同形成了一个能够同时测量间隙和挤压力的集成化敏感元件。The electrode layer of the conductive polymer force sensitive element used in the integrated flexible sensor prepared by the present invention is made on the film substrate by using the flexible printed circuit board technology, wherein the upper and lower electrodes adopt ultra-thin planar eddy current coils instead of traditional plate electrodes. The upper and lower electrodes can use ultra-thin planar eddy-current coils separately, or can use ultra-thin planar eddy-current coils simultaneously. Thus, the upper and lower electrodes form a single-layer or double-layer eddy current detection structure. The ultra-thin planar eddy current coil is integrated with the conductive polymer force sensing element to form an integrated sensing element capable of simultaneously measuring gap and extrusion force.

本发明制备的集成化柔顺式传感器中的传感器阵列的每个平面电涡流线圈各有两条信号线,上、下电极的引线自然形成导电高分子力敏感元件的信号线,阵列中各个集成化敏感元件的信号线汇集一起,形成引出密排电缆,该电缆的另一端设有与多路选通开关相连的插头。Each planar eddy current coil of the sensor array in the integrated flexible sensor prepared by the present invention has two signal wires, and the lead wires of the upper and lower electrodes naturally form the signal wires of the conductive polymer force sensitive elements. The signal wires of the sensitive elements are collected together to form a close-packed outgoing cable, and the other end of the cable is provided with a plug connected with a multi-way strobe switch.

本发明制备的集成化柔顺式传感器中的导电高分子力敏感元件可以制作成单层或双层甚至多层,平面电涡流线圈形状可以是圆形、方形或其它形状。The conductive polymer force sensitive element in the integrated flexible sensor prepared by the present invention can be made into single layer, double layer or even multilayer, and the shape of the planar eddy current coil can be circular, square or other shapes.

本发明制备的集成化柔顺式传感器的制备过程采用了光刻引线、涂覆定位胶、贴附力敏感元件、涂覆封装胶和热压封装的工艺流程。根据测量条件及要求进行选材与设计,所说的薄膜基底可采用适合印刷电路板工艺的柔性材料,如聚酰亚胺薄膜,聚酯薄膜等。The preparation process of the integrated flexible sensor prepared by the present invention adopts the technological process of photoetching leads, coating positioning glue, attaching force sensitive elements, coating encapsulation glue and hot-pressing encapsulation. Material selection and design are carried out according to measurement conditions and requirements. The film base can be made of flexible materials suitable for printed circuit board technology, such as polyimide film, polyester film, etc.

以下介绍本发明制备的集成化柔性传感器敏感元件的工作原理:The working principle of the integrated flexible sensor sensitive element prepared by the present invention is introduced below:

本发明的集成化敏感元件由平面电涡流敏感元件和导电高分子力敏感元件组成,平面电涡流敏感元件的信号引线同时作为导电高分子力敏感元件的信号引线使用。The integrated sensitive element of the present invention is composed of a planar eddy current sensitive element and a conductive polymer force sensitive element, and the signal leads of the planar eddy current sensitive element are simultaneously used as signal leads of the conductive polymer force sensitive element.

a、电涡流敏感元件测量间隙的工作原理:a. Working principle of eddy current sensitive element measuring gap:

通用的电涡流检测的工作原理是:检测激励线圈磁场和被测导体感应涡流磁场之间的交互作用。当敏感线圈通入交流电流时,线圈周围就会产生交变磁场,如果此时将金属导体靶材移入此交变磁场中,靶材表面就会感应出电涡流,而此电涡流又会产生一个磁场,该磁场的方向与原线圈磁场的方向正好相反,从而减弱了原磁场,引起磁场变化。磁场的变化情况是通过敏感线圈的阻抗变化来反映的,线圈的等效阻抗Z一般可表示为如下的函数:The general working principle of eddy current testing is to detect the interaction between the magnetic field of the excitation coil and the induced eddy current magnetic field of the conductor under test. When the sensitive coil is fed with alternating current, an alternating magnetic field will be generated around the coil. If the metal conductor target is moved into this alternating magnetic field at this time, an eddy current will be induced on the surface of the target, and this eddy current will generate A magnetic field whose direction is exactly opposite to the direction of the original coil magnetic field, thus weakening the original magnetic field and causing a change in the magnetic field. The change of the magnetic field is reflected by the impedance change of the sensitive coil, and the equivalent impedance Z of the coil can generally be expressed as the following function:

Z=F(σ,μ,f,x,r)Z=F(σ, μ, f, x, r)

其中,σ,μ分别是被测金属导体的电导率和磁导率,f是激励信号的频率,x是线圈与金属导体之间的距离,r是线圈的尺寸因子,与线圈的结构、形状以及尺寸相关。可见,线圈阻抗的变化完整而且唯一地反映了被测金属导体的电涡流效应。实际检测时,对不需要的影响因素加以控制,就可以实现对上式中某个相关量的检测。作为接近式传感器,线圈到金属靶材之间的距离与线圈的阻抗直接相关,而检测金属表面或近表面的缺陷时,缺陷的存在将引起被测导体电导率和磁导率的变化,进而使线圈的阻抗参数发生改变。通过电涡流传感器可以得到测点位置的球面间隙测量数据。Among them, σ, μ are the electrical conductivity and magnetic permeability of the metal conductor to be tested, f is the frequency of the excitation signal, x is the distance between the coil and the metal conductor, r is the size factor of the coil, and the structure and shape of the coil and size related. It can be seen that the change of coil impedance completely and uniquely reflects the eddy current effect of the metal conductor under test. In the actual detection, the detection of a relevant quantity in the above formula can be realized by controlling the unnecessary influencing factors. As a proximity sensor, the distance between the coil and the metal target is directly related to the impedance of the coil, and when detecting defects on the metal surface or near the surface, the existence of defects will cause changes in the electrical conductivity and magnetic permeability of the measured conductor, and then Change the impedance parameters of the coil. The measurement data of the spherical gap at the measuring point can be obtained through the eddy current sensor.

b、导电高分子敏感元件测量挤压力的工作原理:b. The working principle of the conductive polymer sensitive element to measure the extrusion force:

从微观导电机制的角度分析可知,炭黑填充硅橡胶复合材料产生压阻效应的原因可归结为炭黑颗粒在硅橡胶基体中分布的变化,更准确的说,是导电炭黑颗粒间距的变化。外界压力可以压缩复合材料的体积,由于导电炭黑颗粒的可压缩性远小于硅橡胶基体,因此导电颗粒的间距减小,提高了接触传导和隧道效应发生的几率。随着压力增大,导电炭黑颗粒的间距逐渐减小,由于接触传导和隧道效应机制的作用,在材料的内部形成了导电通道。而接触传导和隧道效应机制的产生,又受到导电颗粒的粒径和形状的影响,因此材料的压阻效应表现出与形貌参数的密切关系。材料的形貌参数值越大,接触传导和隧道效应产生的几率就越高,材料的压阻效应也就越明显。From the perspective of the microscopic conductive mechanism, the reason for the piezoresistive effect of carbon black-filled silicone rubber composites can be attributed to the change in the distribution of carbon black particles in the silicone rubber matrix, more precisely, the change in the distance between conductive carbon black particles . The external pressure can compress the volume of the composite material. Since the compressibility of the conductive carbon black particles is much smaller than that of the silicone rubber matrix, the distance between the conductive particles is reduced, which increases the probability of contact conduction and tunneling. As the pressure increases, the distance between the conductive carbon black particles gradually decreases, and due to the contact conduction and tunneling mechanism, a conductive channel is formed inside the material. The generation of contact conduction and tunnel effect mechanism is affected by the particle size and shape of conductive particles, so the piezoresistive effect of the material shows a close relationship with the shape parameters. The larger the shape parameter value of the material, the higher the probability of contact conduction and tunneling effect, and the more obvious the piezoresistive effect of the material.

