Method of manufacture and use of a flexible computerized sensing device
A thin, flexible computerized sensing platform which can be affixed to a structure to be sensed, which has excellent mechanical coupling between the sensors and the object to be sensed, which can be self-powered and rechargeable, and which can be environmentally sealed, and a method for assembling and utilizing the same.
1 . A flexible sensing apparatus comprising:
a first flexible circuit having upward facing exposed electrical pads;
a second flexible circuit have downward facing exposed electrical pads;
the first and second flexible circuit bonded together with a thin adhesive, the adhesive containing a die-cut area exposing the upward and downward facing exposed electrical pads;
a sensor within the die-cut area;
alignment features on the first flexible circuit and the second flexible circuit configured to align the first flexible circuit with the second flexible circuit;
wherein at least a portion of the upward facing exposed electrical pads and the downward facing exposed electrical pads are in electrical contact with the sensor.
2 . The apparatus of claim 1 further comprising:
the first flexible circuit comprising two portions, a first portion and a second foldable portion configured to be folded over the first portion;
the first portion containing the upward facing exposed electrical pads;
the second foldable portion containing additional upward facing exposed electrical pads which become downward facing electrical pads when the second foldable portion is folded over the first portion;
the first portion coupled to the second foldable portion after folding.
3 . The apparatus of claim 2 wherein:
the first portion and the second foldable portion remain electrically connected after folding and bonding.
4 . The apparatus of claim 1 wherein the alignment features comprise alignment holes in the first flexible circuit and the second flexible circuit.
5 . The apparatus of claim 1 further comprising:
additional upward facing electrical contacts on the first flexible circuit;
additional downward facing contacts on the second flexible circuit;
such that the first flexible circuit and the second flexible circuit become electrically coupled after bonding.
6 . The apparatus of claim 1 , wherein at least one of the first flexible circuit and the second flexible circuit contain additional electrical components.
7 . The apparatus of claim 1 , further comprising:
a protective encapsulation applied to the flexible sensing apparatus after bonding.
8 . The apparatus of claim 7 , further comprising:
a flexible encapsulation applied to one or both of the first flexible circuit and the second flexible circuit, prior to the protective encapsulation.
9 . The apparatus of claim 1 , further comprising:
an integral foldable element coupled to at least one of the first flexible circuit and the second flexible circuit via a bendable joint;
wherein the foldable element is assembled in one of two configurations: folded over the flexible circuit or unfolded and protruding from the flexible circuit.
10 . A flexible sensing apparatus comprising:
a first flexible circuit and a second flexible circuit bonded together with a thin adhesive;
a sensor between the first flexible circuit and the second flexible circuit, coupled electrically to at least one of the first flexible circuit and the second flexible circuit;
a first flexible encapsulation over a portion of the first flexible circuit;
a second protective encapsulation over the flexible sensing apparatus; and
a perforation in the second protective encapsulation to provide an opening for one or more of: light exiting from the sensing apparatus for signaling or air entering the sensing apparatus for an environmental or chemical sensor.
11 . The sensing apparatus of claim 10 , further comprising:
the first flexible circuit comprising two portions, a first portion and a second foldable portion, configured to be folded over the first portion;
the first portion containing upward facing exposed electrical pads;
the second foldable portion containing upward facing exposed electrical pads that become downward facing electrical pads when the second foldable portion is folded over the first portion;
the first portion coupled to the second foldable portion after folding.
12 . The sensing apparatus of claim 11 wherein:
the first portion and the second foldable portion remain electrically connected after folding and bonding.
13 . The sensing apparatus of claim 10 , wherein the first flexible circuit, the second flexible circuit and the adhesive contain alignment features to align the first flexible circuit, the second flexible circuit, and the adhesive.
14 . The sensing apparatus of claim 10 , further comprising:
upward facing electrical contacts on the first flexible circuit;
downward facing contacts on the second flexible circuit;
such that the first flexible circuit and the second flexible circuit become electrically coupled after bonding.
15 . The sensing apparatus of claim 10 , further comprising:
an integral foldable element coupled to at least one of the first flexible circuit and the second flexible circuit via a bendable joint;
wherein the foldable element is assembled in one of two configurations: folded over the flexible circuit and unfolded and protruding from the flexible circuit.
16 . The flexible sensing apparatus of claim 10 further comprising:
alignment features on the first flexible circuit and the second flexible circuit configured to align the first flexible circuit and the second flexible circuit.
17 . A flexible sensing apparatus comprising:
a first flexible circuit comprising a first portion and a second portion, the first portion having upward facing exposed electrical pads, and the second portion containing additional upward facing exposed electrical pads which become downward facing electrical pads when the second portion is folded over the first portion, wherein the first portion is coupled to the second portion after folding;
a second flexible circuit have downward facing exposed electrical pads;
a sensor sandwiched between the first flexible circuit and the second flexible circuit;
an adhesive between the sensor and at least one of the first flexible circuit and the second flexible circuit;
an encapsulation layer covering the flexible sensing apparatus, and holding together the first flexible circuit, the second flexible circuit, and the sensor.
18 . The flexible sensing apparatus of claim 17 , wherein the encapsulation layer provides compression to create an electrical connection between the sensor and at least one of the upward facing exposed electrical pads or the downward facing exposed electrical pads, without need for conductive adhesive.
19 . The flexible sensing apparatus of claim 17 , further comprising:
an exposed area extending from the encapsulation layer to provide interconnection and programming, the exposed area comprising a portion of the first flexible circuit.
20 . The flexible sensing apparatus of claim 17 , further comprising:
a perforation in the encapsulation layer to provide an opening for one or more of: light exiting from the sensing apparatus for signaling or air entering the sensing apparatus for an environmental or chemical sensor.