System and method for quality verification of mixture

Abstract

An electrical characteristic sensor is proposed comprising a laminate structure comprising an insulating layer, an electrically conductive layer and an electrically conductive trace, the laminate structure having a first face 5 separated from a second face by a thickness, the first face having a length and a width. The sensor also includes a first aperture and a second aperture, each of the first aperture and the second aperture extending from the first face of the laminate to the second face of the printed circuit board, the first aperture and the second aperture each including a receive electrode and a transmit electrode. A sensor signal indicative of an electrical characteristic is measured at the receiving electrode when a fluid flows through the first aperture and an electric field is generated at the transmitting electrode.

Description

Background Art

[0001] Many products require mixtures in their manufacture, such as paints, adhesives, resins, etc. for commercial or industrial use. Many mixtures include different materials that may settle or separate over time. The users of the mixtures may not easily recognize that the composition is no longer uniform. Summary of the Invention

[0002] An electrical property sensor is proposed, which includes a laminated structure. The laminated structure includes an insulating layer, a conductive layer and conductive traces. The laminated structure has a first side separated from a second side by a certain thickness. The first side has a length and a width. The sensor further includes a first hole and a second hole. Each of the first hole and the second hole extends from the first side of the laminated structure to the second side of the printed circuit board. The first hole and the second hole each include a receiving electrode and a transmitting electrode. When a fluid flows through the first hole and an electric field is generated at the transmitting electrode, a sensor signal indicating the electrical property is measured at the receiving electrode.

[0003] Systems and methods including such sensors allow direct contact between these sensors and the fluid flowing through the dispenser, because the sensors herein are cost-effective to manufacture and can be discarded after use. The systems and methods herein also allow collecting multiple sensor signals across the fluid flow, thereby providing real-time information about the materials entering and leaving the mixing area. The systems and methods herein also allow bubble detection and removal. The systems and methods herein allow the dispensing system and its operator to change the operating parameters during operation to solve problems (either when the problem is occurring or possibly before the problem occurs), so that less material is wasted and the dispensing can be more accurate.

[0004] The above summary of the present disclosure is not intended to describe every disclosed embodiment or every specific implementation of the present disclosure. The following description more specifically illustrates exemplary embodiments. Throughout this application, guidance is provided by way of lists of examples, which may be used in various combinations. In each case, the recited lists are only used as representative groups and should not be construed as exclusive lists. Therefore, the scope of the present disclosure should not be limited to the specific exemplary structures described herein, but should at least extend to the structures described by the language of the claims and the equivalent forms of these structures. Any element positively cited as an alternative in this specification may be explicitly included in or excluded from the claims as needed in any combination. Although various theories and possible mechanisms may have been discussed herein, in no case should such discussions be used to limit the subject matter that may be protected by the claims. Brief Description of the Drawings

[0005] Figures 1A to 1CIllustrated is a system for dispensing atomized fluid that can benefit from the systems and methods herein.

[0006] Figure 2 Illustrated is an exploded view of a spray gun in which the embodiments described herein can be implemented.

[0007] Figures 3A to 3B Illustrated is a material measurement flow sensor according to an embodiment herein.

[0008] Figures 4A to 4B Illustrated is a spray gun according to an embodiment herein.

[0009] Figure 5A and Figure 5B Illustrated is a material measurement flow sensor in use according to an embodiment herein.

[0010] Figures 6A to 6B and Figures 7A to 7D Illustrated is an example implementation of a dispensing system equipped with a sensor system according to an embodiment herein.

[0011] Figures 8A to 8C Illustrated are the dispersion states that may be experienced using the sensor systems and methods described herein.

[0012] Figure 9 Illustrated is a stir bar configured to provide in-situ conductivity measurements of a mixture.

[0013] Figure 10 Illustrated is an elongate sensor according to an embodiment herein.

[0014] Figures 11A to 11D Illustrated is a sensor having electrodes in a series configuration according to an embodiment herein.

[0015] Figure 12 Illustrated is another embodiment of a system in which the embodiments herein may be useful.

[0016] Figures 13A to 13C Illustrated is a sensor configuration for bubble detection according to an embodiment herein.

[0017] Figure 14 Illustrated is a method for detecting and correcting quality issues in a mixture according to an embodiment herein.

[0018] Figure 15 Illustrated is a quality control system according to an embodiment herein.

[0019] Figures 16A to 16B Illustrated is a sensor configuration according to an embodiment herein.

[0020] Figure 17Illustrated is a method for quality control of a material dispensing system according to an embodiment of the present disclosure.

[0021] Figures 18A to 18C Illustrated is a conductivity measurement system in an example network architecture.

[0022] Figures 19 to 21 Illustrated is an example computing device that can be used in embodiments of the present disclosure.

[0023] Figures 22 to 24 Illustrated are the results described in the examples. Detailed Description

[0024] The present disclosure relates to systems and methods including sensors for in-situ determination of properties of fluids. The present disclosure also relates to data sets received from such sensors and methods for using the data to analyze the fluid properties. Using the systems and methods described herein, the operating conditions of a mixture (e.g., changing pressure, temperature, mixing ratio, etc.) can be adjusted before or during operation, or the compositional consistency (e.g., remixing, exhaust gas, etc.) can be improved.

[0025] Many industrial processes use mixtures, such as, for example, liquid adhesives, liquid food ingredients, liquid coolants, or liquid reaction products. Certain properties of such liquids change over time: dispersions or emulsions can separate, oils can become less viscous as the temperature rises, coolants can age and have a lower heat capacity than initially. The performance of the products used can be affected. For example, paint may have soft curing (or no curing at all), may be brittle, cracked, undergo delamination, or have poor adhesion. If the paint mixture is inconsistent before application, corrective actions may take a significant amount of time, and energy-intensive sanding and surface treatment may be required before a second attempt at a painting operation. Solving these problems requires detailed chemical knowledge, time, and eliminating other causes. For many operations, troubleshooting takes time that cannot be saved.

[0026] A co-pending international application IB2021 / 056362, filed on July 14, 2021, discloses a property sensor for determining property values of a liquid, the property sensor including two PCB boards that define a channel through which the liquid flows. Although this allows for direct contact between the sensor and the fluid, there is a need for a cost-effective sensor that can provide more background information about material mixing. Embodiments of the present disclosure provide systems and methods for effectively and accurately measuring material information for mixture quality control.

[0027] This document describes sensors and sensor systems for measuring the electrical properties of fluids. Broadly speaking, the sensors herein operate by using a provided current or voltage through a transmitting electrode, which generates an electric field. When the fluid flows between the transmitting electrode and the receiving electrode, current is conducted to the receiving electrode. As used herein, the term "sensor" can refer to either a physical sensor that provides a sensor signal indicative of the conducted current or a "sensor system" that includes a processor for calculating the electrical properties of the fluid based on the sensor signal.

[0028] The term "electrical property" is intended to broadly refer to any electrical property of the fluid that can be derived based on impedance measurements of the sensor. For ease of understanding the embodiments, impedance measurements are used as an example herein. However, it is explicitly contemplated that other electrical properties can be calculated and are relevant to the embodiments herein. For example, conductivity measurements or relative permittivity can also be determined from impedance measurement results. As shown herein, conductivity or relative permittivity can be relevant for determining the relevant functionality of a distribution system or the quality of the fluid flowing therein.

[0029] As used herein, the term "real-time" refers to data being processed within a few milliseconds such that it is effectively immediately available for feedback. While some delay due to processing is inevitable, "real-time" is intended to cover systems and methods where data can be collected or input and the user can then interact with the data without significant delay. For example, a user can input data into a system, and subsequently the data is input and is essentially immediately available for viewing or editing.

[0030] As described herein, the sensors are described as measuring the electrical properties of a "fluid". The term "fluid" is intended to be broadly interpreted and is intended to cover liquids with low viscosity, liquids with high viscosity, semi-solid materials, suspensions, molten materials, or other flowable materials.

[0031] As used herein, electrical parameters can be detected by an electrode pair. The fluid can flow between or across the electrode pair. When a voltage or current is applied, the transmitting electrode can generate an electric field, while the receiving electrode receives current or voltage. The sensed electrical parameter can be conductivity, relative permittivity, or impedance. The terms relative permittivity and dielectric constant are used interchangeably herein.

[0032] The sensors are described herein as having one or more "holes" within a "printed circuit board". These terms are intended to be interpreted broadly. For example, the hole may extend completely through the thickness of the sensor along part or all of its length. The hole may have a bevel along part or all of its perimeter. The hole may be elongate, such as a slot, or may be shaped, such as a circular or oval aperture. The hole may have one or more corners or edges, or may have a curvature along part or all of its perimeter. As used herein, a "printed circuit board" is a laminated sandwich structure of conductive and insulating layers. The printed circuit board (PCB) herein may include any number of terminals and conductors that allow voltage to be applied to the emitting electrodes and allow current to be emitted from the receiving electrodes. Alternatively, the PCB may also be configured to allow current to be applied and voltage to be emitted. The PCB may be manufactured using conventional PCB manufacturing techniques or additive manufacturing techniques. As used herein, the PCB is intended to cover any number of layers, with or without edge connectors. Any suitable conductive metal may be used to form the conductive layer. Any suitable insulating material may be used to form the insulating layer.

[0033] The property sensors described herein can be used to sense the properties of fluids produced by a mixing process. These property sensors can also be used to sense the properties of input fluids for a mixing process or for an industrial manufacturing process. Advantageously, separate property sensors for the respective input fluids are placed precisely in front of the mixer. Data from these property sensors that measure the input fluids can be processed together with data from property sensors that measure the mixed fluid, for example in an integrated material property monitoring system. For example, in the case where a fluid composition is mixed from three input fluids, before mixing, the properties of each of the three fluids can be determined using three property sensors located at the respective outlets of three containers that hold the three input fluids. This can assist in quality control and reduce waste that might otherwise occur due to one of the input fluids being outside the specifications of its properties.

[0034] The sensors described herein can determine various properties of a fluid, such as for example the mixing ratio of a two-component adhesive or the curing state or aging state of a curable composition.

[0035] As used herein, the term "curing" is intended to broadly encompass the change of a material from a first state to a second state. For example, some liquids cure to solids. Some mixtures may undergo crosslinking. Some mixtures may undergo pre-polymerization. Some mixtures may undergo transformation. The number of properties that were previously varied to establish a calibration data set representing a calibration impedance response measured at different property values determines the number of properties that can later be determined by a property sensor. A pre-stored calibration data set representing a calibration impedance response measured at one or more sensing frequencies and at different property values of a property of a fluid forms or represents a multi-dimensional data domain specific to that fluid. This data domain allows a property value extractor to determine the value of a property of the fluid from an actually measured response impedance.

[0036] A fluid has many properties: for example, viscosity, density, color, content of volatile components, water content, chemical composition, boiling point, and aging state, curing state in the case of a curable composition of the fluid, or mixing ratio in the case of a mixture of the fluid.

[0037] In addition, certain properties of certain fluids change over time and / or with other parameters, such that the response impedance in the property sensors described herein also changes over time and / or with other parameters. The values of these properties can be derived via the sensors and systems described herein. Additionally, changes over time include changes in properties between different production batches of the fluid. Thus, the property sensors described herein can be used to detect differences in a certain property (e.g., chemical composition) of a suitable fluid between a later production batch and an earlier production batch of the fluid.

[0038] As used herein, a "fluid" can be part of a mixture. For example, one fluid can be mixed with another fluid, can receive or have particles dissolved therein, or can have materials suspended therein. For example, a resin can contain glass microparticles in one or both components.

[0039] According to the present disclosure, there is no particular limitation on the "properties" of a fluid. For example, as described in embodiments herein, one property of interest is the mixing ratio of two or more components of a fluid. In certain of these embodiments, the fluid is a two-component adhesive, and the property of the fluid is the mixing ratio of the components. In other embodiments, the property of interest is the degree of curing or curing state. In certain of these embodiments, the fluid is a curable composition, and the property of the fluid is the degree of curing of the composition.

[0040] In other embodiments, the property of interest is the degree or state of aging. In some of these embodiments, the fluid is an aging fluid, i.e., a fluid in which certain properties change over time once the aging fluid is created. The property sensor can determine the change in the response impedance of the same fluid after a certain aging compared to the response impedance recorded for the aging fluid before aging and at certain times after aging. The property sensor can thereby determine the degree or state of aging of the fluid.

[0041] The properties of a fluid can take on different values. For example, the property "dynamic viscosity" of the fluid "water" can take on values such as 1.30 mPa·s or 0.31 mPa·s. Such values are referred to herein as property values. Some properties may be related not only to numerical property values. The property "degree of curing" can have property values such as, for example, "uncured", "partially cured", or "fully cured". The property "curing state" can have property values such as, for example, "uncured" or "fully cured". The fluid according to the present disclosure can be a viscous fluid. Irrespective of its viscosity, the fluid can be a flowing fluid. The fluid can be a continuously flowing fluid.

[0042] "Fluid" or "fluid mixture" is used herein broadly to refer to a composition comprising two or more components. The components can all be liquids, or they can be particles in a liquid, etc. Generally, "fluid" or "fluid mixture" refers to a flowable substance. The systems and methods herein can be used for a range of fluid applications, including but not limited to: paints, resins for adhesives or other purposes, field-curing gaskets, adhesives or other coating materials, dental impression materials, void fillers, sealants, engineering fluids, thermal interface materials, precursor materials for any of these, or emulsions or any materials that can lose stability over time.

[0043] Figures 1A to 1C Illustrated is a system for dispensing an atomized fluid that can benefit from the systems and methods herein. Figure 1A Illustrated is a spray painting operation 100 in which a paint gun 114 atomizes paint from a paint cup 110 using air from an air source 112. However, while a spray painting operation is illustrated, the container 110 can provide other materials for dispensing. Figure 1B Illustrated is another configuration of a paint gun 130 that receives two materials and provides an atomized mixture. The paint gun 130 can be coupled to Figure 1C the illustrated system 150. The system 150 can include a pumping system for one or two components 132, and / or a pressurized air source.

[0044] Figure 2An exploded view of a spray gun is illustrated in which the embodiments described herein can be implemented. The spray gun 200 includes a container 202 that houses the fluid to be dispensed and so on. However, although the container 202 coupled to the nozzle using a fastener 204 is illustrated, it is expressly contemplated that a larger container can supply fluid to the spray gun 200, for example, using a pump. For example, the spray gun can be actuated when the trigger 208 is pulled.

