Materials and structures for spacer elements in a human-computer interface system

1. A system for a touch sensor comprising:

a substrate comprising:

a top substrate layer; and

a bottom substrate layer defining a set of support locations;

a touch sensor surface arranged over the top substrate layer of the substrate;

a baseplate:

spanning the bottom substrate layer of the substrate; and

defining a set of spring elements:

aligned to the set of support locations of the bottom substrate layer; and

configured to yield to displacement of the substrate toward the baseplate responsive to forces applied to the touch sensor surface; and

a set of spacer elements:

interposed between the set of support locations of the substrate and the set of spring elements of the baseplate;

coupling the substrate to the baseplate;

each spacer element, in the set of spacer elements, comprising:

an elastomer element;

a first adhesive layer:

arranged over the elastomer element; and

coupled to the bottom substrate layer at a support location, in the set of support locations; and

a second adhesive layer:

arranged below the elastomer element; and

coupled to the baseplate at a spring element, in the set of spring elements; and

configured to compress responsive to forces applied to the touch sensor surface.

2. The system of claim 1 :

wherein the substrate further comprises a set of inductor layers comprising:

a first inductor layer comprising a first spiral trace:

coiled in a first direction across the first inductor layer; and

defining a first end and a second end; and

a second inductor layer arranged below the first inductor layer and comprising a second spiral trace:

coiled in a second direction, opposite the first direction, across the second inductor layer;

defining a third end and a fourth end, the third end electrically coupled to the second end of the first spiral trace; and

cooperating with the first spiral trace to form a multi-layer inductor; and

further comprising a first magnetic element:

arranged below the substrate;

defining a first polarity facing the multi-layer inductor; and

configured to inductively couple the multi-layer inductor responsive to forces applied on the touch sensor surface.

3. The system of claim 2 , further comprising a controller configured to:

read a first set of electrical values from the multi-layer inductor;

detect a first change in electrical values at the multi-layer inductor based on the first set of electrical values;

interpret a force magnitude for a touch input applied on the touch sensor surface based on the first change in electrical values; and

in response to the force magnitude exceeding a threshold force magnitude, trigger a first oscillating voltage across the multi-layer inductor during a haptic feedback cycle to induce alternating magnetic coupling between the multi-layer inductor and the first magnetic element.

4. The system of claim 1 :

wherein the substrate further includes:

a set of drive and sense electrode pairs arranged across the top substrate layer of the substrate; and

a multi-layer inductor arranged below the top substrate layer of the substrate; and

further comprising a first magnetic element:

arranged below the substrate;

defining a first polarity facing the multi-layer inductor; and

configured to inductively couple the multi-layer inductor responsive to forces applied on the touch sensor surface.

5. The system of claim 4 , further comprising a controller configured to:

read a first set of electrical values from the set of drive and sense electrode pairs;

detect a touch input at a first location on the touch sensor surface based on the first set of electrical values; and

in response to detecting the touch input, trigger a first oscillating voltage across the multi-layer inductor during a haptic feedback cycle to induce alternating magnetic coupling between the multi-layer inductor and the first magnetic element.

6. The system of claim 1 :

wherein the substrate further comprises:

a multi-layer inductor arranged below the top substrate layer of the substrate; and

a set of sense electrodes arranged across the bottom substrate layer proximal the set of support locations;

wherein the baseplate further comprises a set of drive electrodes:

arranged across a top surface of the baseplate proximal the set of spring elements;

arranged in alignment with the set of sense electrodes at the bottom substrate layer of the substrate; and

configured to capacitively couple the set of sense electrodes to form a set of capacitive force sensors and effect capacitance values of the set of sense electrodes responsive to displacement of the substrate toward the baseplate; and

further comprising a first magnetic element:

arranged below the substrate;

defining a first polarity facing the multi-layer inductor; and

configured to inductively couple the multi-layer inductor responsive to forces applied on the touch sensor surface.

7. The system of claim 6 , further comprising a controller configured to:

read a first set of electrical values from the multi-layer inductor; and

in response to detecting a first change in electrical values at the multi-layer inductor based on the first set of electrical values:

interpret presence of a first touch input applied to the touch sensor surface based on the first change in electrical values;

read a second set of electrical values from the set of capacitive force sensors;

interpret a first force magnitude for the first touch input based on the second set of electrical values; and

in response to the first force magnitude exceeding a threshold force magnitude, trigger a first oscillating voltage across the multi-layer inductor during a haptic feedback cycle to induce alternating magnetic coupling between the multi-layer inductor and the first magnetic element.

