CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from United States Provisional Patent Application number 62/776,567, filed on 07 December 2018, the whole contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to an interface device and a method of manufacturing an interface device.

User interface devices are known to provide users with a means in which to interface with external, or remote objects, such as electronic components or electronic systems. Many such devices take the form of a remote control which can be hand-held in order to provide a usable method of interaction. Some such currently known devices incorporate pressure sensors which provide a means for operating, typically by providing switches for activating or deactivating a system or component.

Such devices consequently provide limited responses and flexibility in use and there remains a need to improve the responsiveness and usability of known interface devices.

BRIEF SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provided an interface device comprising: a main body comprising an inner cavity comprising at least one electronic component therein; and a sensing array comprising a plurality of sensing elements responsive to mechanical interactions; wherein said sensing array forms an outer shell conforming to said main body; and said at least one electronic component is in electrical communication with said sensing array and configured to provide a signal to an external device in response to a mechanical interaction to said sensing array. In an embodiment the mechanical interaction is in the form of an application of pressure and may include a finger press or a gesture. The external device may be any suitable electronic component positioned remote to the interface device.

According to a second aspect of the present invention, there is provided a method of manufacturing an interface device, comprising the steps of: obtaining a main body comprising an inner cavity; introducing an electronic component configured to provide a signal to an external device into said inner cavity; obtaining a sensing array comprising a plurality of sensing elements responsive to mechanical interactions; attaching said sensing array around said main body to form an outer shell conforming to said main body; and providing an electrical connection between said electronic component and said sensing array.

Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings. The detailed embodiments show the best mode known to the inventor and provide support for the invention as claimed. However, they are only exemplary and should not be used to interpret or limit the scope of the claims. Their purpose is to provide a teaching to those skilled in the art. Components and processes distinguished by ordinal phrases such as“first” and“second” do not necessarily define an order or ranking of any sort.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Figure 1 shows an interface device being held in the palm of a user’s hand;

Figure 2 shows a sensing array suitable for forming part of the interface device of Figure 1 ;

Figure 3 shows a schematic view of the sensing array showing the layers of the sensing array in exploded fashion;

Figure 4 shows the sensing array conforming to the main body of the interface device; Figure 5 shows the interface device having an outer skin which provides a protective layer for the sensing array;

Figure 6 shows part of the main body of the interface device illustrating an internal cavity within the interface device containing a plurality of electronic components;

Figure 7 shows an example application of the interface device including a plurality of inputs;

Figure 8 shows a further example application of the interface device, controlling inputs to a menu on a television set;

Figure 9 shows the compressibility of the interface device, which can be used to provide an output to an external device; and

Figure 10 shows an example application whereby a swipe gesture applied to the interface device is utilised for controlling a lighting system.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Figure 1

An example embodiment of an interface device in accordance with an aspect of the present invention is shown in Figure 1. Interface device 101 is shown being held by user 102 in the palm of their hand, thereby providing an interface device which is both ergonomic and easy to use.

Interface device 101 is configured to provide a signal to an external device, such as any suitable electronic component, such that the electronic component can be controlled effectively by a user. Embodiments illustrating this will be described with respect to Figures 8 to 10.

In the embodiment, interface device 101 is configured to be held in the palm of a user’s hand. In this way, an external device can be activated or operated at the touch of a user’s finger(s).

In the embodiment, interface device 101 is substantially spherical. In the embodiment, the spherical device has a radius of between two and ten centimetres (2 to 10 cm). It is appreciated that, in other embodiments, the radius may be larger or smaller than this range. In alternative embodiments; interface device 101 is any other suitable shape or object and may, for example, take the form of, a remote control or a key fob for a car or other vehicle.

Figure 2

In order to enable manipulation of an external device, interface device

101 comprises a sensing array, such as sensing array 201. In the drawing, sensing array 201 is shown in plan view. Sensing array 201 comprises a plurality of sensing elements, such as sensing element 202 which are responsive to mechanical interactions such as an application of pressure from a finger press, so as to enable detection of the application of pressure. In an embodiment, each sensing element comprises a force sensing element and each force sensing element is configured to be able to detect a force in the range of between zero point one and one hundred Newtons (0.1 N to 100N).

As illustrated, each sensing element is connected to at least one other sensing element in the array by means of an interconnect. Thus, referring to sensing element 202, four interconnects (203, 204, 205 and 206) are included which connect to adjacent sensing elements. For example, sensing element 202 is connected by interconnect 204 to sensing element 208. Other sensing elements, for example sensing element 209 show connections to six other adjacent sensing elements by means of six separate interconnects which extend from sensing element 209. In this way, each sensing element is in electrical communication with the other sensing elements in the array, and direct communication with those sensing elements adjacent thereto.

In the embodiment, each sensing element is spaced from an adjacent sensing element with the spacing typically being between one hundred micrometres and two thousand micrometres (100 pm and 2000 pm). When the spacing is smaller in number, this corresponds to a higher resolution sensing array which is capable of finer gesture capture.

