A one-piece shaped single layer piezoresistive array type sensing knit fabric

Abstract

The application discloses a single-layer pressure resistance array type sensing knitted fabric, and belongs to the field of intelligent fabrics, which comprises a sensing base, a horizontal electrode and a vertical electrode, and is a whole knitted fabric. The sensing base is divided into a sensing area and a structure support area, and the horizontal electrode and the vertical electrode are both divided into a functional section and a fixed section. The horizontal electrode functional section and the vertical electrode functional section are respectively located on both sides of the sensing base, and their intersection points are located in the sensing area of the sensing base, so that a sensing unit with a sandwich structure is formed in the area; the horizontal electrode fixed section and the vertical electrode fixed section are distributed in the structure support area of the sensing base and do not contact each other. The sensing base, the horizontal electrode and the vertical electrode are formed by different yarns through a double-needle bed knitting machine, and the sensing array can be knitted by additionally arranging the horizontal electrode and the vertical electrode.

Description

Technical Field

[0001] This invention belongs to the field of smart fabrics, specifically relating to a single-layer piezoresistive array type sensor knitted fabric that is woven in one piece. Background Technology

[0002] Piezoresistive array sensing fabrics are soft and breathable, and can acquire pressure sensing data with spatial information within a certain range, making them a popular area of ​​research in flexible sensing. Currently, common methods include stacking two or three pieces of fabric to form a "sandwich" structure for the sensing array; or weaving core-spun yarn into a single fabric on a shuttle loom, with the sensing array formed by the interweaving of the core-spun yarn. Of these two methods, the former requires sewing, resulting in thick, multi-layered sensing fabrics that are not comfortable to wear; the latter, due to the use of shuttle weaving, involves complex machining processes and is very costly for small-batch production. Single-piece knitted piezoresistive array sensing fabrics can meet the needs of reducing thickness and saving development costs, but this design and implementation are currently lacking. Summary of the Invention

[0003] To achieve a single-piece knitted form of piezoresistive array (PVA) sensor fabric, thereby reducing the thickness and development cost of PVA sensor fabrics, this invention provides a single-layer PVA sensor knitted fabric that is knitted in one piece. The sensor knitted fabric achieves this through a specially designed needlework structure, eliminating the need for sewing, embroidery, or printing; the sensor array is obtained immediately upon finishing the fabric.

[0004] The technical solution adopted by this invention to solve its technical problem is:

[0005] A single-layer piezoresistive array type sensor knitted fabric woven in one piece, comprising:

[0006] The sensing substrate is divided into a sensing area and a structural support area. The sensing area is composed of weakly conductive yarn, and the structural support area is composed of weakly conductive yarn or insulating yarn.

[0007] The transverse electrode is divided into a transverse electrode functional section and a transverse electrode fixing section, and is made of highly conductive yarn.

[0008] The longitudinal electrode is divided into a longitudinal electrode functional section and a longitudinal electrode fixing section, and is made of highly conductive yarn.

[0009] The transverse electrode functional segment and the longitudinal electrode functional segment are located on both sides of the sensing substrate, with their intersection point located in the sensing area, forming a "sandwich" structure sensing point in the sensing area; the transverse electrode fixing segment and the longitudinal electrode fixing segment are distributed in the structural support area, and the highly conductive yarns of the two fixing segments do not contact each other. The single-layer piezoresistive array type sensing knitted fabric, composed of the sensing substrate, the transverse electrode, and the longitudinal electrode, is directly knitted by a double needle bed knitting machine, and has array piezoresistive sensing function immediately after knitting, without the need for multiple fabric layers or sewing, printing, or gluing.

[0010] Furthermore, the resistivity of the weakly conductive yarn is greater than that of the well-conducting yarn.

[0011] Furthermore, the double-needle bed knitting machine is a double-needle bed computerized flat knitting machine, a double-needle bed circular knitting machine, or a hand-cranked flat knitting machine, and the needle pattern is directly designed by the pattern-making software or implemented by manually cranking the machine.