8. The system of claim 1 :

wherein the baseplate defines:

a nominal plane arranged below the substrate; and

the set of spring elements arranged about a perimeter of the baseplate;

wherein each spring element in the set of spring elements comprises a flexure:

formed in the baseplate;

defining a stage; and

configured to return to approximately the nominal plane in response to absence of a touch input applied to the touch sensor surface; and

wherein each spacer element, in the set of spacer elements, couples a support location, in the set of support locations, on the bottom layer of the substrate, to a stage of a spring element in the set of spring elements.

9. The system of claim 1 :

wherein the substrate further comprises:

a first set of drive and sense electrode pairs arranged across the top substrate layer of the substrate; and

a second set of sense electrodes arranged across the bottom substrate layer proximal the set of support locations;

wherein the baseplate further comprises a second set of drive electrodes:

arranged across a top surface of the baseplate proximal the set of spring elements;

arranged in alignment with the second set of sense electrodes at the bottom substrate layer of the substrate; and

configured to capacitively couple the second set of sense electrodes to form a set of capacitive force sensors and effect capacitance values of the second set of sense electrodes responsive to displacement of the substrate toward the baseplate; and

further comprising a controller configured to:

read a first set of electrical values from the first set of drive and sense electrode pairs;

read a second set of electrical values from the set of capacitive force sensors;

detect a lateral position and a longitudinal position of a touch input applied to the touch sensor surface based on the first set of electrical values;

interpret a first force magnitude of the touch input based on the second set of electrical values; and

output a touch image containing the lateral position, the longitudinal position, and the force magnitude.

10. The system of claim 1 , wherein the first adhesive layer of each spacer element, in the set of spacer elements, is formed of a first adhesive type and comprises:

a first sub-adhesive layer arranged across a top surface of the elastomer element;

a second sub-adhesive layer:

arranged over the first sub-adhesive layer; and

coupled to the bottom substrate layer of the substrate at a support location, in the set of support locations; and

a first carrier layer:

interposed between the first sub-adhesive layer and the second sub-adhesive layer; and

configured to support the first adhesive layer coupling the substrate to the elastomer element.

11. The system of claim 10 , wherein the first carrier layer comprises:

a first thermoplastic layer defining:

a top surface; and

a bottom surface;

a first pressure sensitive adhesive layer:

arranged across the bottom surface of the first thermoplastic layer; and

coupled to the first sub-adhesive layer; and

a second pressure sensitive adhesive layer:

arranged across the top surface of the first thermoplastic layer; and

coupled to the second sub-adhesive layer.

12. The system of claim 10 , wherein the second adhesive layer of each spacer element, in the set of spacer elements:

is formed of a second adhesive type different from the first adhesive type; and

comprises:

a third sub-adhesive layer arranged across a bottom surface of the elastomer element opposite the first sub-adhesive layer; and

a fourth sub-adhesive layer:

arranged below the third sub-adhesive layer opposite the second sub-adhesive layer; and

coupled to a top surface of the baseplate at a spring element, in the set of spring elements; and

a second carrier layer:

interposed between the third sub-adhesive layer and the fourth sub-adhesive layer; and

configured to support the second adhesive layer coupling the baseplate to the elastomer element.

13. The system of claim 1 :

wherein the elastomer element of each spacer element, in the set of spacer elements:

is formed of a silicone material; and

defines a first height; and

wherein the first adhesive layer of each spacer element, in the set of spacer elements:

defines a second height, less than the first height of the elastomer element; and

comprises:

a primer applied over the elastomer element;

a first plastic layer arranged over the elastomer element and bonded to the primer applied to the top surface of the elastomer element; and

a first intermediate adhesive layer applied across a top surface of the elastomer element and arranged between the elastomer element and the first plastic layer.

14. The system of claim 13 , wherein the first adhesive layer of each spacer element, in the set of spacer elements further comprises:

a first sub-adhesive layer:

formed of a first adhesive type; and

arranged across a top surface of the plastic layer;

a second sub-adhesive layer:

formed of a second adhesive type, different from the first adhesive type;

arranged over the first sub-adhesive layer; and

coupled to the bottom substrate layer of the substrate at a support location, in the set of support locations; and

a first carrier layer:

interposed between the first sub-adhesive layer and the second sub-adhesive layer; and

configured to support the first adhesive layer coupling the substrate to the elastomer element.