[0045] Figures 3A to 3B A material measurement flow sensor according to an embodiment of the present disclosure is illustrated. Figure 3A A PCB material measurement flow sensor 300 is illustrated. As Figure 3A illustrated, the sensing system 300 includes a PCB board 302 that has one or more ground portions 330 and TX contacts 440. The TX contacts provide a transmit signal to each transmit electrode 310. Four RX contacts (not shown) located on the back side of the PCB receive an indication of the sensed impedance for each electrode pair among the electrode pairs. The potential of each receive electrode 320 is individually electronically regulated to ground potential. In some embodiments, the regulator action on each receive electrode is interpreted as an impedance signal for each electrode pair. In the illustrated embodiment, four separate measurement channels can each provide information through its own TX contact 340 and RX contacts (not shown).

[0046] In the illustrated embodiment, the sensing system 300 has four electrode pairs, where each of the four transmit electrodes 310 is paired with one of the four receive electrodes 320. However, it is expressly contemplated that there can be more or fewer electrode pairs depending on the available area on the PCB board and the sensing requirements.

[0047] Each electrode pair is decoupled from adjacent electrode pairs such that four separate conductivity measurements are received, where one conductivity measurement is received from each electrode pair 310, 320. In some embodiments, the sensing system 300 is placed perpendicular to the flow of the material such that a first sensing region 352 receives a first portion of the material flow, a second sensing region 354 receives a second portion of the material flow, a third sensing region 356 receives a third portion of the material flow, and a fourth sensing region 358 receives a fourth portion of the material flow. Thus, the system 300 can generate four different signals simultaneously with respect to a single material flow, thereby better reflecting whether the mixing ratio (or other measurement parameter) is consistent across the sensing region.

[0048] Compared to prior sensing systems, conductivity measurement requires both a positive and a negative electrode, which would require two PCBs for each electrode pair. In contrast, the system 300 allows four measurements to be made simultaneously with a single PCB. It also provides a larger surface area for the material flow with a shorter sensor distance.

[0049] Figure 3AEmbodiments are illustrated where each electrode pair is part of slots 352, 354, 356, 358. However, it is also contemplated that instead of being enclosed on both sides, the sensing region may include a pair of electrodes in a "comb" structure on a protrusion or within a hole. However, from a structural point of view, especially for viscous fluids, it is preferred that both ends are enclosed.

[0050] As further described herein, electrodes 310, 320 can be formed by metallizing the inner surfaces of the carrier sheets 352, 354, 356, 358, for example, using copper. This metallization process can connect electrode 320 to electrode 410. Therefore, a decoupling or disconnection step is required. This can be done by disconnecting the connection, for example, by drilling at positions 350A and 350B as illustrated in the figure, by punching out a perforated component, milling, punching, etching, laser cutting, or another suitable method.

[0051] The systems and methods herein can be used for a variety of dispensed materials. PCB boards typically have a maximum operating temperature of less than 170 °C, which limits the temperature of the materials that can be dispensed by the sensor system 300. The materials can have a range of viscosities, for example, up to about 10 5 Pa s. Higher viscosities may result in insufficient dispensing pressure to force the material through slots 352 to 358 without damaging the sensor. However, higher viscosity materials can be accommodated by increasing the width of slots 352 to 358. However, the sensing system 300 may be less sensitive. Similarly, for materials with particles (such as suspensions), the particle size must be less than the width of slots 352 to 358. Additionally, the systems herein may be limited to solvents that do not cause corrosion or otherwise damage the PCB 302 or electrodes 310, 320.

[0052] Figure 3B Another embodiment of the sensing system 360 is illustrated, which includes a built-in temperature sensor 370. The temperature sensor 370 is located within a slot having a connection point 372 for a ground signal and a connection point 374 for a temperature signal. The ground signal connection point 372 is connected to a ground signal communicator 382. The temperature signal communication point 374 is connected to a temperature signal communicator 376. Similar to Figure 3A 's embodiment, there are also four impedance or conductivity sensor slots 380, each slot connected to the ground signal 382. However, it should be noted that in Figure 3B 's embodiment, there are two different slot spacings. A first spacing 362 exists between the first and second slots 380 and between the third and fourth slots 380, while a second spacing 364 exists between the second and third slots 380. The increased spacing 364 can provide improved shielding against interference between the electromagnetic fields generated by each electrode pair.

[0053] Many mixing processes rely at least in part on temperature, and material properties such as viscosity vary with temperature. Temperature sensors inserted from an external point are typically fragile and need to be in the middle of the flow of the material being tested. In Figure 3B an embodiment, the temperature sensor is sealed within a housing that keeps the temperature sensor isolated from the material. The sealing layer can be, for example, a layer of varnish that allows for improved thermal contact relative to other housing materials. As illustrated, the temperature sensor is connected via contacts 382 on an edge connector.

[0054] Figures 3A to 3B An embodiment is illustrated in which slots 352 to 358, 370, and 380 are shaped like ovals, having a generally straight body and rounded ends. However, other configurations can be employed. For example, electrodes 310, 320 can be bent or otherwise shaped to accommodate the available volume of the dispensing system.

[0055] Although Figure 3A to FIG. 3C illustrate embodiments in which each of slots 352 to 358 includes a single electrode terminal, it is expressly contemplated that in some embodiments, one or more of slots 352 to 358 can accommodate multiple electrode terminals, e.g., having one or more terminals along the length of one or more of slots 352 to 358. Having a third or fourth terminal can allow for more accurate measurement of electrical parameters. Instead of a circuit configuration including an ohmmeter that measures resistance, there are alternative ammeters and voltmeters. A voltmeter measures the voltage across a circuit, while an ammeter measures the current flowing through a circuit. Impedance (e.g., resistance) can be derived from the measured voltage and current. Such a setup can result in more accurate measurement results of electrical parameters in the fluid flowing through slots 352 to 358.

[0056] FIGS. 3C to 3D illustrate a housing for a sensor according to some embodiments herein. In some embodiments, a sensor (such as sensor 300 or 360) can be directly received by a material dispensing system. However, it is also contemplated that in some embodiments, housing 390 can directly receive sensor 396. Housing 390 includes a receiving slot 392 for receiving the sensor, as illustrated by configuration 394.

[0057] In some embodiments, housing 390 is built into the dispensing system such that sensor 396 is received by the dispensing system. In some embodiments, the dispensing system receives housing 390 in which sensor 396 has already been installed. In some embodiments, sensor 396 can be sealed within housing 390 such that the dispensing system receives housing 390.

[0058] Figures 4A to 4B A spray gun according to an embodiment herein is illustrated. Figure 4AIllustrates Figure 2 an exploded view of, which lists potential placement options for the conductivity sensor, such as Figure 3A the conductivity sensors described in FIGS. 3A to 3D, or any other sensor configuration described herein.

[0059] As Figure 4A illustrated, one potential placement option is within the container 420, such as within the mixing impeller, within the cup itself, or within the lid.

[0060] Additionally or alternatively, another potential placement option is to place the sensor at the feed point of the spray gun. In Figure 4A this illustrated embodiment, this will provide an indication of the quality of the mixture as it enters the gun. In a two-part spray gun (as Figure 4B illustrated), there may be two sensors at the feed point, each for each feed prior to mixing. If one or both feeds are themselves mixtures, this can be particularly useful for troubleshooting. Some of the dispensers described herein benefit from a needle valve 440 that allows flow regulation.

[0061] Additionally or alternatively, another placement option would be in the atomizing head 460.

[0062] Figure 4B Illustrates a two-part spray gun according to an embodiment herein. An additional placement option for a two-part spray gun would be behind the spray nozzle 480 to ensure proper mixing of the two (or more) incoming components prior to spraying.

[0063] Using the systems and methods described herein, multiple parameters related to the quality of the mixture can be monitored either before or during the use of the mixture. Monitoring the quality of the mixture can refer to any one of consistency, texture, composition, or other related quality indicators. The sensor systems and methods of use herein can provide an indication of the mixing ratio, curing (e.g., open time, cure rate, temperature change), and can provide in-situ process indicators such as aging, bubble detection, or concentration, batch-to-batch variation, raw material quality, and phase separation. Using the sensor systems herein, quality issues (mixing ratio imbalance, phase separation, etc.) can be automatically detected and an indication for correcting the quality issue can be provided such that correction can be made in-situ.

[0064] Early detection of quality issues can help reduce the correction time and thus will reduce the operating time, correction supply costs, and correction operation time and costs. The sensors described herein can be implemented in many parts of the dispensing operation (at intake, during mixing or after mixing, within the dispenser, within the container, etc.).

[0065] The sensors described herein are capable of communicating with a computerized control system that can provide an alternating current (AC) voltage to generate an electric field required to measure conductivity, impedance, or dielectric constant using a suitable sensing system such as the sensing systems described herein. In some embodiments, the control system can also provide current. While various examples of the present disclosure are described with respect to the use of AC, it should be understood that in other examples, direct current (DC) can be used to implement the techniques of the present disclosure.

[0066] When performing an actual measurement of the quality control parameters of a mixture, the measured impedance response (MIR) can be recorded in the control system, with each measured impedance response (MIR) being measured at certain measurement sensing frequencies (MSF).

[0067] To derive, for example, the value of the mixing ratio from the measured impedance response at the measurement sensing frequency, the software running on the control system identifies those triples within the calibration impedance response triple set that have the closest calibration response impedance to the measured impedance response and the closest calibration sensing frequency to the measured sensing frequency. This identification and potential interpolation can be readily performed by using a parameterized multi-dimensional polynomial that models multiple triples of multiple data sets, namely (CMR, CSF, CIR). The software derives the value of the (hitherto unknown) mixing ratio in the actual measurement from these calibration data.

[0068] The same sensing frequencies used for calibration will generally also be used for measurement. However, the mixing ratio may occur in measurements where the calibration impedance response is not determined during calibration. Thus, there may not be an exact match between the sensing frequency and the response impedance among the triples in the calibration data set. In such cases, interpolation between two appropriately chosen calibration triples that contain two calibration impedance responses close to the measured response impedance yields an interpolated calibration mixing ratio, which can then be considered the mixing ratio in the measurement. The interpolation is performed by the software on the control system 220 using a parameterized multi-dimensional polynomial.

[0069] The result of the interpolation and derivation is the value of the mixing ratio of components A and B when the mixture passes through the PCB sensor during measurement.

[0070] In this embodiment, the calibrated impedance response is measured according to two parameters, namely the sensing frequency and the mixing ratio. In other embodiments, the dependence of the impedance response on other parameters, such as for example the temperature of the adhesive in the sensing area, may be considered. Then, the dataset of the calibrated impedance response will be a quadruple of values, such as (CMR, CSF, CIR, temperature), and the pre-stored calibrated impedance response set will be a set of quadruples forming a four-dimensional data domain that is specific to the mixture. Considering other parameters may make the dataset a quintuple of values or a higher-order tuple of values, such that the dataset of the calibrated impedance response is a multi-dimensional data domain and can be represented by a different parameterized multi-dimensional polynomial.

[0071] The control system may record the value of the mixing ratio with a timestamp to ensure quality. The mixing ratio derived during the actual measurement may be continuously checked against the desired mixing ratio. If the deviation of the mixing ratio derived during the actual measurement from the desired mixing ratio is greater than acceptable, the control system appropriately changes the flow rate of either component to adjust the measured mixing ratio towards the desired mixing ratio.

[0072] The method of forming a sensor system (such as those illustrated herein) may be similar to the method described in PCT / US22 / 52343 (e.g., Figure 5 and the associated description), which application is incorporated herein by reference.

[0073] Figures 5A to 5B An in-use material measurement flow sensor according to an embodiment herein is illustrated. As illustrated in two images, a sensor according to an embodiment herein may be placed in direct contact with the material or fluid, thereby providing a conductivity measurement based on that direct contact. This provides a more accurate mixing ratio measurement than other methods that do not allow direct contact between the sensor and the material. However, as Figure 5A and Figure 5B illustrate, the sensor is coated with the material after use. In scenarios where the material of interest is corrosive, highly viscous, or curable, it is beneficial to be able to discard the sensor after use.

[0074] Figures 6 through 7 illustrate an example implementation of a dispensing system equipped with a sensor system according to an embodiment herein. Figures 6A to 6B Views 600, 650 of a PCB sensor 620 are illustrated, which is incorporated into a nozzle such that fluid flow from a container (not shown) passes through the sensor 620 from an adapter 630 and is subsequently dispensed by an atomizing nozzle 610.

[0075] Figures 7A to 7D The placement of the sensor within a conduit is illustrated. Figure 7AIllustrates sensor 710 within conduit 700. Sensor 710 has four electrode pairs, each electrode pair placed within a slot such that when the mixture passes through the conduit (into the field), the mixture is forced through the slots of sensor 710, contacting each electrode pair, and the sensed conductivity measurements are transmitted to a control system, e.g., via edge connector 712. A change in the conductivity measurement between one electrode slot and another may indicate a change in the quality consistency of the mixture.

[0076] Figure 7B Illustrates a perspective view 700 of conduit 722. Conduit 722 may be coupled to another part of a dispensing system or a fluid delivery system. Conduit 722 may be coupled to another part of the fluid flow system using threads 726 or another suitable fastening system.

[0077] Figure 7C and Figure 7D Illustrates a cross - section view of the conduit. In Figure 7C Overmolded plastics 744, 740, 760 are used as seals to hold the PCB sensor in place. Such seals may have end stops to confirm that the sensor is in position. However, other seal options and position confirmation options (e.g., snaps or clips) are also possible. The illustrated seals may include barbs to maintain the connection.

[0078] In Figure 7D a different seal configuration is illustrated where an O - ring may be used. Corresponding recesses may be machined in the conduit to receive O - ring 764 to stabilize the sensor against the pressure of the fluid flow.

[0079] In some embodiments, the illustrated conduit may be replaceable such that the sensing assembly is a single - use component. In other embodiments, the sensor is removable such that the PCB sensor is a single - use sensor.

[0080] Figures 7A to 7D The illustrated exemplary embodiments relate to a PCB - based impedance sensor that may be attached to a static mixer using an adapter or other connection mechanism to provide real - time mixing ratio information. Using an adapter that can receive the PCB unit allows for the compatibility of the PCB sensor with many dispensing systems.

[0081] Figures 8A to 8C Illustrates three dispersion states that may be detected using the sensor systems and methods described herein. Figure 8A Illustrates a stable dispersion 810 where the particles (or another fluid) are uniformly dispersed throughout the mixture. From a colloidal perspective, a dispersion is stable when the flocculation of the particles that would prevent separation is inhibited because the particles repel each other. Figure 8BAn example of a dispersion 820 undergoing emulsion stratification is illustrated, where separation is occurring such that one material is separating to the top of the mixture. Figure 8C An example of a dispersion 830 is illustrated, where sedimentation is occurring and particles are settling to the bottom of the container.