[0012] Furthermore, the needlework of the sensing area is knitting; before the transverse electrode is knitted in, all loops of the weakly conductive yarn knitting the sensing area are turned to the single needle bed, and after the transverse electrode passes through the sensing area in a floating form, the sensing area resumes knitting; the single needle bed can be a front needle bed or a back needle bed, referred to as a transfer needle bed; the needlework of the structural support area is any combination of empty needle, knitting, tucking, or picking holes.

[0013] Furthermore, the needlework of the transverse electrode functional section is a hollow needle, and the needlework of the transverse electrode fixing section is any combination of hollow needle, knitting, tucking, or picking holes.

[0014] Furthermore, the needlework of the longitudinal electrode functional section can be any combination of empty needle or single needle bed knitting, and the needlework of the longitudinal electrode fixing section can be any combination of empty needle or knitting.

[0015] Furthermore, the transverse electrode functional segment is located on the non-transfer needle bed side of the sensing area, and the longitudinal electrode functional segment is located on the transfer needle bed side of the sensing area; the transverse electrode fixing segment is woven in the last column near the transverse electrode functional segment, and the coil is formed on the needle bed of the non-transfer needle bed; the stitching method of the structural support area is any combination of empty needle, knitting, tucking, or picking.

[0016] Furthermore, the longitudinal electrode is moved slightly by the yarn feeder using a hollow needle technique to avoid needle collisions during the weaving of the sensing area, the structural support area, and the transverse electrode.

[0017] Furthermore, the number of rows and columns of the lateral electrode functional segment and the lateral electrode fixed segment can be adjusted; the number of rows of the longitudinal electrode functional segment and the longitudinal electrode fixed segment can be adjusted; by adding the lateral electrode and the longitudinal electrode, a sensing array is obtained; the needle method of each sensing unit in the sensing array is not limited to each other.

[0018] The beneficial effects of this invention are that it provides a single-layer piezoresistive array type sensor knitted fabric that is woven in one piece, achieving a single-layer form of the piezoresistive array type sensor fabric. Achieving a one-piece weaving effect using a dual-needle bed knitting machine eliminates the need for cutting and sewing in the production of the piezoresistive array type sensor knitted fabric, simplifying the process, reducing labor and development costs, and facilitating mass production. The single-layer characteristic of the piezoresistive array type sensor knitted fabric reduces the thickness of the sensor fabric, which helps improve wearing comfort. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of a single-layer piezoresistive array type sensor knitted fabric woven according to the present invention.

[0020] Figure 2 This is an analysis of a single-layer piezoresistive array type sensor knitted fabric circulation unit of the present invention.

[0021] Figure 3 This is a schematic diagram of an electrode arrangement and needle method for a circulation unit of the present invention;

[0022] In the figure: 1. Sensing substrate; 11. Sensing area; 12. Structural support area; 2. Lateral electrode; 21. Lateral electrode functional segment; 22. Lateral electrode fixing segment; 3. Longitudinal electrode; 31. Longitudinal electrode functional segment; 32. Longitudinal electrode fixing segment. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0024] like Figure 1 , Figure 2 As shown, the single-layer piezoresistive array type sensor knitted fabric of the present invention includes: a sensing substrate 1, a transverse electrode 2, and a longitudinal electrode 3.

[0025] Specifically, the sensing substrate 1 is divided into a sensing region 11 and a structural support region 12; the lateral electrode 2 is divided into a lateral electrode functional segment 21 and a lateral electrode fixing segment 22; and the longitudinal electrode 3 is divided into a longitudinal electrode functional segment 31 and a longitudinal electrode fixing segment 32.

[0026] Specifically, the sensing knitted fabric, which is composed of the sensing substrate 1, the transverse electrode 2 and the longitudinal electrode 3, is directly knitted by a double needle bed knitting machine.

[0027] Optionally, the double-needle bed knitting machine is a double-needle bed computerized flat knitting machine, a double-needle bed circular knitting machine, or a hand-cranked flat knitting machine, and the needle pattern is directly designed by the pattern-making software or implemented by manually cranking the machine.