In the embodiment, each interconnect comprises a conductive ink which therefore allows for electrical conduction across the array. In an embodiment, the conductive ink which forms the interconnects is printed onto the substrate 210 which supports the array. The conductive ink may be any suitable conductive ink and may comprise a metallic material.

In the embodiment, the interconnects are printed as solid straight lines, however, it is appreciated that, in alternative embodiments, the interconnects are printed as undulating lines. For example, the undulating lines may take the form of a sine curve or a variation on a sine curve. This particular feature provides stretchability of the interconnects. Thus, when substrate 210 comprises a stretchable material, the entire array 201 has increased flexibility.

As an alternative, or in addition, the conductive ink may be of a flexible composition which is resistant to damage during flexing. In this way, the sensing array 201 is configured to be flexible and stretchable.

It is appreciated that the arrangement of the sensing elements shown in Figure 2 is by way of example and, in further embodiments, the triangular tessellations may be replaced with alternative geometric arrangements which fall within the same principles of activation.

Figure 3

An alternative schematic exploded view of sensing array 201 is shown in Figure 3. Sensing array 201 provides a force sensing element and comprises a first electrode array 301 and a second electrode array 302. An active layer 303 is positioned between electrode array 301 and electrode array 302. This arrangement enables sensing array 201 to be responsive to both single touch and multi-touch mechanical interactions of varying intensity, although it is appreciated that alterative arrangements may perform the same functions.

In the embodiment, first electrode array 301 comprises a plurality of conductive traces which form a plurality of rows across the layer of the array in a first direction. In contrast, the second electrode array 302 comprises a further plurality of conductive traces which form a plurality of columns across the layer of the array in a second direction. In the embodiment, the first and second directions are orientated at ninety degrees (90°) to each other.

Active layer 303, positioned between first electrode array 301 and second electrode array 302 comprises a pressure sensitive material, which, in the embodiment, comprises a quantum tunnelling composite material. A quantum tunnelling composite material of this type is configured to exhibit a change in electrical resistance based on a change in applied force. The quantum tunnelling composite material may comprise a printable ink or film and is available from the present applicant, Peratech Holdco Limited and sold under the trade mark QTC®.

In the embodiment, the first electrode array 301 , second electrode array 302 and active layer 303 are sequentially printed as inks onto substrate 210 to form the overall array. Thus, when overlaid in this way, the plurality of sensing elements each occur at each intersection of the first electrode array and the second electrode array. Specifically, the combination of the intersections between the first electrode array and the second electrode array can be used to calculate the position of a mechanical interaction, while the active layer is configured to provide an extent property or intensity of a force applied in a conventional manner by interpretation of the electrical outputs. This combination allows for single or multiple touch events to be measured via the sensing array.

In the embodiment, a stretchable, flexible substrate 210 is provided which allows the sensing array 201 to be flexible in its entirety. In this illustrated embodiment, sensing array 201 is shown in exploded view, however, it is appreciated that the sensing array has a relatively small thickness 304 - under around fifty micrometres (50 pm) in total with the printed electrode arrays and active layer comprising around twenty micrometres (20 pm) of the total thickness 304.

Figure 4

By ensuring that the sensing array is flexible and of low thickness, it is possible to apply sensing array 201 to a main body 401 . Thus, when applied, sensing array 201 forms an outer shell which conforms to main body 401 and takes the shape of main body. In this way, sensing array 201 can be shaped into a suitable interface device, such as the spherical interface device 101 shown in Figure 1 , which can be easily utilised by a user.

Main body 401 can be any suitable three-dimensional shape having a surface onto which sensing array 201 conforms. In further embodiments, as an alternative to the sphere shown, main body 401 takes an alternative shape, however, sensing array 201 still conforms to the external surface of the main body of interface device 101 in a substantially similar manner. Due to the low thickness of the sensing array, the main dimensions of the interface device can be defined by the main body as the sensing array wraps around the main body.

Figure 5

In the embodiment, interface device 101 further comprises an outer skin forming a protective layer for sensing array 201. Figure 5 illustrates an outer protective layer 501 shown partially removed from the main body. It is appreciated that in practice, protective layer 501 covers the entire sensing array 201 and the entire surface of the sphere.

In the embodiment, outer skin 501 comprises a compressible material, and, in one embodiment the outer skin comprises an elastomeric material. It is appreciated that any suitable material may be utilised for the outer skin, provided that it provides a degree of protection for the sensing array and is also suitable for a user to apply a pressure or force to the sensing array underneath. In an embodiment, outer skin 501 may be chosen to provide an aesthetically pleasing texture to a user or a texture which corresponds to the intended application of the interface device.

In the embodiment, outer skin 501 has a thickness of between one hundred and five hundred micrometres (100 pm to 500 pm) which allows for sensing array 201 to respond to an applied mechanical interaction, such as a finger press or other force application.

Thus, outer skin 501 provides a further layer of low thickness and an outer surface for the interface device. In addition, by making outer skin 501 compressible, the interface device can be responsive to a user and utilised in the manner of a ball that can be squeezed to activate the sensing array, as will be illustrated further in Figure 9. Figure 6

A further illustration of interface device 101 is shown in Figure 6 in diagrammatic form whereby main body 401 is shown as a cut-open hemisphere. It is anticipated that the spherical main body 401 may comprise two similarly shaped hemispheres which can be secured together to form the full spherical main body shown previously.