[0082] So far, a sensor system has been described that can be used to evaluate the quality of a mixture during a dispensing operation. However, it is explicitly contemplated that the same or similar sensors can be used to evaluate a mixture in a container. For example, a paint spraying operation typically involves mixing different fluids or mixtures into a container before coupling the container to a dispenser.

[0083] Additionally, many materials may be stored in large containers before use, and these containers may be opaque or otherwise not allow visual inspection. For example, many materials are stored in 55 - gallon drums before use, and these drums are opaque. It is difficult to visually confirm sedimentation or whether the mixture is approaching phase separation.

[0084] Figure 9 An embodiment of a stir bar is illustrated that is configured to provide in - situ conductivity measurements of a mixture. Schematic 900 illustrates a stir bar 910 that can be used with a container (such as a paint mixing cup 920). However, stir bar 910 can also be suitable for other containers and other mixtures.

[0085] Stir bar 910 provides a sensor 916 that can be moved through the mixture (or placed in a flowing mixture). Stir bar 910 includes a window 914 to allow connection of edge connectors to wire leads. However, in some embodiments, the wire leads can be connected to the edge connectors in another suitable manner. In some embodiments, stir bar 910 includes one or more retaining clips 912, or other suitable wire - holding features that assist in coupling the edge connectors of sensor 916 to the wire leads.

[0086] Sensor 916 is illustrated as being coplanar with stir bar 910. This can allow for easier cleaning of sensor 916 after a stirring operation (e.g., by wiping stir bar 910). However, it is explicitly contemplated that sensor 916 and / or stir bar 910 can be single - use products such that they are discarded between uses.

[0087] In other embodiments, sensor 916 is offset from stir bar 910 (e.g., mounted to one side or the other) such that wire leads can be connected without window 914.

[0088] Stir bar 910 is configured such that when it is moved relative to the mixture, the mixture is forced to flow through a slot in sensor 916.

[0089] Figure 10 Illustrates an extended sensor according to an embodiment of the present disclosure. Sensor 1000 is illustrated in Figure 10 as having a separation length 1030 between an electrode portion 1020 and an edge connector 1010. The edge connector 1010 should not contact the mixture. Thus, having a separation 1030 between the edge connector 1010 and the electrode portion 1020 increases the flexibility of use of the conductivity sensor, for example allowing the sensor 1000 to be used in deeper containers to ensure uniformity throughout the depth of the container. The sensor 1000 can be immersed and used to agitate the sensor within the mixture without the edge connector to contact the fluid (and short circuit), thereby allowing real-time monitoring and visualization of material characterization data (conductivity, temperature, and dielectric constant).

[0090] Figures 11A to 11D Illustrates a sensor having electrodes in a series configuration according to an embodiment of the present disclosure. So far, the sensor configuration has been discussed in which the electrode slots 1102 are coplanar along the edge of the sensor opposite the edge connector 1108. A temperature sensor 1104 is also included on the PCB board. Also included is a length 1106 between the edge connector 1108 and the electrode slot 1102 closest to the edge connector 1108 to reduce the likelihood of the edge connector 1108 contacting the fluid in the container.

[0091] Figure 11B Illustrates scenario 1130, which shows the use of sensor 1100 in an incomplete mixture in container 1140. The arrangement of the sensors in the vertical stack along the PCB allows each electrode slot to be positioned at a different depth within the container 1140. The electrode pair 1142 measures a first conductivity at depth 1132 at the lowest depth. The electrode pair 1144 at the second lowest depth measures a second conductivity at depth 1134. The conductivity at depth 1132 will be different from the conductivity at depth 1134 because of the different composition. Similarly, the conductivity measured by the electrode pair 1146 at depth 1136 will be different from the conductivity measured by the electrode pair 1148 at depth 1138 because of the different concentration.

[0092] Although Figure 11A and Figure 11B illustrates a sensor 1100 having four electrode pairs arranged in a vertical stack on a PCB, it is expressly contemplated that there may be a different number of electrode pairs, such as only 2 electrode pairs, only 3 electrode pairs, or more than 4 electrode pairs, such as five electrode pairs, six electrode pairs, or more than six electrode pairs. Additionally, there is a spacing between the electrodes, which can be longer or shorter than the illustrated spacing.

[0093] In some embodiments, the sensor 1100 includes only one electrode pair. One electrode pair can be used, for example, to measure an ongoing mixing process.

[0094] Sensors such as sensor 1100 may be particularly useful for containers containing dispersions or emulsions that currently require continuous rotation or constant motion to prevent settling or creaming. However, the resulting mixing quality is unproven. Sensor 1100 may be used to measure the current dispersion / emulsion consistency or built into a stir bar or other stirring tool so that an in-situ mixing mark can be provided to ensure that the mixture is well mixed, but that time is not wasted on over-mixing.

[0095] Figures 11C to 11D Example mixtures and resulting conductivity measurements using sensor 1100 are illustrated. Figure 11C A stable dispersion 1150 is illustrated which results in very similar conductivity measurements from each electrode pair. Figure 11C A dispersion 1160 is illustrated that undergoes sedimentation, which results in conductivity measurements that differ between different electrode pairs because the concentration varies with the depth of the electrode pair in the mixture.

[0096] Sensors (such as Figures 11A to 11D Those exemplified) may be particularly useful for measuring flocculation or aggregation in situ, potentially before significant sedimentation or phase separation has occurred. This can help ensure that corrective action is taken more quickly.

[0097] Figure 12 Another embodiment of a system in which embodiments herein may be useful is illustrated. System 1200 illustrates an exemplary dispensing system 1200 having a controller 1202, which may include a motor providing pressure for dispensing the mixture through a dispenser 1210. Dispensing the mixture may have quality control issues that are not obvious to the operator. The systems and methods herein may be used to detect and correct quality control issues. As described above Figures 7A to 7D As described, the sensors described herein can be placed in a conduit (e.g., a sensing region 1210 where material is first provided). As material flows through or leaves the sensing region 1210, the material may entrain bubbles or droplets formed from only one component (or a subset of the components) of the mixture. If material from the sensing region 1210 is provided for combination into a mixture downstream, the bubbles will also affect the resulting mixing ratio. For the dispensed mixture, this may result in an incorrect mixing ratio being dispensed. For viscous fluids, this may result in areas of the work surface not receiving the dispensed fluid.

[0098] Similarly, improperly mixed mixtures present quality control issues. Droplets can indicate that phase separation is about to occur in the mixture.

[0099] It is important to detect and potentially remove air and / or droplets from the dispensing system. Thus, in some embodiments, before reaching the dispenser 1240, the material passes through a sensing region 1210 that includes any of the PCB-based sensors described herein. The sensor detects inconsistent mixtures (e.g., air bubbles or droplets), enabling the activation of a corrective action mechanism 1220 before the material reaches the dispenser 1240.

[0100] For entrained air bubbles, the valve 1230 can be opened, allowing the portion containing the air bubbles to leave through the material stream 1250. When the air bubbles have passed, the valve 1230 closes, and the material continues on to the dispensing system 1240.

[0101] Similarly, if phase separation or other quality issues are detected in the mixture passing through the sensing region 1210, the valve 1230 can divert the mixture in the stream 1250 for corrective actions such as remixing, degassing, over-purifying, etc. Phase separation can be detectable when droplets of the first material begin to form from aggregation.

[0102] The controller 1202 can also cause the dispenser 1240 to stop dispensing until the mixture is considered to be well mixed. In the illustrated embodiment, the material from the stream 1250 can be returned by the controller 1202 to the sensing region 1210 to confirm that the quality is sufficient to resume dispensing. The controller 1202 can provide notifications to other systems (e.g., a motion controller that moves 1240 relative to the surface receiving the dispensed material) connected to the dispensing system 1240 and / or to the operator via a user interface on a display, an audible marker, etc.

[0103] In some embodiments, the valve 1230 opens and closes automatically based on an indication directly from the sensing system 1220, the controller 1202, or another control system that sends commands for corrective actions based on conductivity measurements received from the system 1220.

[0104] Figure 12 is a schematic diagram of the system 1200, where the components for one material line are clearly illustrated. However, it is explicitly contemplated that, as illustrated, the dispensed mixture can be formed from two components, and a similar system can be provided for the second component.

[0105] Figures 13A to 13C Illustrates a sensor configuration that can be particularly useful for detecting the aggregation of air bubbles or droplets of a second phase formed before phase separation.

[0106] Figure 13AAn inclinometer sensor is illustrated that may be particularly useful for detecting bubbles or droplets in a mixture. The sensor includes four electrode pairs in four slots 1302, 1304, 1306, and 1308 of different sizes. Slot 1302 is wider than slot 1304, slot 1304 is wider than slot 1306, and slot 1306 is wider than slot 1308. Slots 1302 through 1308 are illustrated in an arrangement from thickest to thinnest; however, other arrangements are explicitly contemplated as possible. Similarly, while four coplanar electrode pairs are illustrated, all coplanar electrode pairs are substantially the same distance from the connection end of the sensor (e.g., the portion connected to a signal reader). Edge connector 1314 is shown as an example, however other suitable connections are possible.

[0107] Slots 1302 through 1308 are designed to both detect bubbles or droplets and provide an indication of size. Generally, a uniform mixture without bubbles or droplets provides an insulating effect and maintains a uniform conductivity across all electrode pairs. When a droplet reaches the width of one of the slots, the droplet will connect the two sides of the electrodes, resulting in a detectable change in conductivity.

[0108] Figure 13A The illustrated design is shown with a linearly increasing slot width, e.g., 1 mm, 2 mm, 3 mm, and 4 mm. The linear increase in diameter corresponds to a cubic increase in the volumetric flow rate through the orifice. Such a configuration provides a good understanding of how quickly phase separation will occur and / or how stable the mixture is. For example, if there is more than an hour until phase separation, it may still be possible to dispense the mixture without taking corrective action.

[0109] However, it is explicitly contemplated that some embodiments may require smaller or larger slot sizes. For example, the thinnest slot may be as thin as 100 μm, or thinner than 150 μm, or thinner than 200 μm, or thinner than 300 μm, or thinner than 400 μm. One or more slots may be thinner than 500 μm. One or more slots may be thinner than 1 mm. For other applications, such as a stir bar for larger measurement operations, such as inspecting the mixture quality of a 50 - gallon drum. For example, larger slot sizes (such as slots sized at least 5 mm, at least 10 mm, at least 15 mm, or even at least 22 mm) may be useful.

[0110] In addition to changes in width, the slots can also change in length to accommodate specific applications. For example, when checking the shelf life of larger containers, the entire sensor may need to be much longer (e.g., up to or exceeding 1 meter in length). In such cases, the holes must be larger, both to increase signal strength and to allow significant flow-through. The length can be increased to increase signal strength, balanced with the chosen width to allow flow-through without sacrificing signal strength. For example, for a sensor with a length in meters, the size could be 10 cm long and 1 cm wide.

[0111] For example, when a droplet (or bubble) reaches a diameter as wide as or wider than the narrowest slot 1308, it connects the two electrodes within slot 1308, thus generating a conductivity spike only for electrode pair 1308, because it will not connect the two sides of slot 1306 until the droplet (or bubble) diameter grows to a width as wide as or wider than slot 1306. Once the bubble (or droplet) passes through slot 1308, the conductivity returns to the baseline of the mixture. The conductivity spike frequency changes according to the number of droplets (bubbles) in the mixture.

[0112] Sensor 1300 also includes a temperature sensor 1310, which is illustrated as running along electrode pairs 1302 to 1308. It is explicitly contemplated that the temperature sensor 1310 can be positioned in another suitable location. Additionally, it is contemplated that for some embodiments, such as for mixtures that do not significantly change viscosity within the operating temperature range, the temperature sensor 1310 is not required.

[0113] Sensor 1300 is also illustrated as having a length 1312 that separates edge connector 1314 from electrode pairs 1302 to 1308. However, if sensor 1300 is used as an in-line flow sensor, such as installed in a conduit as illustrated in Figure 7A to FIGS. 6D, then the length 1312 may not be necessary.

[0114] Figure 13B and Figure 13C A sensor connected to wire leads 1340 is illustrated, showing how the length 1312 provides additional separation from electrode pairs 1302 to 1308 when used in container 1350.

[0115] So far, this document has described many sensor configurations, in which single-row parallel electrodes are illustrated (e.g., in the horizontal configurations of FIGS. 3 to 7 and FIG. 13, or in the vertical configuration such as FIG. 11). However, it is explicitly contemplated that arrangements combining the features of the two configurations are possible. For example, a grid of electrode pairs can be used to simultaneously detect consistency and mixing quality (or the presence of droplets / bubbles) at multiple depths. Additionally, while the embodiments herein illustrate multiple sets of four electrode pairs in different configurations, it is explicitly contemplated that more or fewer electrode pairs can be present in any vertical or horizontal arrangement.

[0116] So far, this document has described embodiments of sensors formed by PCBs, which are designed to receive fluid flow through holes therein. However, it is explicitly contemplated that the sensors herein can adopt other shapes and configurations.

[0117] Figure 14 A through Figure 14 E illustrate flexible sensor configurations that can be used in the embodiments herein.

[0118] Figure 14 A illustrates an embodiment in which the sensor 1600 can be adhered to a surface. The adhesive backing 1604 adheres to the flexible substrate 1606, opposite the electrodes 1602. In some embodiments, the electrodes 1602 include a gold conductive pattern. However, other materials may be suitable for other applications. A reader connection 1608 is present at one end of the sensor 1600. The connection 1608 can be an industrial edge connector or a data transmitter such as an NFC or RFID tag. For some applications, a low-power wireless solution is preferred.

[0119] Figure 14 B illustrates two sensors placed opposite each other. When a voltage or current is emitted by the electrodes 1612, the emitting electrodes 1612 placed opposite the receiving electrodes 1616 provide an electrical parameter signal of the material flowing in the direction 1618, thereby generating an electric field 1614. As Figure 14 illustrated in B, four separate sensing regions are illustrated on the receiver, such that four sensor signals can be emitted, thereby providing a better understanding of the material flowing between the electrodes 1612 and 1616.

[0120] Figure 14 C through Figure 14Example D illustrates another flexible sensor configuration. The sensor may include two electrodes 1622, which may be positioned in a flat configuration 1620 or a parallel configuration 1630 to enable somatosensory measurements as fluid passes between the electrodes 1622. However, since the electrodes 1622 are printed on a flexible backing, it is expressly contemplated that other configurations are possible. For example, the flat configuration 1620 may be used to obtain surface sensing measurements. Additionally, the electrodes 1622 may be rolled into a channel sensor having a circular, oval, or polygonal shape, as illustrated in FIGS. 7 to Figure 9 and as illustrated in the associated description of PCT / IB2023 / 062401, which is incorporated herein by reference. Such configurations may be applicable to static mixers.