[0028] Specifically, such as Figure 2 As shown, the transverse electrode functional segment 21 and the longitudinal electrode functional segment 31 are located on both sides of the sensing substrate 1, and their intersection point is located in the sensing region 11, forming a "sandwich" structure sensing point in the sensing region 11; the transverse electrode fixing segment 22 and the longitudinal electrode fixing segment 32 are distributed in the structural support region 12 and do not contact each other.

[0029] Specifically, as shown in Figure 3, the sensing area 11 and the structural support area 12 are stitched with a front needle bed; the transverse electrode functional section 21 is stitched with a blank needle; and the transverse electrode fixing section 22 is stitched with a rear needle bed. The longitudinal electrode functional section 31 is stitched with a blank needle; and the longitudinal electrode fixing section 32 is stitched with a blank needle.

[0030] Optionally, the needlework of the sensing area 11 can also be double-needle-bed knitting, where the needles are flipped to the transfer needle bed before the transverse electrode is knitted in. The needlework of the structural support area 12 can also be any combination of loose needles, knitting, tucking, or picking holes, regardless of the needle bed. The float yarn of the transverse electrode functional section 21 is on the non-transfer needle bed side of the sensing area 11, and the needlework is loose needles or tucking followed by unhooking. The transverse electrode fixing section 22 is knitted in the last column near the transverse electrode functional section 21, and the loops are formed on the needle bed of the non-transfer needle bed of the sensing area 11. The needlework of other parts can be any combination of loose needles, knitting, tucking, or picking holes, regardless of the needle bed. The needlework of the longitudinal electrode functional section 31 can also be single-needle-bed knitting; the needlework of the longitudinal electrode fixing section 32 can also be knitting.

[0031] Optionally, the material of the sensing region 11 is a blended yarn of metal wire and insulating fiber, or a yarn or fiber composed of conductive particles mixed with high-molecular organic matter or only conductive high-molecular organic matter, such as carbon fiber, metal particle fiber, and polypyrrole fiber; the material of the structural support region 12 is cotton yarn, polyester, spandex, or insulating blended yarn, or the same material as the sensing region 11; the material of the transverse electrode 2 is stainless steel, silver, or copper wire, or a blended yarn spun from metal wire and insulating fiber, or a metal-plated yarn; the material of the longitudinal electrode 3 is stainless steel, silver, or copper wire, or a blended yarn spun from metal wire and insulating fiber, or a metal-plated yarn.

[0032] Specifically, such as Figure 3 As shown, the longitudinal electrode 3 moves the yarn feeder in a small range using a hollow needle technique to avoid needle collisions during the weaving of the sensing area 11, the structural support area 12, and the transverse electrode 2. Optionally, the yarn of the longitudinal electrode 3 can be introduced by the yarn feeder at the beginning of fabric weaving, and the introduction direction of multiple sets of longitudinal electrodes 3 can be on the same side or opposite sides.

[0033] Optionally, the number of rows and columns of the transverse electrode 2 can be adjusted; the number of rows of the vertical electrode functional segment 31 can be adjusted; and the number of rows and columns of the vertical electrode fixed segment 32 can be adjusted.

[0034] Specifically, a sensing array is obtained by adding the transverse electrode 2 and the longitudinal electrode 3; the needle pattern of each sensing unit in the sensing array is not limited to each other. The yarn feeders of the transverse electrode 2, the sensing substrate 1, and the longitudinal electrode 3 are arranged in sequence, with the yarn feeders involved in the sensing substrate 1 in the middle.

[0035] In another embodiment of the present invention, the transverse electrode 2 and the longitudinal electrode 3 are core-spun yarns.

[0036] Specifically, the core yarn is made of stainless steel, silver, or copper wire, or a blended yarn spun from metal wire and insulating fiber, or metal-plated yarn, with a resistivity of less than 100 Ω / cm; the coating material is made of carbon-doped organic coating, metal-particle-doped organic coating, conductive compound coating, carbon-doped chemical fiber, metal-particle-doped chemical fiber, or polypyrrole fiber, with a resistivity range of 10 Ω / cm. 4 ~10 9 Ω / cm.

[0037] The remaining steps are the same as in the basic implementation.

[0038] In another embodiment of the present invention, the longitudinal electrode 3 avoids needle collision by adjusting the height of the corresponding yarn feeder. The remaining steps are the same as in the basic embodiment.