从导电渗流现象的角度分析,材料的电阻率在导电渗流区内随导电填料体积浓度的变化十分明显。这是因为,当外界压力减小了聚合物基体的体积时,导电颗粒的体积浓度相应增加,引起材料电阻率的明显变化。材料变形引起了导电渗流变化,随着材料变形,炭黑体积浓度,材料的电阻率随之减小。当炭黑体积浓度越接近渗流阈值,材料的压阻效应就越明显。在有效介质普适方程中,炭黑的体积浓度、渗流阈值和材料的形貌参数一起表征了导电渗流现象,也说明炭黑填充硅橡胶复合材料的压阻效应是其导电渗流现象的一个具体表现。另外,材料的变形不但引起电阻率的变化,还改变了其电阻几何系数(即沿电流方向上材料的长度与横截面积的比值)。综上所述,炭黑填充硅橡胶复合材料的受力变形是其产生压阻效应的直接原因。From the perspective of the conductive seepage phenomenon, the resistivity of the material changes significantly with the volume concentration of the conductive filler in the conductive seepage area. This is because, when the external pressure reduces the volume of the polymer matrix, the volume concentration of conductive particles increases correspondingly, causing a significant change in the resistivity of the material. The deformation of the material causes the change of the conductive seepage. With the deformation of the material, the volume concentration of carbon black and the resistivity of the material decrease. When the volume concentration of carbon black is closer to the percolation threshold, the piezoresistive effect of the material is more obvious. In the effective medium universal equation, the volume concentration of carbon black, the percolation threshold and the shape parameters of the material together characterize the conductive percolation phenomenon, which also shows that the piezoresistive effect of carbon black-filled silicone rubber composites is a specific aspect of its conductive percolation phenomenon. Performance. In addition, the deformation of the material not only causes a change in resistivity, but also changes its geometric coefficient of resistance (that is, the ratio of the length of the material to the cross-sectional area along the current direction). In summary, the stress deformation of carbon black-filled silicone rubber composites is the direct cause of the piezoresistive effect.

在宏观表象上,由于压力的作用,构成敏感元件的导电高分子材料产生了电阻变化,这种变化在一定范围内与压力呈现线性比例关系。On the macro surface, due to the effect of pressure, the conductive polymer material that constitutes the sensitive element produces a change in resistance, and this change is linearly proportional to the pressure within a certain range.

以下介绍本发明制备的阵列式集成化柔顺传感器的工作方式:The working mode of the array integrated compliant sensor prepared by the present invention is introduced as follows:

实际工作时,将传感器贴附在曲面间。通过振荡电路测量传感器每个电涡流线圈的阻抗变化,通过电阻取样电路测量传感器每对电极间的电阻变化,根据标定曲线,得到对应的间隙值和挤压力值。通过信号取样和阵列扫描电路以及多路选通开关,对敏感元件进行快速循环扫描,可以测出每个敏感元件的测量值。由于这些敏感元件的分布方式是已知的,因此,对测量结果进行数据处理,就可以得到曲面间隙和挤压力的分布。In actual work, attach the sensor between the curved surfaces. The impedance change of each eddy current coil of the sensor is measured by the oscillating circuit, the resistance change between each pair of electrodes of the sensor is measured by the resistance sampling circuit, and the corresponding gap value and extrusion force value are obtained according to the calibration curve. Through the signal sampling and array scanning circuit and the multi-way strobe switch, the sensitive element can be scanned in a fast cycle, and the measured value of each sensitive element can be measured. Since the distribution of these sensitive elements is known, the distribution of surface clearance and extrusion force can be obtained by data processing of the measurement results.

Claims (1)