[0121] Figure 14 Example E illustrates another flexible sensor configuration. The sensing surface 1642 of the sensor 1640 may utilize surface sensing technology to provide an electrical characteristic signal to a reader using an edge connector 1646. Although an edge connector 1646 is illustrated, other data transfer mechanisms, such as NFC or RFID tags, are contemplated.

[0122] Annotation 1648 illustrates a simplified view 1648 of the electrode configuration for surface sensing. An interdigital comb structure, where the transmitting electrode portions are interleaved with the receiving electrode portions. The transmitting electrode portions generate an electric field on the surface of the sensor 1640, and the receiving portions sense the signal, which is reported to a signal reader by the edge connector 1646. However, although an edge connector is illustrated, it is expressly contemplated that other suitable data transfer options may be used.

[0123] Figure 14 A to Figure 14 Examples A to E illustrate flexible sensors. Flexible sensors can be formed using a variety of suitable techniques. Printing techniques can be used to print patterns on many flexible or rigid material substrates, such as thin film transistors, capacitors, coils, resistors, etc. Printed electronics offer significant opportunities for low-cost electronics with simpler manufacturing. However, printed electronics may only be suitable for applications where low performance is acceptable.

[0124] Another potentially suitable technique is in-mold electronics. The electronics can be printed on a moldable substrate, such as PET or another suitable substrate, using functional inks. The substrate is then thermoformed into a shape. Once the electronics are formed (e.g., a single surface sensing device or two somatosensory devices), the sensor is assembled such that a voltage or current can be applied to the transmitting electrode and a signal can be received from the receiving electrode.

[0125] The laminated structure consists of at least one non-conductive or insulating layer. In embodiments where electronic devices are integrated onto the surface of standard components (e.g., molded materials, composite materials, etc.). In such embodiments, the non-conductive layer can be formed of Durolastic material. A suitable Durolastic material can include FR-4 epoxy resin. However, other suitable materials can also be used. In some embodiments, the non-conductive layer can be formed of polyamide, polycarbonate, polypropylene, phenolic material, ABS, or another suitable material. According to the embodiments herein, the non-conductive layer can be modified to receive solder. According to the embodiments herein, the non-conductive layer must be able to be modified (e.g., by metallization or another suitable process) to receive conductive material.

[0126] As described herein, the laminated structure can be formed of a variety of suitable materials. In some embodiments, additive or subtractive manufacturing techniques are used to form the laminated structure. Such "printable" materials can allow the embodiments herein to be implemented in a variety of additional configurations.

[0127] In some embodiments, classical additive manufacturing techniques (e.g., fused filament fabrication, SLA, IJ) can be used to form the laminated structure. Non-conductive materials for such embodiments can include SLA / SLS materials, which can be, for example, UV curable. Sintered materials such as PA or ceramics can also be used. Fused filament fabrication materials such as ABS or another suitable material can also be used.

[0128] According to the embodiments herein, the conductive material for the laminated structure can include a substrate material with a surface finish. The substrate can be, for example, copper. The surface finish material can include nickel or gold. Liquid inks can be used, and the liquid ink can contain silver or graphite material. In some embodiments, nanomaterials such as graphene- or carbon nanotube-based conductive inks or sprays can be used. For example, silver chloride can be used. In some embodiments, carbon ink can be used alone or as a supplement to conductive silver ink. Carbon ink can provide lubricity, protection of the silver surface, and prevention of silver migration. Some conductive inks can include, for example: AgNW, AgNP, AuNP, CuNW, CuNP, PdNP, or mixtures thereof.

[0129] Dielectric inks can be used in some embodiments herein to print dielectric layers, conformal coatings, and / or encapsulations. Non-conductive dielectric inks can insulate multi-layer circuits to allow circuit crossings and multi-layer applications. Dielectric inks provide flexibility, moisture resistance, and improved strength.

[0130] According to some embodiments herein, resistive inks can be used. Resistive inks can be based on a blend of silver, carbon, and non-conductive pigments to adjust the resistance levels of printed resistors, potentiometers, and heating elements.

[0131] In some embodiments of the present disclosure, 3D electronic printing techniques are used, such as piezo / valve jetting, aerosol-based jetting, multi-nozzle inkjet, 3D dispensing, printing / laser ablation, pneumatic spraying, and / or US spraying.

[0132] Using 3D printing techniques, the sensors described in the embodiments of the present disclosure can be directly formed on a surface in contact with a fluid, e.g., into a conduit, dispenser, mixing unit, container, etc. A greater range of functional elements (such as flexibility) is possible. Depositing an electro-functional ink on a substrate results in an active or passive device.

[0133] For example, a conduit can be formed with a conductive pattern that allows for the measurement of electrical parameters. The conduit can include a plurality of sensing regions along its length to track electrical parameters as a fluid passes through each sensing region.

[0134] Printed electronics can be directly printed into a housing, conduit, container, 2K cartridge, static mixer, etc. For example, a housing can be formed from two components, one component having a transmitting electrode and the other component having a receiving electrode. One component or the other can include edge connectors or another suitable data transmitter.

[0135] The sensors and sensing systems of the present disclosure can be used in a variety of quality control applications for flowing materials or static materials. Equipment has failure points, and as components wear due to use, the risk of equipment failure increases. When a failure occurs, maintenance is required.

[0136] When a failure is not detected, reactive maintenance is required to repair or replace a failed component. When signs of a failure are detected before the failure occurs, predictive maintenance can be taken. Predictive maintenance can be performed before damage occurs.

[0137] One example where the sensors of the present disclosure may be useful is in the manufacture and maintenance of electric vehicle batteries. The battery and its housing include many conductive material sealants, fillers, materials that separate battery cells, etc. In one embodiment, the housing can include thermoformed sensors (similar to those described herein) that can form an electronic circuit when the housing is sealed, and the electronic circuit can be used to detect the conductivity of any material in contact with the housing. Alternatively, a sensor with a flexible backing can be placed inside the housing where fluid will contact the sensor. If the sensor signal is not as expected, errors in manufacture can be corrected before the battery is placed in a vehicle. Additionally, sensors placed inside an installed battery can report signals during use and can be used as a way to determine whether a recall is needed or whether maintenance is required. The sensor can have a data transmitting device that operates wirelessly and associates the sensed signal with a vehicle ID. Health monitoring can also be useful for applications other than electric vehicles, such as in aerospace manufacturing, etc.

[0138] So far, the sensor systems described herein are based on a single PCB board. Such systems are relatively inexpensive, so their use and replacement offer high cost performance. However, a disadvantage of the designs described so far is the large stray field compared to the main field present between each pair of electrodes. The stray field effect is caused by the short distance between the material flow input end and the material flow output end, such as the thickness of the PCB. One way to reduce the stray field effect is to weld multiple PCBs into a PCB stack, where each PCB has holes containing electrodes.

[0139] Figure 15 Figures A through 165 illustrate stacked PCB electrodes according to embodiments of the present disclosure. Figure 15 Figure A illustrates a stacked PCB sensor similar to the Figures 11A to 11B PCB board, while Figure 15 Figure B illustrates a stacked PCB sensor similar to the Figures 13A to 13C PCB board. As illustrated, in one embodiment, the sensor stack 1700 may include four PCB sensors, including a 4-layer PCB 1702, two stacked PCBs 1704, and a top PCB 1706, where the two stacked PCBs are provided to obtain the required sensitivity by increasing the electrode surface area. In some embodiments, the flow through the sensor stack 1700 is indicated by arrow 1710.

[0140] Similarly, the sensor stack 1720 illustrates a stack of four PCB sensors, having a 4-layer PCB 1722, two stacked PCBs 1724, and a top PCB 1726. The flow through the sensor stack 1720 is indicated by arrow 1730.

[0141] Although Figure 15 the embodiments of Figures A through Figure 15 B all illustrate four-layer sensor stacks, it is expressly contemplated that fewer or more PCB sensors may be coupled together. For example, as few as two PCBs, or as many as five, six, seven, eight, nine, ten, or more PCBs.

[0142] The stacked sensor 1700 provides the benefits of a single PCB sensor with reduced stray field effect. This compact design also improves the shielding of the sensitive electrodes and can also be used as an electrode chuck without the need for an additional housing, since the sensitive area can be sealed inside. In some embodiments, the sensitive area is sealed inside by welding and can withstand the applied pressure from the material sensor without the need for an additional housing.

[0143] In addition, the stacked sensor 1700 can utilize smaller electrodes, allowing the sensor stack 1600 to be integrated into active or passive mixing nozzles at the material input and output ends. In the sensor stack, only one electrode 1702 has an edge connector configured to connect to a lead wire. As Figure 15 A to Figure 15 B illustrate, for embodiments where a stir bar is a suitable carrier for detecting conductivity, the stacked sensor can include a temperature sensor and can include an elongate portion. However, it is expressly contemplated that a stacked sensor in any configuration can be suitable for placement in a conduit, such as Figures 7A to 7D illustrated.

[0144] Figure 16A Figures 16A to 16D illustrate sensors according to embodiments herein. It is illustrated herein that a plurality of electrode slots can be organized in rows such that each slot is approximately the same distance from the connection end of the sensor (e.g., the end that directly interacts with a signal reader, either through a wired system or wirelessly). It is also illustrated herein that a plurality of electrode slots can be organized in columns such that each slot has a different distance from the connection end. It is also expressly contemplated that in some embodiments, the electrode slots can be organized in both rows and columns. The sensors 1800, 1830 can provide Figures 11A to 11B and Figures 13A to 13C the desired features of two sensor configurations.

[0145] Figure 16A Illustrated is a sensing setup 1700 where the sensor 1810 is partially submerged in a solution 1820. The sensor 1810 includes electrode slots of a first size 1802 and a second size 1804. The electrode slots are arranged in both rows 1808 and columns 1808. Arranging the electrode slots in both rows and columns provides additional insight into the material.

[0146] Figure 16A Illustrated is a uniform solution 1820, while Figure 16B illustrates a solution 1850 undergoing sedimentation, which may be an indication of material aging. The sensor 1840 can provide twelve different sensor signals for analysis, one sensor signal from each pair of electrodes through which the material can flow. The difference between the signals from electrode slots 1842 and 1844 can indicate aging. The difference between the signals from electrode slots 1844 and 1846 can indicate the viscosity of the solution 1850.

[0147] Many production sites store raw materials in large containers (such as barrels). Material separation results in a lighter phase at the top and a heavier phase at the bottom. The quality may decrease as the separation increases.

[0148] Additionally, it is desirable to have a sensor that can handle materials with a wider viscosity range. Electrode slots with a smaller width may not handle higher viscosity materials well, while electrode slots with a wider width may not be as precise for low viscosity materials. Sensors 1810, 1840 can handle a wider range of viscosities while also providing signals along the depth of the material container. Although only four rows of electrode pairs are illustrated, it is explicitly contemplated that there may be more rows in other embodiments to accommodate the container depth. Additionally, although only three columns are illustrated, it is explicitly contemplated that additional columns with wider or narrower electrode slots are also possible.

[0149] Figures 16C and 16D illustrate example signal curves that may be received from sensor 1810 or 1840. Curve 1860 indicates a low viscosity material, while sensor 1870 indicates a high viscosity material.

[0150] The sensor systems herein can be used to detect the viscosity of a material, as illustrated by the comparison between curves 1860 and 1870. The viscosity of the material affects the rate of exchange of the material within the gap between the electrodes. The delay between the signal of a large gap and the signal of a smaller gap indicates the viscosity of the material. Lower viscosities result in shorter delays, while higher viscosities result in longer delays.

[0151] It should be noted that Figures 16A to 16B only one sensor 1810, 1830 is illustrated. However, it is explicitly contemplated that the sensitivity can be increased by stacking sensors 1810, 1830, such as for example Figure 15 A to Figure 15 B as described.

[0152] Figure 17 A method for detecting and correcting quality issues in a mixture according to an embodiment herein is illustrated. Method 2000 can be implemented using sensor systems (such as those described herein), combinations thereof, or other suitable sensors.

[0153] In block 2010, inconsistencies in the mixing are directed. Inconsistencies may be entrained air, mixing ratio drift, inconsistent mixing (droplet formation, precipitation, emulsion delamination), or another inconsistency from normal flow. Detection can be accomplished by detecting spikes in the sensed electrical parameters detected by one or more electrode pairs on the PCB sensor, as illustrated in block 2002. Detection can also be achieved by detecting a change in the sensed value measured between a first electrode pair and a second electrode pair of the sensor system, as illustrated in block 2004. Other detection methods 2008 described herein can be used. Detection can occur when the mixture flows through or past the electrode pairs.

[0154] In some embodiments, the electrical parameter sensor can be a disposable sensor that is discarded after use. The sensor can include one or more pairs of electrodes in a coplanar arrangement such that the dispensed material flows across different electrode pairs. The sensor can also or alternatively include a plurality of sensing regions arranged in a line such that the material flow is parallel or substantially parallel to the sensing regions. Multiple electrode pairs including electrodes with different sides can help detect bubbles or droplets of different sizes as they flow across the sensing regions.

[0155] In block 2020, detected inconsistencies are corrected. The correction can include further mixing the mixture 2022, for example to ensure a consistent concentration, correcting detected mixing ratio drift, reducing the risk of phase separation, and / or stabilizing the dispersion or emulsion. The correction can also include degassing the mixture 2024 to remove detected bubbles or entrained air introduced during the remixing step. The degassing can be done using, for example, a vacuum or by purging a portion of the mixture containing the entrained air. Other suitable correction measures 2028 (such as correcting the mixture composition), such as purification, can also be used.

[0156] In some embodiments, detected bubbles can be mitigated without purification, for example by sending a signal to the motor controlling the fluid flow to increase the speed and dispense an amount of material needed to replace the air volume occupied by the bubbles. In some embodiments, if no bubbles are present, the applied pressure can be increased or the volumetric flow rate can be increased to provide a similar volume of material.

[0157] In block 2040, the consistency of the mixture can be confirmed before the mixture is dispensed in block 2030. For example, using the sensors described herein, the consistency of the mixture can be confirmed by stabilizing conductivity spikes (e.g., reducing the severity and / or number) or by confirming that the conductivity difference across the electrode pairs has narrowed to an acceptable level. If the consistency is not confirmed, the process can return to block 2020 so that correction can continue, or a new correction strategy can be selected.

[0158] FIG. 18 illustrates a quality control system according to an embodiment herein. The quality control system 2150 can be used to identify and correct detected inconsistencies in a mixture. The quality control system 2150 can be implemented in a static environment (e.g., implemented as an immersion rod or other analytical tool for the contained fluid) or in a dynamic environment (e.g., in a fluid flow conduit) where the fluid moves across electrode pairs in a PCB board.

