BACKGROUND

Force sensors are often used to control or regulate a force that is applied to a component. In one type of force sensor, the force sensor is positioned in such a way that forces to be measured act on the sensor. The force sensor may be configured to transform a measurement of forces into an electrical signal for further use in the control or regulation of the forces. This type of force sensor may be used in a variety of applications, such as for measuring braking force of electromechanical brakes in automobiles. For example, a force-compliant element of the force sensor may be coupled to some component of the braking system and as forces are applied, the force-compliant element temporarily deforms. In this example, the strain on the force-compliant element may be measured and used to generate an electrical signal that is indicative of the forces acting on the component of the braking system.

SUMMARY

The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular descriptions of exemplary embodiments of the invention as illustrated in the accompanying drawings wherein like reference numbers generally represent like parts of exemplary embodiments of the invention.

In a particular embodiment, a force sensor apparatus is disclosed that includes a force-compliant element that deforms in response to forces applied to the force sensor apparatus. The apparatus also includes a sensing element coupled to the force-compliant element and configured to generate a signal indicating the degree that the force-compliant element deforms in response to the application of forces to the force sensor apparatus. In this embodiment, the apparatus also includes a printed circuit board configured to receive the signal from the sensing element and a support structure having a surface on which the printed circuit board is coupled. The support structure has an outer rim that is attached to the force-compliant element. The apparatus also includes a sensor housing that covers the printed circuit board. The sensor housing has an outer rim attached to the force-compliant element.

In another embodiment, a force sensor apparatus is disclosed that includes a force ring configured to deform in response to applications of forces to the force sensor apparatus. The force ring has a plurality of sensing elements configured to produce an electrical signal that is indicative of the amount of deformation in the force ring. The apparatus also includes a printed circuit board configured to process the electrical signal from the force ring. In this embodiment, the apparatus also includes a sensor cap covering the printed circuit board and a portion of the force ring. The sensor cap has an inner rim and an outer rim attached to the force ring. The apparatus also includes a circular environmental seal between the inner rim of the sensor cap and the inner rim of the force ring.

In a particular embodiment, a method of assembling a force sensor apparatus is disclosed. The method includes attaching a printed circuit board (PCB) having electrical components to a support ring; electrically coupling the electrical components of the PCB to at least two sensing elements on a force ring, the at least two sensing elements configured to measure forces applied to the force sensor apparatus; attaching the support ring to the force ring; positioning a sensor cap over the PCB and the support ring; and attaching the sensor cap to the force ring.