15. A system for a spacer element within a touch sensor comprising:

an elastomer element:

defining:

a top surface;

a bottom surface; and

a first height between the top surface and the bottom surface; and

a first adhesive layer:

arranged over the elastomer element; and

defining a second height less than the first height of the elastomer element;

comprising:

a first sub-adhesive layer arranged across the top surface of the elastomer element;

a second sub-adhesive layer arranged over the first sub-adhesive layer; and

a first carrier layer interposed between the first sub-adhesive layer and the second sub-adhesive layer and configured to support formation of the first adhesive layer over the elastomer element; and

second adhesive layer:

arranged below the elastomer element opposite the first adhesive layer;

defining a third height matching the second height of the first adhesive layer and less than the first height of the first elastomer element; and

comprising:

a third sub-adhesive layer arranged below the bottom surface of the elastomer element;

a fourth sub-adhesive layer arranged below the third sub-adhesive layer; and

a second carrier layer interposed between the third sub-adhesive layer and the fourth sub-adhesive layer and configured to support formation of the second adhesive layer below the elastomer element.

16. The system of claim 15 , wherein the first carrier layer of the first adhesive layer comprises:

a first thermoplastic layer defining:

a top surface; and

a bottom surface;

a first pressure sensitive adhesive layer:

arranged across the bottom surface of the first thermoplastic layer; and

coupled to the first sub-adhesive layer; and

a second pressure sensitive adhesive layer:

arranged across the top surface of the first thermoplastic layer; and

coupled to the second sub-adhesive layer.

17. The system of claim 15 :

wherein the first adhesive layer further comprises:

a first primer applied over the elastomer element;

a first plastic layer:

bonded to the first primer applied to the top surface of the elastomer element;

interposed between the top surface of the elastomer element and the first sub-adhesive layer; and

configured to rigidly support the first sub-adhesive layer, the second sub-adhesive layer, and the first carrier layer over the elastomer element; and

a first intermediate adhesive layer applied across a top surface of the elastomer element and arranged between the elastomer element and the first plastic layer; and

wherein the second adhesive layer further comprises:

a second primer applied below the elastomer element;

a second plastic layer:

bonded to the second primer applied to the bottom surface of the elastomer layer;

interposed between the bottom surface of the elastomer element and the third sub-adhesive layer; and

configured to rigidly support the third sub-adhesive layer, the fourth sub-adhesive layer, and the second carrier layer below the elastomer element; and

a second intermediate adhesive layer applied across a bottom surface of the elastomer element and arranged between the elastomer element and the second plastic layer.

18. The system of claim 15 :

further comprising:

a substrate defining a first support location; and

a first spring element arranged below the substrate at the first support location;

wherein the elastomer element is interposed between the first support location of the substrate and the first spring element;

wherein the first adhesive layer comprises:

the first sub-adhesive layer and the second sub-adhesive layer formed of a first adhesive type; and

the second sub-adhesive layer bonded to the substrate at the support location; and

wherein the second adhesive layer comprises:

the third sub-adhesive layer and the fourth sub-adhesive layer formed of a second adhesive type, different from the first adhesive type; and

the fourth sub-adhesive layer coupled to the spring element below the substrate.

19. The system of claim 15 , wherein the elastomer element is formed of a material selected from a group comprising silicone, polyurethane, styrene-butadiene, polyisoprene, polyisoprene, polyisobutylene, and polychloroprene.

20. A system for a spacer element within a touch sensor comprising:

an elastomer element:

defining:

a top surface;

a bottom surface; and

a first height between the top surface and the bottom surface; and

a first adhesive layer:

arranged over the elastomer element; and

defining a second height less than the first height of the elastomer element;

comprising:

a first sub-adhesive layer arranged across the top surface of the elastomer element;

a second sub-adhesive layer arranged over the first sub-adhesive layer; and

a first carrier layer interposed between the first sub-adhesive layer and the second sub-adhesive layer and configured to support formation of the first adhesive layer over the elastomer element;

a first primer applied over the elastomer element;

a first plastic layer:

interposed between the top surface of the elastomer element and the first sub-adhesive layer; and

configured to rigidly support the first sub-adhesive layer, the second sub-adhesive layer, and the first carrier layer over the elastomer element; and

a first intermediate adhesive layer applied across a top surface of the elastomer element and arranged between the elastomer element and the first plastic layer;

second adhesive layer:

arranged below the elastomer element opposite the first adhesive layer;

defining a third height matching the second height of the first adhesive layer and less than the first height of the first elastomer element; and

comprising:

a third sub-adhesive layer arranged below the bottom surface of the elastomer element;

a fourth sub-adhesive layer arranged below the third sub-adhesive layer; and

a second carrier layer interposed between the third sub-adhesive layer and the fourth sub-adhesive layer and configured to support formation of the second adhesive layer below the elastomer element;

a second primer applied below the elastomer element;

a second plastic layer:

interposed between the bottom surface of the elastomer element and the third sub-adhesive layer; and

configured to rigidly support the third sub-adhesive layer, the fourth sub-adhesive layer, and the second carrier layer below the elastomer element; and

a second intermediate adhesive layer applied across a bottom surface of the elastomer element and arranged between the elastomer element and the second plastic layer.