[0159] Some systems or methods of the present disclosure may benefit from using relative thresholds instead of absolute thresholds. A reference level may be important for making measurements to have more accurate relative thresholds. For example, if a conductivity measurement drops below a factor proportional to the reference level (e.g., drops to 50% of the reference level), an inconsistency may be determined, such as a concentration gradient indicating poor mixing, droplets indicating phase separation, or entrained air. Relative thresholds can help reduce material waste during accidental purging, or reduce the time wasted attempting to correct inconsistencies that may not exist or may not be at a level requiring correction.

[0160] The inconsistency detection system 2150 can be implemented by a suitable computing device in communication with the sensing system 2130. The sensing system 2130 can include one or more electrode pairs 2132 in direct contact with the material flow. The electrode pairs 2132 can be positioned such that fluid flows between them, or such that the fluid contacts their surfaces. The electrode pairs 2132 can be part of a printed circuit board, such as formed in holes machined or built into the printed circuit board. The holes can be closed at both ends, or open at one end, in a comb-like structure for example. The electrode pairs 2132 can be printed onto the PCB. The printed electrode pairs 2132 can be arranged in a comb-like structure. The sensing system 2130 can also include a temperature sensor 2134. In some embodiments, the temperature sensor 2134 can be shielded from direct contact with the material flow. The sensing system 2132 can include other features 2138.

[0161] Sensor signals from the sensing system 2130 are received by the quality control system 2150 using an active signal retriever 2152. The active signal retriever 2152 can receive signals from the sensing system 2130 periodically or continuously during operation. The received sensor signals can be impedance signals, conductivity signals, dielectric constant signals, or a combination thereof. In embodiments where conductivity values are used to detect inconsistencies, a conductivity signal generator 2154 can convert the received signals into conductivity values. The signal values and / or conductivity values can be provided to a data repository, for example, using a signal communicator 2156. A similar process can be performed for applications where different electrical parameters are preferred for analysis purposes.

[0162] The historical signal retriever 2158 can communicate with the data repository to retrieve previously captured signal values. The historical signal values of interest can include signal values retrieved from the same batch of material or material mixture within a recent time period. For example, the values retrieved within the previous few seconds or minutes may be significant. In some embodiments, the signal values may drift over a longer time period due to temperature changes, material aging, mixture ratio fluctuations, etc. However, inconsistencies can be detected as rapid changes in conductivity or differences in conductivity measurements in the sensing system from each other. In some embodiments, the threshold generator 2160 periodically or continuously generates relative thresholds based on the historical signals. The relative threshold can be an absolute value, for example, specifying an increase or decrease of X% over time Y indicates an inconsistency. If the conductivity values have fluctuated more significantly, the threshold change value can be larger, while if the conductivity values have not fluctuated significantly, the threshold change value can be smaller.

[0163] The signal analyzer 2162 compares the received signal or the calculated conductivity with the threshold, and if a deviation outside the allowed threshold is detected, the command generator 2164 generates a command and conveys the command to the device 2180 using the command communicator 2166.

[0164] In some embodiments, the device 2180 can include a display component, and the generated command can be an update to a graphical user interface presented on the display component indicating the detected inconsistency. In some embodiments, the device 2180 can include a feedback component (such as audio, visual, or tactile feedback) that indicates to the controller the detection of a bubble. The device 2180 can also be a correction mechanism, and the command generator 2164 can generate a command to perform a correction mechanism selected based on the detected inconsistency, for example, a purge valve, remix command, degassing command, etc.

[0165] The system 2150 can include other features 2168.

[0166] In some embodiments, the threshold generator includes a machine learning model for predicting future conductivity time series data based on historical data. The prediction can include a so-called confidence interval. Training can be done in advance on a reference dataset without detected quality control issues or with quantified quality control issues. Then, the signal analyzer 2162 compares the received signal to determine whether the received signal falls within or outside the confidence interval.

[0167] In some embodiments, the threshold generator generates predictions of conductivity values at regular intervals (e.g., 10 ms, 100 ms, etc.), where the confidence bands are based on historical signals retrieved by the historical signal retriever. If the measured actual value drops below the lower confidence band or rises above the upper confidence band, the signal analyzer detects an inconsistency. If the conductivity measurement is within the confidence band, the signal analyzer 2162 provides an output that no inconsistency has been detected or that no inconsistency requiring correction has been detected. The command generator 2164 may provide an indication that the GUI of the device 2180 does not need to be updated.

[0168] Due to the noise present in the data, relative thresholds are an important part of the air detection system. The statistical concept of confidence bands explains this: if the data has more noise, the confidence bands are further away from the current value and the inconsistency detection algorithm will not produce false detections due to noisy data, where simple thresholding methods may be affected in such cases.

[0169] While conductivity is discussed herein as the value of interest, it is expressly contemplated that other material parameters such as current flow, relative permittivity (er), or impedance may alternatively or also be used in the detection algorithm.

[0170] Measuring conductivity can provide valuable information about the quality of the mixture. For example, as described herein and in the example section of PCT / US2022 / 52343, conductivity measurements can be used to determine consistency issues due to batch-to-batch variations, entrained air, droplet formation, aging, concentration gradients, dispersion separation, or emulsion separation.

[0171] Figure 19 A method for quality control of a material dispensing system according to embodiments herein is illustrated. The method 2200 can be used with the dispensers or other suitable sensing systems described herein.

[0172] In block 2210, one or more components to be dispensed are provided to a sensing area. The sensing area can be a material dispenser, a transfer line to the material dispenser, or other delivery mechanism or container within a nozzle, atomizer, or fluid system. For example, the material dispenser can dispense a liquid 2212, particles in a suspension 2214, or other form. The material can also be a mixture 2216 of materials, such as an emulsion or another A and B component mixture. The emulsion must be dispensed as a stable emulsion, and the reactive A:B components should be provided in the desired mixing ratio. Other components 2218 can also be provided to the sensing area prior to dispensing.

[0173] In block 2220, the mixture passes through a sensing system before being dispensed, stored, removed from storage, etc. Passing through the sensing system may involve passing a portion of the sensing body such that the material (e.g., the mixture or a component) is in direct contact with the sensor. The direct contact between the material and the electrode pair ensures accurate measurement. By sensing

[0174] In block 2230, conductivity measurements are received from the sensing system. The sensing system can have multiple sensors, such as multiple electrode pairs, which detect electrical parameters of the material when sufficient voltage is passed through them. Based on the sensed parameter values, many conditions of the material can be determined. For a mixture, the mixing ratio can be determined. For a curable material, the curing progress can be detected. Aging and differences between batches of material can also be detected. Instability indicators (such as entrained air, impending phase separation, etc.) can also be detectable. The sensor measurements can be made continuously, e.g., receiving a signal every second, or more frequently. Measurements can also be made in parallel, e.g., from each of multiple electrode pairs or sensing regions. In some embodiments, the electrode pairs or sensing regions can be coplanar with each other. The sensed electrical parameters can include conductivity 2232, impedance 2234, or dielectric constant 2236, or another suitable parameter.

[0175] In block 2240, feedback is provided based on the electrical parameter measurements. The feedback can include a characterization of the material, as shown in block 2252. For example, the mixing ratio can be detected, and the entrained air or single-component fluid pockets, aging indicators, or other parameters of interest can be calculated and provided. Predictions can also be provided, as shown in block 2254. For example, based on the trend of previous conductivity sensor readings, it may be possible to predict the future behavior of the material being measured. Other characterization information 2258 can also be provided. For example, the trend of conductivity readings in one direction can indicate that the mixing ratio is moving towards the edge of an acceptable range and thus the mixing rate should be changed, or that an increase in instability is tending towards phase separation. Similarly, conductivity readings can indicate that a curable component is curing.

[0176] The feedback can also indicate a need for corrective action. For example, an emulsion or dispersion undergoing separation may need to be stabilized 2242 (e.g., remixing, heating, etc.). The feedback can also indicate a need for purification of one or more components or the mixture, as shown in block 2244. In embodiments where the material has a corrosive effect or cures over time, the predictive feedback can provide an indication that the sensor needs to be replaced, as shown in block 2246. Other predictive information can also be provided, as shown in block 2238, which can trigger other actions, as shown in block 2248.

[0177] In some embodiments, as illustrated herein, providing feedback may also include providing conductivity readings, material characterizations or predictions, or other useful information, such as material source, lot number, material name, dispense temperature, dispense pressure, material concentration, mixing ratio, or any other information, to a customer, a controller of the dispenser.

[0178] Figure 20 A through Figure 20 C illustrate conductivity measurement systems in a system network according to embodiments herein.

[0179] In Figure 20 the example shown in A, some items are similar to those shown in the previous figures. Figure 20 Figure A specifically shows that the conductivity sensing system 2310 can be located at the remote server location 2302. Thus, the computing device 2320 accesses those systems through the remote server location 2302. The user 2350 can also use the computing device 2320 to access the user interface 2322. For example, the user 2350 can interact with an application on the user interface 2322 of their smartphone 2320 or laptop computer 2320 or other computing device 2320 to receive information from the dispensing system or the quality control system.

[0180] Figure 20 Figure A shows that it should also be envisioned that some elements of the systems described herein are provided at the remote server location 2302, while other elements are not provided at that remote server location. By way of example, the data repositories 2330, 2340, or 2360 can be provided at a location separate from the location 2302 and accessed through the remote server at the location 2302. Regardless of where they are located, they can be directly accessed by the computing device 2320 through a network (wide area network or local area network), hosted as a service at a remote site, provided as a service, or accessed by a connection service residing at a remote location. Additionally, the data can be stored substantially anywhere and can be intermittently accessed by interested parties or forwarded to interested parties. For example, physical carriers can be used instead of electromagnetic wave carriers, or in addition to electromagnetic wave carriers. This can allow the user 2350 to interact with the system 2310 through their computing device 2360 to initiate a seal inspection process.

[0181] It will also be noted that the elements of the systems described herein, or portions thereof, can be provided on a variety of different devices. Some of these devices include servers, desktop computers, laptop computers, embedded computers, industrial controllers, tablet computers, or other mobile devices, such as palmtop computers, cellular phones, smartphones, multimedia players, personal digital assistants, etc.

[0182] A conductivity measurement system can be any suitable system configured to collect conductivity measurements, perform analysis, and provide the analysis to a receiving device, storage device, or graphical user interface generator using the systems and methods herein. Figure 16 of PCT / US22 / 52343 depicts the operation of such a system and is incorporated herein by reference.

[0183] System 2310 receives conductivity measurements from one or more sensors 2370. Each sensor may include one or more pairs of electrodes on a PBC. In some embodiments, the electrodes may be coplanar and similarly spaced from one end of the PCB, or may be coplanar and along the length of the PCB. The sensors may be formed by metallization or another process. Sensors 2370 are decoupled from each other such that independent conductivity signals are received from each sensor. Each sensor 2370 may include a positive and negative electrode that are decoupled from each other.

[0184] Conductivity measurement system 2310 may receive sensor signals as conductivity signals or dielectric constant signals or impedance signals. In embodiments where the received signal is an impedance signal, a conductivity value may be calculated based on the impedance signal. Similarly, a dielectric constant may be calculated based on the received impedance signal. Calculations and / or predictions may be made based on the received sensor signals as described herein. The mixing ratio may be calculated based on calibration data stored in data repository 2360, which may indicate conductivity data from pure components and / or known mixtures of components. As described above, sensors may be placed at both the inlet and outlet of the sensing zone, and thus, system 2310 may receive sensor signals from all sensors associated with the material dispensing system. In some embodiments, system 2310 may be configured to correct for the time delay between sensor signal capture and analysis. In other embodiments, correction may not be necessary where trend information is particularly relevant.

[0185] Systems and methods utilizing machine learning algorithms are described herein. Machine learning models may be preferred as they may better handle noisy data, make predictions about future signal trends, and make adjustments before the mixing quality changes significantly. The systems and methods described herein may calculate the mixing ratio in real time. Using machine learning techniques, the mixing ratio may be predicted in advance. This allows for faster adjustment, thus keeping the mixing ratio closer to the target value for more time. For some current dispensers, many materials are entrained in the static mixer such that when a change in the mixing ratio is detected, the materials already in the mixer will continue to have an incorrect mixing ratio for at least the adhesive value of the mixer, and thus, identifying mixing ratio problems earlier may save materials and potential cleanup.

[0186] Similarly, as described herein, a machine learning model can receive information from multiple systems, such as multiple sensors within a dispensing system, including conductivity sensors, temperature sensors, motor speed signals, material information, etc. In some embodiments, multiple machine learning models are used simultaneously, with each machine learning model being used by a separate system such that the models for each system can learn and improve the overall model. However, it is explicitly contemplated that non-machine learning models can also be used.

[0187] The sensing systems herein are described as having the functionality of sending and receiving communicable information to and from other devices. This can be accomplished through application programming interfaces, such that system 2310 can receive and communicate with, for example, a pump controller, a pipeline pressure sensor, a movement controller for a portion of the dispensing system, a temperature sensor, a heating element, a data repository having information about any of the materials being dispensed or the mixtures being produced, etc.

[0188] In embodiments using machine learning models, the data repository can also include analyzers that learn the usage behavior of a particular dispensing system in order to improve operations and predictions. Similarly, the frequency and pattern of dispensing can provide information about curing and improve the mixing model. For example, usage data such as dispensing frequency, purging frequency, dispensing pattern, replacement of sensors, etc. can be collected and used to train the model to more accurately predict trends and provide corrective actions.

[0189] Similarly, as described herein, display 2360 can display a GUI created by generator 2320, which is periodically updated using information collected by system 2310 and / or any of the data repositories 2330 to 2360. The information can be updated passively or an alert or notification can be provided upon update. For example, the current status information can be presented, and if the mixing ratio drifts into an unacceptable range, an alert (visual, audio, or tactile) can be provided. Additionally or alternatively, a notification can be provided when a device command is generated or when operator intervention is required.

[0190] In some embodiments, the signal encoder and regressor can operate locally, such as using a computer processing device associated with the material dispensing system. Alternatively, the encoder or regressor or both can be deployed in a cloud-based storage system.

[0191] The output of the encoder can be directly used to apply pressure changes on the cartridges associated with one or more components to ensure that the mixture meets a predefined mixing ratio. For example, if the mixed material contains too much of part A, the pressure on the cartridge containing part A is decreased, and the pressure on the cartridge containing part B is increased.

[0192] The regressor can then obtain the encoded signals and generate the mixing ratio signals. The regressor can be a machine learning-based algorithm that can be trained in any suitable manner.