1、一种测量曲面间隙和力的集成化柔顺式传感器的制备方法,其特征在于该方法包括以下步骤:1. A method for preparing an integrated compliant sensor for measuring surface gap and force, characterized in that the method comprises the following steps: (1)制备平面电涡流敏感元件:(1) Preparation of planar eddy current sensitive elements: (1—1)在聚酰亚胺薄膜基底上按行和列开孔,聚酰亚胺薄膜的厚度为100μm—200μm,开孔的孔径为250—350μm;(1-1) Open holes in rows and columns on the polyimide film substrate, the thickness of the polyimide film is 100 μm-200 μm, and the aperture of the holes is 250-350 μm; (1—2)在聚酰亚胺薄膜基底的正反两个表面以及上述开孔的表面上分别镀复铜箔,铜箔的厚度为15μm—20μm;(1-2) Copper foil is respectively plated on the front and back surfaces of the polyimide film substrate and the surface of the above-mentioned opening, and the thickness of the copper foil is 15 μm-20 μm; (1—3)对上述反面铜箔进行光刻,以上述开孔为中心形成电涡流线圈,在每个电涡流线圈的一侧形成内引线,对上述正面铜箔进行光刻,在上述开孔之间形成外引线;(1-3) Photolithography is carried out on the above-mentioned reverse copper foil, an eddy current coil is formed centering on the above-mentioned opening, an inner lead is formed on one side of each eddy-current coil, the above-mentioned front copper foil is photo-etched, and an electric current coil is formed on the above-mentioned opening. Outer leads are formed between the holes; (2)制备超薄柔顺导电高分子敏感元件:(2) Preparation of ultra-thin and flexible conductive polymer sensitive elements: (2—1)将粒径小于1微米的导电炭黑粉末、粒径为10—50纳米的二氧化硅分散剂粉末和液态单组份硅橡胶在浓度为95%以上的丙酮有机溶剂中混合,混合时各成分的体积百分比浓度为:单组份硅橡胶:导电炭黑粉末:二氧化硅分散剂粉末:丙酮有机溶剂=100:10—15:1—3:300—500;(2-1) Mix the conductive carbon black powder with a particle size of less than 1 micron, the silicon dioxide dispersant powder with a particle size of 10-50 nanometers, and the liquid one-component silicone rubber in an acetone organic solvent with a concentration of more than 95%. , the volume percent concentration of each composition when mixing is: single-component silicone rubber: conductive carbon black powder: silicon dioxide dispersant powder: acetone organic solvent=100:10—15:1—3:300—500; (2—2)在超声振荡下进行机械搅拌,搅拌环境温度为40-60℃,搅拌时间为2-4小时,得到凝胶状态混合体;(2-2) Perform mechanical stirring under ultrasonic vibration, the temperature of the stirring environment is 40-60° C., and the stirring time is 2-4 hours to obtain a gel state mixture; (2—3)将占上述混合体总体积量的3—5%的顺丁橡胶颗粒加入到该混合体中,继续机械搅拌20-30分钟,使丙酮挥发;(2-3) Add 3-5% butadiene rubber particles accounting for the total volume of the mixture into the mixture, continue mechanical stirring for 20-30 minutes, and volatilize the acetone; (2—4)将上述丙酮挥发后的混合体滴入旋转平台,旋涂成型,得到厚度为70—100微米的导电高分子膜;(2-4) drop the above-mentioned acetone volatilized mixture into a rotating platform, and spin-coat to form a conductive polymer film with a thickness of 70-100 microns; (2—5)将占上述导电高分子膜总体积1%的正硅酸乙脂交联剂和占上述导电高分子膜总体积2%的二月桂酸二丁基锡催化剂混合成溶液,将该混合溶液涂在上述导电高分子膜的表面,使导电高分子膜硫化,硫化时间为24小时以上,得到超薄柔顺导电高分子敏感元件;(2-5) the tetraethyl orthosilicate crosslinking agent accounting for 1% of the total volume of the above-mentioned conductive polymer film and the dibutyltin dilaurate catalyst accounting for 2% of the total volume of the above-mentioned conductive polymer film are mixed into a solution, and the mixed The solution is coated on the surface of the conductive polymer film to vulcanize the conductive polymer film, and the vulcanization time is more than 24 hours to obtain an ultra-thin and flexible conductive polymer sensitive element; (3)集成化柔顺式传感器的封装:(3) Packaging of integrated flexible sensors: (3—1)在上述平面电涡流敏感元件的每相邻两列电涡流线圈之间涂覆一层定位胶;(3-1) Coating a layer of positioning glue between every adjacent two rows of eddy current coils of the above-mentioned planar eddy current sensitive element; (3—2)将上述制备的超薄柔顺导电高分子敏感元件剪成条状,将剪成条状的超薄柔顺导电高分子敏感元件粘贴在上述定位胶上;(3-2) Cut the ultra-thin and compliant conductive polymer sensitive element prepared above into strips, and paste the ultra-thin and compliant conductive polymer sensitive element cut into strips on the above-mentioned positioning glue; (3—3)在上述已经粘贴超薄柔顺导电高分子敏感元件的平面电涡流敏感元件的基底周边涂覆具有热固性的封装胶,利用封装胶将另一层平面电涡流敏感元件粘附在表面,得到集成化柔顺式传感器,粘附时,使上、下两层平面电涡流线圈、内引线和开孔分别相对。(3-3) Coat the periphery of the substrate of the above-mentioned planar eddy current sensitive element pasted with ultra-thin and flexible conductive polymer sensitive element with thermosetting encapsulation glue, and use the encapsulation glue to adhere another layer of planar eddy current sensitive element to the surface , to obtain an integrated flexible sensor, when adhering, the upper and lower layers of planar eddy current coils, inner leads and openings are respectively opposite.
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