[0039] Obviously, the described embodiments are only some preferred examples of the present invention, and not all examples. Each embodiment focuses on the differences from other embodiments, and the same or similar parts between embodiments can be referred to each other. The scope of protection of the present invention is not limited to the above embodiments, and all technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A single-layer piezoresistive array type sensor knitted fabric formed in one knitting process, characterized in that, include: The sensing substrate is divided into a sensing area and a structural support area. The sensing area is composed of weakly conductive yarn, and the structural support area is composed of weakly conductive yarn or insulating yarn. The transverse electrode is divided into a transverse electrode functional section and a transverse electrode fixing section, and is made of highly conductive yarn. The longitudinal electrode is divided into a longitudinal electrode functional section and a longitudinal electrode fixing section, and is made of highly conductive yarn. The transverse electrode functional segment and the longitudinal electrode functional segment are located on both sides of the sensing substrate, and their intersection point is located in the sensing area, forming a "sandwich" structure sensing point in the sensing area; the transverse electrode fixing segment and the longitudinal electrode fixing segment are distributed in the structural support area, and the conductive yarns of the two fixing segments do not contact each other. The single-layer piezoresistive array type sensing knitted fabric, which is composed of the sensing substrate, the transverse electrode and the longitudinal electrode, is directly knitted by a double needle bed knitting machine. After knitting, it has the array piezoresistive sensing function without the need for multiple fabrics to be stacked or sewn, printed or pasted. The needlework of the sensing area is knitting; before the transverse electrode is woven in, all the loops of the weakly conductive yarn in the sensing area are turned to the single needle bed. After the transverse electrode passes through the sensing area in the form of a floating thread, the sensing area resumes knitting; the single needle bed is a front needle bed or a back needle bed, called a transfer needle bed; the needlework of the structural support area is any combination of empty needle, knitting, tucking, or picking holes.

2. The single-layer piezoresistive array type sensor knitted fabric according to claim 1, characterized in that: The resistivity of the weakly conductive yarn is greater than that of the well-conducting yarn.

3. The single-layer piezoresistive array type sensor knitted fabric according to claim 1, characterized in that: The double-needle bed knitting machine is a double-needle bed computer flat knitting machine, a double-needle bed circular knitting machine, or a hand-cranked flat knitting machine. The needle pattern is designed directly by the pattern-making software or implemented by manually cranking the machine.

4. The single-layer piezoresistive array type sensor knitted fabric according to claim 1, characterized in that: The needlework technique for the transverse electrode functional section is empty needle, and the needlework technique for the transverse electrode fixing section is any combination of empty needle, knitting, tucking, or picking holes.

5. The single-layer piezoresistive array type sensor knitted fabric formed in one knitting process according to claim 1, characterized in that: The needlework of the longitudinal electrode functional section can be any combination of empty needle or single needle bed knitting, and the needlework of the longitudinal electrode fixing section can be any combination of empty needle or knitting.

6. The single-layer piezoresistive array type sensor knitted fabric according to claim 1, characterized in that: The transverse electrode functional segment is located on the non-transfer needle bed side of the sensing area, and the longitudinal electrode functional segment is located on the transfer needle bed side of the sensing area; the transverse electrode fixing segment is woven in the last column near the transverse electrode functional segment, and the coil is formed on the needle bed of the non-transfer needle bed.

7. A single-layer piezoresistive array type sensor knitted fabric woven in one piece according to any one of claims 1 to 6, characterized in that: The longitudinal electrode is moved in a small range by the empty needle method to avoid needle collision when weaving the sensing area, the structural support area and the transverse electrode.

8. A single-layer piezoresistive array type sensor knitted fabric woven in one piece according to any one of claims 1 to 6, characterized in that: The number of rows and columns of the lateral electrode functional segment and the lateral electrode fixed segment can be adjusted; the number of rows and columns of the longitudinal electrode functional segment and the longitudinal electrode fixed segment can be adjusted; by adding the lateral electrode and the longitudinal electrode, a sensing array is obtained; the needle method of each sensing unit in the sensing array is not limited to each other.

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