[0193] The first training option is a separate training option where the encoder-decoder model is trained on a set of signals for various parts of Part A, Part B, and different mixtures. The machine learning regressor is then trained in a second step on the encoded signals and the corresponding mixing ratios.

[0194] The second training option is an alternating training option where a batch of signals is used for one training step in the encoder-decoder and then for one training step in the encoder-machine learning regressor part. The training steps include a forward pass of the data in the batch, the calculation of gradients, and the application of the gradients to optimize the weights in the model.

[0195] The third training option is a combined training option where the encoder-decoder pair and the triple of the machine learning model are optimized simultaneously. This means that the batch is forwarded through the encoder and the obtained representation is forwarded through the decoder and the machine learning regressor. Then, the gradients calculated using the two outputs are applied to a weighted combination in the backward pass.

[0196] Alternating or combined training can provide the following benefits: learning the representation of the signals in a way that has a positive effect on the performance of the regressor, which can lead to lower errors when estimating the mixing ratios. Learning the representation of the signals for various materials and mixing ratios also allows the model to be used for materials of the same chemical family that have not been seen before.

[0197] Unlike systems that use only a single signal from the mixed material, this novel approach allows for adaptation to batch-to-batch variations in the raw materials, where for the same mixing ratio, a variation in one of the parts can lead to a variation in the mixed signal. It is also able to track the mixing of new materials of the same family by learning to fuse the signals of the two parts into a mixed signal.

[0198] Data tracking collected from the sensor system can be processed to provide additional information as described herein. For example, the sensor can provide signals that can be processed to indicate the need for a corrective action.

[0199] As described herein, in some embodiments, the sensor includes four electrode pairs. The time series of the conductivity can be analyzed from four sensor capacitors to determine when a corrective action has been successful, e.g., when remixing has been completed, when phase separation has been reversed, or when the mixture has reached stability again.

[0200] For example, mixing (or remixing) may take time to reach a steady state. For example, when starting a mixing operation, the backpressure and different viscosities of the components can result in a poor start to mixing and a gradual stabilization. The same variance can be used to track stability and indicate when the dispenser can dispense the material onto the workpiece or into a receiving container. The trend of the variance can be analyzed against a threshold. The threshold is specific to each material. However, instead of determining a threshold, an augmented Dickey-Fuller (ADF) test can be used to test the stationarity of the signal. The advantage of doing so is that manual thresholds typically need to be adjusted for new batches, but the ADF test can adapt.

[0201] The sensors described herein can also be used to detect non-uniformities. These four electrode pairs should also record similar readings. Due to manufacturing tolerances, some constant offset is possible, but during a stable mixing process, the variations in these four signals should be synchronous.

[0202] Once each signal has stabilized, these four sensors should have a high covariance. A negative covariance indicates persistent anti-correlated behavior and represents spatial non-uniformity.

[0203] Similarly, a single component of the mixture may also be non-uniform, for example, because it has settled in the barrel or been insufficiently mixed during the manufacturing process. The augmented Dickey-Fuller test can again be used to confirm stability over a longer period. The relevant time period will be determined by the time it takes to empty the container.

[0204] Architecture 2300 illustrates an embodiment of a specific implementation of the electrical parameter sensing system 2310. For example, architecture 2300 can provide computing, software, data access, and storage services that do not require the end user to know the physical location or configuration of the system delivering these services. In various embodiments, a remote server can deliver these services over a wide area network such as the Internet using an appropriate protocol. For example, a remote server can deliver applications over a wide area network, and they can be accessed via a web browser or any other computing component. FIGS. 1 to Figure 19 The software or components shown or described and the corresponding data can be stored on a server at a remote location. The computing resources in a remote server environment can be consolidated at a remote data center location, or they can be dispersed. The remote server infrastructure can deliver services through a shared data center, even if they appear as a single access point for the user. Thus, the components and functions described herein can be provided from a remote server at a remote location using a remote server architecture. Alternatively, they can be provided by a conventional server directly installed on the client device, or in some other way.

[0205] Figure 20 B illustrates an exemplary system architecture. In Figure 20In an embodiment of B, the system is connected by wires such that it is not a wireless or open distribution solution. In embodiments where wireless connections would have a slower transmission rate or be potentially unreliable, wired communication may also be preferred. However, as discussed with respect to Figure 20 A, a wireless system is also envisioned as possible.

[0206] The electrical parameter sensor 2380 may capture electrical parameter signals from, for example, one or more of the PCB sensors described herein and provide the sensor signal to the signal converter 2382, where signal conversion occurs if needed. However, in some embodiments, it is explicitly envisioned that the sensor 2380 may provide the sensor signal directly to the processor 2384. The signal converter 2382 may, for example, convert impedance to conductivity, convert an analog signal to a digital signal, or may perform another suitable conversion.

[0207] The processor 2384 receives the electrical parameter indication and generates an electrical parameter value output that may be provided to one or more devices 2386. The devices 2386 may include a computing device with a display, a smart phone with a display, a laptop computer with a display, or another device, such as a storage medium that stores the sensor signal for future reference. The processor 2384 may also query one or more data repositories 2388 in order to generate additional indications. For example, the data repository 2388 may include past conductivity sensor signals, conductivity sensor signal thresholds, commands to adjust dispensing parameters based on the conductivity signal threshold, etc. The processor 2384 may take action accordingly.

[0208] According to an embodiment herein, the system may also have a pressure sensor 2390 that generates a pressure signal indicative of the pressure detected at a point within the dispensing system. If needed, the signal converter 2392 may convert the pressure signal from one form to another, from amperes to voltage, analog to digital, etc.

[0209] The processor 2384 or another suitable processor may generate a pressure output that may be provided to one or more devices 2386. The processor 2384 may continuously receive signals from the pressure sensor 2390 and the conductivity sensor 2380 throughout the process and may also be able to continuously generate an output, thereby providing substantially real-time information about the dispensing system. The processor 2384 may include one or more suitable machine learning techniques, may query a look-up table, or may perform another suitable data analysis technique on the received conductivity signal or pressure signal.

[0210] The processor 2384 can communicate wirelessly with sensors 2380, 2390, communicate with these sensors using a wired connection or through any other suitable network. The processor 2384 can receive signals as encrypted signals, can provide outputs as encrypted outputs, or can operate without a proper encryption protocol.

[0211] Any number of suitable communication routes are envisioned, such as directly from sensor 2390 to processor 2384, from sensor 2380 through signal converter 2382, and directly to data repository 2388, where the communication route can be retrieved by processor 2384. Similarly, an information acquisition request from device 2386 can be sent directly to conductivity sensors 2380, 2390, sent to data repository 2388, or sent to processor 2384.

[0212] In some embodiments, an MQTT broker is used to allow, for example, device 2386 to subscribe to a subset of data from, for example, sensor 2390 or processor 2384.

[0213] In some embodiments, processor 2384 also communicates with data repository 2388 such that conductivity and pressure signals are also stored for later analysis. - For example, a dataset including conductivity and pressure signals over time can be used to train machine learning algorithms or can be used for troubleshooting purposes. For example, a machine learning algorithm may be able to detect patterns in the dataset, such as mixing ratio deviations and the need for purification, and provide an indication of how to detect when a mixing ratio deviation occurs and / or a threshold to avoid the deviation from becoming severe.

[0214] Figure 20 Example B illustrates a single processor that receives information from a single set of sensors for dispensing operations. However, it is explicitly envisioned that a production environment can have multiple dispensers that operate with multiple conductivity sensors and pressure sensors that continuously provide status information. Thus, it is expected that multiple users may want to view information about multiple production lines simultaneously. Figure 23 Example C illustrates a configuration of a system that can be capable of providing such functionality.

[0215] Figure 20 Example C illustrates a signal analysis system that communicates with multiple devices using a cloud-based network. As Figure 24 Illustrated in C, the signal analysis system 2400 can communicate with a local analysis system 2440, for example, as Figure 20 Described in B. The signal analysis system 2400 can receive multiple sensor signal data 2410 from multiple dispensing operations, such as prime pipeline 2404, any operating pipeline 2402, and / or laboratory setup 2406. As described with respect to Figure 20As described in B, the sensor signal 2400 can be a digital signal, an analog signal, a conductivity measurement signal, a pressure signal, or other signal information. For example, a low inventory detection signal, a valve switch indication, or any other detectable indication from any one of systems 2402 to 2406.

[0216] The signal analysis system 2400 can analyze the received sensor signal information 2400, for example, using any suitable analysis tools such as look-up tables, comparison thresholds, and / or machine learning algorithms to detect parameter trend information, which can indicate problems or actions to be taken, such as purification, adjusting the mixing ratio, etc.

[0217] The signal analysis 2400 can provide an output tag 2420 to a plurality of suitable devices 2450. The signal analysis system 2400 can provide output information 2120 continuously or in response to a request for 2434 information. Our request 2430 can be a one-time request for current status information or a request to receive continuous updates to continue.

[0218] Figure 21 Examples A to 21D illustrate a sensing system according to an embodiment herein. The current sensing setup includes components from different manufacturers, and data preparation and processing are done using separate computing devices. However, there is a desire to have a robust and compact system that quickly processes data with limited downtime or startup time so that quality issues with the material are quickly detected.

[0219] In some embodiments herein, the sensor (e.g., "intelligent sensor") includes signal preparation and processing within a single housing. Such intelligent sensors include processing components, e.g., a microprocessor, a microcontroller, a digital signal processor, or other processing circuitry. In some embodiments, the sensor also includes one or more standardized interfaces for interfacing with other systems (e.g., a fieldbus system, a sensor network, an input / output link, etc.). In some embodiments herein, sensor signal processing is done without an external computer. The sensing system herein provides decentralization, increased reliability, reduced cost, increased flexibility, and simplification.

[0220] In some embodiments, the sensor systems herein include a concentrator that integrates electronic components in a single housing. In some embodiments, all the electronic components are on one PCB. In some embodiments, an analog front end with signal conversion (e.g., an AD converter, a DA converter, or both) is connected to a microcontroller that performs signal conversion, processing, and provides an output signal. The sensing systems herein may also incorporate operating circuits, including power supplies, I / O protection circuits, signal conditioning, reset management, and / or debug circuits and interfaces. In some embodiments herein, the concentrator includes user interface components, such as LED signaling, UART, USB, wireless interfaces (e.g., WiFi, cellular networks), dot matrix or alphanumeric displays, industrial bus systems, and / or tactile interface components, such as buttons, switches, touchscreens, etc.

[0221] The systems herein may include user-accessible data, such as signal values, pass / fail (e.g., "yes" or "no", "go" or "stop", etc.). The systems herein may provide quality or quantity indications. The systems herein may provide a data stream with time- and / or frequency-related data for storage and / or further processing. The systems herein may include algorithms and / or calibrations required for data manipulation.

[0222] Figure 21 FIG. A illustrates a schematic diagram of a sensing system according to an embodiment herein. The sensing system 2500 may be used with sensors such as those described in embodiments herein, or with another suitable sensor. The sensor signal reader 2502 is connected to a sensor, such as an edge connector of a PCB board including one or more electrode pairs. In some embodiments, there is a transimpedance amplifier to convert current measurements to voltage. The concentrator 2510 receives the sensor signal, processes the sensor signal, and provides an output. The output may be provided using the I / O device 2506 and / or another wired or wireless communication protocol 2508. The power supply 2512 may provide power to the concentrator 2510. Although a wired power supply 2512 is illustrated, it may be possible to provide power wirelessly, or the concentrator 2510 may be integrated into a material distribution system from which it draws power.

[0223] Figure 21 FIG. B illustrates an example interface 2520 of the concentrator that may receive sensor signals using one or more sensor signal receiving ports 2524. In some embodiments, other data or inputs may be received through another receiver 2522.

[0224] Figure 21Example C illustrates another interface 2530 that may receive the coupling of an input / output device. Power may be provided, for example, using port 2434. Data may be communicated from the concentrator using computer link 2436.

[0225] Figure 21 Example D illustrates a component diagram of a sensing system 2540 according to an embodiment herein. One or more sensors 2542 provide sensor signals that are received by one or more receivers 2544 coupled to or included in a housing 2570. In some embodiments, system 2540 includes an analog front end that may include a filter 2548 and / or an analog multiplexer 2546. There may be a converter, e.g., a DA converter or a DC converter 2549. The concentrator 2550 may include non-volatile memory 2552, flash memory 2554, or another suitable information storage device. A temperature sensor 2556 may be incorporated into the concentrator 2350 or receive a temperature signal from a temperature sensor. The concentrator 2550 may include a clock 2558. The concentrator 2562 may also include reset functionality 2562.

[0226] In embodiments where a large number of sensor signals are received (e.g., from more than just a few sensing regions), the multiplexer 2546 may be particularly important. In some embodiments, the multiplexer 2562 may facilitate switching from receiving signals from a first plurality of sensing regions to receiving signals from a second plurality of second sensing regions, etc. Embodiments are described herein where sensor signals are retrieved by scanning four independent sensing regions. However, it is expressly contemplated that for some applications, there may be a greater number of sensing regions. For example, a fluid or mixture may be stored in a large drum. To determine if separation is occurring, it may be helpful to have sensing regions along a portion or all of the height of the drum. Up to 80 or more sensing regions may be needed to cover that distance. The multiplexer 2546 may switch between groups of sensing regions in order to gain an understanding of the state of the mixture throughout the storage container.

[0227] The sensor analyzer 2570 may include calibration data and / or functionality 2572. A real-time operating system 2573 may manage the functionality. The sensor analyzer 2570 may include a Fourier transformer 2576. The sensor analyzer 2570 may include a waveform generator 2576. The sensor analyzer may include other applications 2575 that provide other functionality, such as detecting material properties, such as mixing ratio, material aging, cure progress, etc. The sensor analyzer 2570 may also include an identifier 2574 that identifies the type of sensor.

[0228] The concentrator 2550 may include a power management system 2560 that includes or accesses a power source 2566. The power quality 2568 may be monitored. The energy consumption 2569 may be tracked. The conversion input and output ranges 2564 may be stored. The symmetric voltage 2567 may be used.

[0229] Figure 22 An dispensing system according to an embodiment herein is illustrated. Many dispensing operations are performed with a portable hand-held system. Incorrect material quality or machine settings may result in dispensing errors or adhesive failures. For example, incorrect mixing ratios or incorrect pressure settings may produce unacceptable products. A hand-held dispensing system that can provide real-time sensing and feedback to the user is desired. Figure 22 An example of a system that can receive and process sensor signals without a separate computing device is described. Many embodiments of sensors that can be used with a dispenser are described herein. Systems for measuring pressure in a dispensing system are described herein. System 2600 also includes a dispenser 2610. The dispenser 2610 is illustrated as an adhesive dispenser 2610, however other dispensers may also benefit from the systems described herein. The dispenser 2610 includes an in-line sensor 2630 that senses the electrical characteristics of the material being dispensed. A pressure sensor 2640 is incorporated into the dispenser 2610 and monitors the pressure within the dispenser.