As previously described, interface device 101 comprises main body 401 having a sensing array 201 which forms an outer shell conforming to main body 401. In the embodiment, main body 401 comprises an inner cavity designated generally as 601. Inner cavity 601 comprises at least one electronic component therein. In the illustrated embodiment, inner cavity 601 houses a plurality of electronic components, including, for example, a sensing circuit 602, processor 603, power source 604 and a wireless module 605. In addition, interface device 101 further comprises a sensing circuit USB diagnostics module 606 for providing diagnostic assessments. It is anticipated that other or alternative electronic components may be included therein.

In the embodiment, power source 604 comprises a battery, and in an example embodiment, the battery is a conventional type available under the designation CR2032. It is appreciated that any other suitable power source may be incorporated into the interface device for powering the electronic components. In the embodiment, sensing circuit 602 and processor 603 are in electrical communication with sensing array 201 thereby allowing them to process mechanical interactions provided from a user interacting with interface device 101. Sensing circuit 602 and processor 603 are therefore powered by power source 604 and are provided with the capability of providing a signal to an external device in response to a mechanical interaction to sensing array 201.

In the embodiment, wireless module 605 may comprise a Bluetooth® module, a Zigbee® module or other wireless standard transmission module. In this way, the electronic components describe allow interface device 101 to communicate wirelessly to a variety of external devices as required by sending a control signal to the external device by means of the wireless module 605.

While in the illustrated embodiment, the electronic components are shown as independent components which are in electrical communication with sensing array 201 , it is appreciated that, in alternative embodiments, fewer electronic components may be present where combined components are available. For example, an integrated circuit (IC) chip may be provided that provides the capacity to process inputs from the sensing array 201 as well as preparing the wireless signal for transmission to the external device.

Figure 7

Interface device 101 as described herein provides an intuitive controller for any suitable external device. By providing a sensing array capable of identifying positional properties of a touch event (by means of the electrode array layers) and extent or intensity of the touch event (by means of the active layer), interface device 101 is configured to interpret a variety of gestures to communicate various signals to different external devices by means of the wireless communication.

In a first example application, interface device 101 receives a plurality of inputs 701 , 702, 703, 704 and 705 corresponding to a user’s fingers and thumb. A gesture can be provided across the surface of the outer skin 501 , such as by applying the thumb and fingers at different positions on the outer skin, to provide an adjustment of volume of an external device, such as, in this example, a television or audio system. In this example, sensing array 201 responds to inputs 701 , 702, 703, 704 and 705 in a sophisticated manner by identifying the position of each of the inputs, and processing these inputs by means of the electronic component therein, such as the processor, to provide a suitable volume on the external device.

The compressible surface of the outer skin 501 provides a response to a user which may result in the inputs forming temporary indentations in the surface of the outer skin 501. This provides a more tactile response to a user. Figure 8

In a further example application, user 801 utilises interface device 101 in the palm of their hand to operate external device 802, which, in this example, comprises a television set.

In the embodiment, user 801 may provide a five-finger press, utilising each digit on their hand to activate menu 803 on television 802. In order to scroll through the series of options, a variable press or lighter press may be applied, with selection taking the form of a higher press. Thus, the interface device allows for multiple inputs and gestures for controlling television 802.

In a further embodiment, a similar approach may be taken to provide an input to a personal computer or a mobile telephone or other suitable electronic device. In this way, these devices can be operated wirelessly.

Figure 9

In addition to the operation and selection of inputs/menus of an external device such as television 802, interface device may be further utilised to provide an activation/deactivation input to enable switching of the external device on and off.

In the embodiment of Figure 9, interface device 101 is shown in a first configuration where it comprises a substantially spherical form, indicated by the numeral 901 , and a second configuration where it comprises a deformed elliptical form 902. In the embodiment, a user squeezes interface device 101 to change the conf guration of interface device from first configuration 901 to second configuration 902.

This provides a further gesture in which, in one example, interface device 101 may be used to provide a simple on/off switch for a user.

Figure 10

An example application in which interface device 101 is utilised to control a lighting system 1001 is shown in Figure 10.

In this example embodiment, user 1002, again, holding interface device 101 in the palm of their hand, moves their thumb forwards and backwards across the surface of interface device 101. Thus, interface device 101 can use this gesture to adjust the brightness of lighting system 1001 by providing a gesture action with their thumb in line with arrow 1003. In an alternative embodiment, this action may be utilised to select activation of a plurality of light sources within the lighting system in a similar way.

It is appreciated that other combinations of finger presses with (or without) variations in individual finger pressure/force can be envisioned that could be assigned specific actions onto the controlled external device. It is also possible that the interface device may be used in applications involving grip strength measurement for exercising, medical or rehabilitation purposes or similar.

The invention therefore provides a device that has the ability to capture gestures, in the form of combinations of several finger inputs, to determine intent, while being in the form of a device which fits naturally in the palm of a hand.