[0230] The dispenser 2610 also includes a signal processing system 2620. A signal receiver receives the sensed parameter signals from the sensor 2630. A processing unit (which may include any suitable processor or processing circuitry) processes the sensed signals. A memory may store calibration signals, historical signals, etc. A display 2650 may present the processed information to the user, the processed information being received, for example, from the signal processing system 2620 using a communication module. The display 2650 may be integrated into the dispenser 2610 or into another display visible to the dispenser operator (such as a mobile computer, a work-site display, etc.). However, while the display 2650 is illustrated as communicating the processed information to the operator, it is expressly contemplated that in some embodiments herein, the output from the signal processing system 2620 may be presented as audio or tactile feedback.

[0231] Based on the sensed signals, the signal processing system 2620 may also effect a change in dispensing parameters. For example, a mixing ratio deviating from a specified mixing ratio may be sensed. The signal processing system 2620 may adjust the mixing ratio by changing the pump speed of one component based on the sensed mixing ratio drift. The signal processing system 2620 may control the pump speed directly or indirectly such that an instruction to change the pump speed is sent to the pump controller. The signal processing system 2620 may also communicate the mixing ratio drift, for example, via the display 2650. In some embodiments, the signal processing system 2620 may only communicate detected material issues (such as mixing ratio, aging, curing, pressure, etc.), and the operator may need to take steps to manually resolve the issue. However, it is expressly contemplated that in some embodiments, the dispenser parameters are automatically adjusted in real time based on signals from sensors 2630, 2640.

[0232] Information regarding expected process parameters (such as mixing ratio, dispensing pressure) may be detected in any suitable manner. In some embodiments, the dispenser receives the expected process parameters from an NFC tag, RFID tag, or other information storage system on the material to be dispensed.

[0233] Figures 23 to 2 FIG. 5 illustrates an example device that may be used in the embodiments shown in the previous figures. Figure 23 FIG. illustrates an example mobile device that may be used in the embodiments shown in the previous figures. Figure 23 is a simplified block diagram of an exemplary example of a handheld or mobile computing device that may be used as, for example, a worker device or a supervisor / safety officer device, in which the present system (or a portion thereof) may be deployed. For example, the mobile device may be deployed in the operator's compartment of a computing device for generating, processing, or displaying data.

[0234] Figure 23 FIG. provides a general block diagram of the components of a mobile cellular device 2716 that may run some of the components shown and described herein. The mobile cellular device 2716 interacts with these components, or runs some of the components and interacts with some of the components. In device 2716, a communication link 2713 is provided that allows the handheld device to communicate with other computing devices and, in some embodiments, provides a channel for automatically receiving information (such as by scanning). Examples of the communication link 2713 include protocols that allow communication via one or more communication protocols, such as a wireless service for providing cellular access to a network and a protocol for providing a local wireless connection to a network.

[0235] In other examples, the application may be received on a removable Secure Digital (SD) card connected to interface 2715. Interface 2715 and communication link 2713 communicate along bus 2719 with processor 2717 (which may also embody the processor), which bus is also connected to memory 2721 and input / output (I / O) component 2723, as well as clock 2725 and location system 2727.

[0236] In one embodiment, I / O component 2723 is provided to facilitate input operations and output operations, and device 2716 may include input components such as buttons, touch sensors, optical sensors, microphones, touchscreens, proximity sensors, accelerometers, orientation sensors, and output components (such as display devices, speakers, and / or printer ports). Other I / O components 2723 may also be used.

[0237] Clock 2725 illustratively includes a real-time clock component that outputs time and date. The clock may also provide timing functions for processor 2717.

[0238] Illustratively, location system 2727 includes components that output the current geographical location of device 2716. The location system may include, for example, a Global Positioning System (GPS) receiver, LORAN system, dead reckoning system, cellular triangulation system, or other location systems. The location system may also include, for example, mapping software or navigation software that generates desired maps, navigation routes, and other geographical functions.

[0239] Memory 2721 stores operating system 2729, network settings 2731, applications 2733, application configuration settings 2735, data repository 2737, communication driver 2739, and communication configuration settings 2741. Memory 2721 may include all types of tangible volatile and non-volatile computer-readable memory devices. The memory may also include computer storage media (described below). Memory 2721 stores computer-readable instructions that, when executed by processor 2717, cause the processor to perform computer-implemented steps or functions in accordance with the instructions. Processor 2717 may also be activated by other components to facilitate its functionality. It should be explicitly contemplated that although physical memory repository 2721 is illustrated as part of the device, cloud computing options are available where some of the data and / or processing is done using remote services.

[0240] Figure 24It is shown that the device can also be a smart phone 2871. The smart phone 2871 has a touch-sensitive display 2873, which displays icons or tiles or other user input mechanisms 2875. The mechanism 2875 can be used by the user to run applications, make phone calls, perform data transfer operations, etc. Generally speaking, the smart phone 2871 is built on a mobile operating system and provides more advanced computing capabilities and connectivity than non-smart phones. It should be noted that other forms of devices are possible.

[0241] However, although Figure 24 An embodiment is illustrated in which the device 2800 is a smart phone 2871, but it is clearly conceivable that a display can be presented on another computing device.

[0242] FIG. 25 is an example of a computing environment in which elements or portions thereof (e.g.) of the systems and methods described herein can be deployed. Referring to Figure 20 A, an example system for implementing some embodiments includes a general-purpose computing device in the form of a computer 2910. The components of the computer 2910 may include, but are not limited to, a processing unit 2920 (which may include a processor), a system memory 2930, and a system bus 2921 that couples various system components including the system memory to the processing unit 2920. The system bus 2921 can be any of a variety of bus structures, including a memory bus or memory controller using any of a variety of bus architectures, a peripheral bus, and a local bus. The memory and programs described in relation to the systems and methods herein can be deployed in Figure 20 the corresponding part of A.

[0243] The computer 2910 typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by the computer 2910 and includes both volatile / non-volatile media and removable / non-removable media. By way of example and not limitation, computer-readable media may include computer storage media and communication media. Computer storage media is different from a modulated data signal or carrier wave and does not include a modulated data signal or carrier wave. Computer storage media includes hardware storage media that includes volatile / non-volatile and removable / non-removable media implemented in any method or technology for storing information such as computer-readable instructions, data structures, program modules, or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disk (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and that can be accessed by the computer 2910. Communication media can embody computer-readable instructions, data structures, program modules, or other data in a transport mechanism and includes any information delivery media. The term "modulated data signal" means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal.

[0244] The system memory 2930 includes computer storage media in the form of volatile and / or non-volatile memory, such as read only memory (ROM) 2931 and random access memory (RAM) 2932. A basic input / output system 2933 (BIOS) that contains basic routines that help to transfer information between elements within the computer 2910 (such as during start-up) is typically stored in the ROM 2931. The RAM 2932 typically contains data and / or program modules that can be immediately accessed and / or are currently being operated on by the processing unit 2920. By way of example and not limitation, FIG. 25 illustrates an operating system 2934, application programs 2935, other program modules 2936, and program data 2937.

[0245] The computer 2910 may also include other removable / non-removable and volatile / non-volatile computer storage media. By way of example only, FIG. 29 illustrates a hard disk drive 2941 that reads from or writes to non-removable, non-volatile magnetic media, non-volatile disk 2952, optical disk drive 2955, and non-volatile optical disk 2956. The hard disk drive 2941 is typically connected to the system bus 2921 through a non-removable memory interface, such as interface 2940, and the optical disk drive 2955 is typically connected to the system bus 2921 through a removable memory interface, such as interface 2950.

[0246] Alternatively or additionally, the functionality described herein may be performed, at least in part, by one or more hardware logic components. By way of example, and not limitation, illustrative types of hardware logic components that can be used include field programmable gate arrays (FPGAs), application specific integrated circuits (e.g., ASICs), application specific standard products (e.g., ASSPs), systems on a chip (SOCs), complex programmable logic devices (CPLDs), and the like.

[0247] The drivers discussed above and Figure 23 illustrated provide storage means for computer readable instructions, data structures, program modules, and other data for a computer 2910. In FIG. 25, for example, a hard disk drive 2941 is illustrated as storing an operating system 2944, application programs 2945, other program modules 2946, and program data 2947. Note that these components may be the same as or different from the operating system 2934, application programs 2935, other program modules 2936, and program data 2937.

[0248] A user can enter commands and information into the computer 2910 through input devices such as a keyboard 2962, a microphone 2963, and a pointing device 2961 (such as a mouse, trackball, or touchpad). Other input devices (not shown) may include a joystick, game pad, satellite dish, or scanner, among others. These input devices and other input devices are typically connected to the processing unit 2920 through a user input interface 2960 coupled to the system bus, but may be connected by other interfaces and bus structures. A visual display 2991 or other type of display device is also connected to the system bus 2921 via an interface such as a video interface 2990. In addition to a monitor, the computer may also include other peripheral output devices such as speakers 2997 and printers 2996, which may be connected through an output peripheral interface 2995.

[0249] The computer 2910 operates in a networked environment using a logical connection to one or more remote computers, such as remote computer 2980, via a local area network (LAN) or a wide area network (WAN).

[0250] When used in a LAN networking environment, the computer 2910 is connected to the LAN 2971 through a network interface or adapter 2970. When used in a WAN networking environment, the computer 2910 typically includes a modem 2972 or other means for establishing communications over the WAN 2973, such as the Internet. In a networked environment, program modules may be stored in a remote memory storage device. FIG. 26 illustrates, for example, that a remote application 2985 may reside on a remote computer 2980.

[0251] In the detailed description of the preferred embodiments, reference is made to the accompanying drawings, which illustrate specific embodiments in which the invention may be practiced. The illustrated embodiments are not intended to be an exhaustive listing of all embodiments in accordance with the invention. It should be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the invention. Accordingly, the following detailed description is not to be taken in a limiting sense, and the scope of the invention is defined by the appended claims.

[0252] Unless otherwise specified, all numbers expressing feature sizes, amounts, and physical properties used in this specification and the claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

[0253] Unless the context clearly dictates otherwise, as used in the specification and the appended claims, the singular forms "a", "an", and "the" encompass embodiments having plural referents. Unless the context clearly dictates otherwise, as used in the specification and the appended claims, the term "or" is generally employed in its sense including "and / or".

[0254] If spatial relational terms are used herein, including but not limited to "proximal", "distal", "lower", "upper", "below", "beneath", "above", and "on top", they are used for convenience in describing the spatial relationship of one or more elements relative to another element. Such spatial relational terms encompass different orientations of the device during use or operation in addition to the specific orientation depicted in the figures and described herein. For example, if the object depicted in the figures is flipped or inverted, the portions previously described as being below or beneath other elements would then be above or on top of those other elements.

[0255] As used herein, for example when an element, component, or layer is described as forming a "conformal interface" with another element, component, or layer, or being "on", "connected to", "coupled to", "stacked on", or "in contact with" another element, component, or layer, it can be directly on, directly connected to, directly coupled to, directly stacked on, or directly in contact with it, or for example intervening elements, components, or layers can be on, or connected to, coupled to, or in contact with a particular element, component, or layer. For example, when an element, component, or layer is, for example, referred to as being "directly on" another element, "directly connected to" another element, "directly coupled to" another element, or "directly in contact with" another element, there are no intervening elements, components, or layers. The techniques of the present disclosure can be implemented in a variety of computer devices, such as servers, laptop computers, desktop computers, notebook computers, tablet computers, handheld computers, and smart phones, etc. Any component, module, or unit is described to emphasize the functional aspect and does not necessarily need to be implemented by different hardware units. The techniques described herein can also be implemented in hardware, software, firmware, or any combination thereof. Any feature described as a module, unit, or component can be implemented together in an integrated logic device or can be independently implemented as discrete but cooperating logic devices. In some cases, the various features can be implemented as an integrated circuit device, such as an integrated circuit chip or chipset. Additionally, although the present specification describes a variety of different modules throughout, many of which perform unique functions, all of the functions of all of the modules can be combined into a single module, or even split into additional additional modules. The modules described herein are merely exemplary and are described for the purpose of being more easily understood.

[0256] If implemented in software, the techniques can be implemented at least in part by a computer-readable medium that includes instructions that, when executed by a processor, perform one or more of the methods described above. The computer-readable medium can include a tangible computer-readable storage medium and can form part of a computer program product that can include packaging material. The computer-readable storage medium can include random access memory (RAM), such as synchronous dynamic random access memory (SDRAM), read-only memory (ROM), non-volatile random access memory (NVRAM), electrically erasable programmable read-only memory (EEPROM), FLASH memory, or magnetic or optical data storage media, etc. The computer-readable storage medium can also include non-volatile storage devices, such as hard disks, magnetic tapes, optical discs (CDs), digital versatile discs (DVDs), Blu-ray discs, holographic data storage media, or other non-volatile storage devices.

[0257] As used herein, the term "processor" may refer to any one of the foregoing structures or any other structure suitable for a particular implementation of the techniques described herein. Additionally, in some aspects, the functionality described herein may be provided within dedicated software modules or hardware modules configured to perform the techniques of the present disclosure. Even when implemented in software, the techniques may use hardware (such as a processor) for executing the software and a memory for storing the software. In any such case, the computers described herein may define a particular machine capable of performing the particular functions described herein. Additionally, the techniques may be fully implemented in one or more circuits or logic elements (which may also be regarded as processors).

[0258] An electrical property sensor is presented. The electrical property sensor includes a laminated structure. The laminated structure includes an insulating layer, a conductive layer, and conductive traces. The laminated structure has a first side separated by a certain thickness from a second side, and the first side has a length and a width. The sensor further includes a first hole and a second hole. Each of the first hole and the second hole extends from the first side of the laminated structure to the second side of a printed circuit board. The first hole and the second hole each include a receiving electrode and a transmitting electrode. When a fluid flows through the first hole and an electric field is generated at the transmitting electrode, a sensor signal indicating an electrical property is measured at the receiving electrode.

[0259] The sensor may be implemented such that the sensor signal can be converted into an electrical property value of the fluid, and the electrical property value is conductivity, impedance, or permittivity.

[0260] The sensor may be implemented such that the first hole is parallel to the length and perpendicular to the width.

[0261] The sensor may be implemented such that the first hole is at a first distance from an edge connector, the second hole is parallel to the first hole, and a distance of a second center of the second hole from the edge connector is similar to a distance of a first center of the first hole from the edge connector.

[0262] The sensor may be implemented such that the second hole is parallel to the first hole, and the second hole is located at a second length from the edge connector, and the second length is different from a first length of the first hole from the edge connector.

[0263] The sensor may be implemented such that the first hole has a first width, the second hole has a second width, and the second width is greater than the first width.

[0264] The sensor may be implemented such that the second width is less than 20 mm.

[0265] The sensor may be implemented such that the second width is less than 1 mm.

[0266] The sensor can be implemented such that the second width is less than 0.5 mm.

[0267] The sensor can be implemented such that the second width is less than 300 μm.

[0268] The sensor can be implemented such that the first width is at least 50 μm.

[0269] The sensor can be implemented such that the first width is at least 100 μm.

[0270] The sensor can be implemented such that the fluid flows through the first hole such that the fluid directly contacts the receiving electrode.

[0271] The sensor can be implemented such that the fluid flow is a first portion of the fluid flow, and when a second portion of the fluid flows through the second hole, a second impedance signal is generated using a second transmitting electrode and a second receiving electrode.

[0272] The sensor can be implemented such that the second receiving electrode is decoupled from the first receiving electrode such that the impedance signal is different from the second impedance signal.

[0273] The sensor can be implemented such that the sensor is part of a sensor stack composed of an impedance sensor and a second impedance sensor.

[0274] The sensor may further include a temperature sensor.

[0275] The sensor can be implemented such that the temperature sensor is electrically isolated from the fluid flow.

[0276] The sensor can be implemented such that the sensor includes a housing, and the housing can be communicatively coupled to an adapter for attachment to a dispensing system.

[0277] The sensor can be implemented such that the length of the laminate structure is more than twice the length of the first hole.

[0278] The sensor can be implemented such that the length of the laminate structure is more than three times the length of the first hole.

[0279] The sensor can be implemented such that the length of the laminate structure is more than four times the length of the first hole.

[0280] The sensor can be implemented such that the laminate structure is a printed circuit board.

[0281] A sensing system for a mixture is proposed. The sensing system includes a sensing region containing the mixture and a sensor within the sensing region. The sensor includes: a laminated structure including an insulating layer, a conductive layer, and conductive traces; a first hole and a second hole located within the laminated structure, each of the first hole and the second hole containing a receiving electrode spaced apart from a transmitting electrode. The sensor is configured such that when the mixture is in direct contact with the transmitting electrode and the receiving electrode of each of the first hole and the second hole, and when an electric field is generated at the transmitting electrode, a sensor signal is received at the receiving electrode of each of the first hole and the second hole. The system further includes a communication component that communicates a first electrical parameter of the mixture based on a first sensor signal from the receiving electrode of the first hole and a second electrical parameter based on a second sensor signal from the receiving electrode of the second hole.

[0282] The system can be implemented such that the sensing region is a container that holds the mixture.

[0283] The system can be implemented such that the sensing system detects a difference between a first current signal and a second current signal and indicates instability in the mixture based on the difference.

[0284] The system can be implemented such that the instability indicates precipitation, emulsion stratification, entrained air, droplet formation, or inconsistent mixing in the mixture.

[0285] The system can be implemented such that a controller generates an inconsistency correction plan based on the instability.

[0286] The system can be implemented such that the inconsistency correction plan includes mixing, degassing, or heating.

[0287] The system can be implemented such that the controller is configured to continue receiving current signals from the first hole and the second hole during the inconsistency correction plan.

[0288] The system can be implemented such that the sensing region is a conduit through which the mixture flows.

[0289] The system can be implemented such that for detecting the instability, the controller is configured to detect in-situ the difference between the first current signal and the second current signal, compare the difference with an acceptable threshold difference, and generate an instability indication if the difference exceeds the threshold difference.

[0290] The system can be implemented such that an indication that the instability has been resolved is generated based on detecting that the difference between the first current signal and the second current signal has decreased below the threshold difference.

[0291] The system can be implemented such that the sensing region includes a mixing chamber that receives a first component stream and a second component stream.

[0292] The system can be implemented such that the sensing region is located within a dispenser configured to dispense the mixture.

[0293] The system can be implemented such that the electrical parameter is impedance, conductivity, or permittivity.

[0294] The system can be implemented such that the electrical parameter indicates a mixing ratio.

[0295] The system can be implemented such that the electrical parameter is an indication of fluid aging.

[0296] The system can be implemented such that the electrical parameter indicates a curing progress.

[0297] The system can be implemented such that the emitting electrode is perpendicular to the surface of the laminate structure.

[0298] The system can be implemented such that the emitting electrode is aligned with the length of the hole, and the receiving electrode is parallel to the emitting electrode.

[0299] The system can be implemented such that the second hole is parallel to the first hole.

[0300] The system can be implemented such that the length of the laminate structure is more than twice the length of the first hole.

[0301] The system can be implemented such that the length of the laminate structure is more than three times the length of the first hole.

[0302] The system can be implemented such that the length of the laminate structure is more than four times the length of the first hole.

[0303] The system can be implemented such that the first hole is at a first distance from the edge connector, the second hole is parallel to the first hole, and the second hole is at a similar distance from the edge connector.

[0304] The system can be implemented such that the second hole is parallel to the first hole, and the second hole is located at a second length from the edge connector, the second length being different from the first length of the first hole from the edge connector.

[0305] The system can be implemented such that the first hole has a first width, the second hole has a second width, and the second width is greater than the first width.

[0306] The system can be implemented such that the sensor is a first sensor, and the system further includes a second sensor.

[0307] The system can be implemented such that the laminated structure is a first laminated structure, and the sensor includes: a second laminated structure, a third hole within the second laminated structure including a third receiving electrode spaced apart from a third transmitting electrode, and the system is configured such that the fluid flows through the third hole and directly contacts the third transmitting electrode and the third receiving electrode.

[0308] The system can be implemented such that the third hole is positioned such that the fluid first flows through the first hole and then through the third hole.

[0309] The system can be implemented such that the second laminated structure is coupled to the first laminated structure.

[0310] The system can be implemented such that the laminated structure includes a temperature sensor.

[0311] The sensor system further includes: a housing that receives the sensor at an angle relative to the fluid passage.

[0312] The system can be implemented such that the angle is less than 90°.

[0313] The system can be implemented such that the angle is less than 75°.

[0314] The system can be implemented such that the angle is less than 60°.

[0315] The system can be implemented such that the angle is less than 45°.

[0316] The system can be implemented such that the angle is less than 30°.

[0317] The system can be implemented such that the laminated structure is a printed circuit board.

[0318] A dispensing system is proposed, the dispensing system including: a mixing unit configured to receive a first fluid stream and a second fluid stream and produce a mixture; a sensor located within the fluid flow stream of the dispensing system. The sensor includes a laminated structure including an insulating layer, a conductive layer and conductive traces, a first hole and a second hole, each of the first hole and the second hole extending from a first side of the laminated structure to a second side of the laminated structure. Each of the first hole and the second hole includes a transmitting electrode on a first portion of the hole and a receiving electrode on a second portion of the hole. The sensor is configured to receive a portion of the mixture through each of the first hole and the second hole, contact both the transmitting electrode and the receiving electrode, and the sensor generates a sensor signal indicative of the mixture. The system further includes: a dispenser configured to dispense the mixture; and a communication component configured to convey the sensor signal.

[0319] The system can be implemented such that the sensor is downstream of the mixing unit.

[0320] The system can be implemented such that the sensor is upstream of the mixing unit and downstream of the first fluid source.

[0321] The system can be implemented such that the sensor is configured to be in direct contact with the first fluid stream.

[0322] The system can be implemented such that the laminate structure is positioned within the fluid flow stream such that the fluid flows through the holes.

[0323] The system can be implemented such that the laminate structure is perpendicular to the fluid flow.

[0324] The system can be implemented such that the sensor is the first sensor positioned downstream of the mixer, and the dispensing system includes a second sensor positioned upstream of the mixer.

[0325] The system can be implemented such that the fluid flow includes a first component fluid flow and a second component fluid flow, and the sensor is configured to receive both the first component fluid flow and the second component fluid flow simultaneously.

[0326] The system can be implemented such that the sensor is configured such that the first fluid flows through the hole, and a second fluid flows through a second hole in the printed circuit board, the second hole including a second transmitting electrode and a second receiving electrode.

[0327] The system can include a housing that houses the sensor and physically separates the first fluid flow from the second fluid flow.

[0328] The system can be implemented such that the second sensor is placed in the first fluid stream, and the system further includes a third sensor placed in a second fluid stream upstream of the mixer.

[0329] The system can be implemented such that the laminate structure includes a third hole that includes a third transmitting electrode and a third receiving electrode.

[0330] The system can be implemented such that for either the first electrode and the second electrode, the transmitting electrode is parallel to the length of the hole and parallel to the receiving electrode.

[0331] The system can include an analyzer that is configured to receive the sensor signal and provide an indication.

[0332] The system can be implemented such that the indication includes the aging of the first fluid.

[0333] The system can be implemented such that the analyzer is configured to determine the indication by comparing the sensor signal with a stored sensor signal.

[0334] The system can be implemented such that the indication includes an indication of the curing progress of the mixture.

[0335] The system can be implemented such that the indication includes a mixing ratio.

[0336] The system can include an analyzer configured to receive a first sensor signal from the first sensor, a second sensor signal from the second sensor, and a third sensor signal from the third sensor.

[0337] The system can be implemented such that the analyzer is configured to provide a mixing ratio indication based on the received sensor signals.

[0338] The system can be implemented such that the analyzer is configured to provide a batch quality indication based on the received sensor signals.

[0339] The system can be implemented such that the analyzer is configured to provide an aging indication based on the received sensor signals.

[0340] The system can be implemented such that the indication includes the mixing quality across the cross-section of the fluid flow.

[0341] The system can be implemented such that the analyzer is configured to determine the indication by applying a prediction model to the sensor signal.

[0342] The system can be implemented such that the indication includes a bubble indication.

[0343] The system can be implemented such that the bubble indication includes an indication that the sensed conductivity has spiked.

[0344] The system can be implemented such that the conductivity spike is greater than a relative threshold.

[0345] The system can be implemented such that a control signal is generated based on the indication to purify the fluid flow.

[0346] The system can be implemented such that a control signal is provided to the motor in response to the sensor signal to adjust the motor speed of the motor.

[0347] The system can be implemented such that purification is automatically initiated in response to the sensor signal.

[0348] The system further includes a display component that receives the sensed signal and provides a visual indication of the sensed signal.

[0349] The system can be implemented such that the visual indication is a mixed quality indication.

[0350] The system can be implemented such that the communication component provides the sensed signal to a data repository.

[0351] The system can be implemented such that the sensor includes a temperature sensor.

[0352] The system can be implemented such that the sensor is coplanar with the receiving electrode and the transmitting electrode.

[0353] The system can be implemented such that the temperature sensor is isolated from the fluid flow.

[0354] The system can be implemented such that the temperature sensor is isolated by a varnish layer or an epoxy-based adhesive layer.

[0355] The system can be implemented such that the sensor is a first sensor, and the system further includes a second sensor coupled to the first sensor.

[0356] The system can be implemented such that the coupling includes a conductive material.

[0357] The system can be implemented such that the conductive material is solder.

[0358] The system can be implemented such that the second sensor is coupled such that the fluid first flows through the first hole and then through a second hole, and the second sensor includes the second hole.

[0359] The system can be implemented such that the first sensor is a four-layer laminate structure and the second sensor is a two-layer laminate structure.

[0360] The system can be implemented such that the laminate structure is at a non-orthogonal angle with respect to the fluid flow.

[0361] The system includes a pressure sensor that detects a pressure indication at the outlet of a reservoir or a pump.

[0362] The system can be implemented such that the communication component conveys the pressure signal substantially in real time.

[0363] The system can include a pump system that continuously pumps fluid between a dispenser inlet and a reservoir.

[0364] The system can include an analyzer that receives the signal indicating the mixture and provides a mixture indication to the device.

[0365] The system can be implemented such that the analyzer generates the mixture indication based on the signal indicator of the mixture.

[0366] The system can be implemented such that the analyzer converts the signal indicative of the mixture into an indication of the mixture.

[0367] The system can include an analyzer that receives the pressure signal and provides a pressure indication to the device.

[0368] The system can be implemented such that the analyzer generates the pressure indication based on the pressure signal.

[0369] The system can be implemented such that the analyzer converts the pressure signal into the pressure indication.

[0370] The system can be implemented such that the dispensing system includes a sensor housing that houses the sensor.

[0371] The system can be implemented such that the sensor housing maintains the sensor at an angle relative to the fluid flow.

[0372] The system can be implemented such that the angle is less than 75°.

[0373] The system can be implemented such that the angle is less than 60°.

[0374] The system can be implemented such that the angle is less than 45°.

[0375] The system can be implemented such that the angle is less than 30°.

[0376] The system can be implemented such that the sensor housing and the dispenser form an integral body.

[0377] The sensor can be implemented such that the sensor housing is coupled to an adapter that can communicatively couple a fluid flow from the dispenser through the sensor housing.

[0378] The sensor can be implemented such that the laminated structure is a printed circuit board.

[0379] A signal analysis system for a plurality of dispensing systems is proposed. The signal analysis system includes: a first dispensing system having a first sensor that detects a first sensor signal from a first sensor within the first dispensing system, the first sensor including a first laminated structure; a second dispensing system having a second sensor that detects a second sensor signal from a second sensor within the first dispensing system, the second sensor including a second laminated structure. The system includes an analyzer that receives the first sensor signal and the second sensor signal and generates a first sensor output and a second sensor output. The signal analysis system provides the first sensor output to a first device and provides the second sensor output to a second device.

[0380] The system can be implemented such that the first sensor signal is received and a first output is provided in situ.

[0381] The system can be implemented such that the sensor signal is received using a wireless protocol.

[0382] The system can be implemented such that the output is communicated to the first device using a wireless protocol.

[0383] The system can be implemented such that the first sensor includes a transmitting electrode and a receiving electrode, each electrode being coplanar with the surface of the laminated structure.

[0384] The system can be implemented such that the set of electrodes each have a width.

[0385] The system can be implemented such that one of the electrodes on the first sensor has a first width, a second electrode has a second width, and wherein the second width is wider than the first width.

[0386] The system can be implemented such that the set of electrodes on the first sensor each have a first end and a second end, and each of the electrodes has a distance measured from the edge connector to the first end.

[0387] The system can be implemented such that the set of electrodes on the first sensor includes a first electrode having a first electrode first end and a first electrode second end, a second electrode having a second electrode first end and a second electrode second end. A first distance measured from the first electrode first end and the edge connector and a second distance measured from the second electrode first end, and the first distance and the second distance are different.

[0388] The system can be implemented such that each of the electrodes on the first sensor has a width and a length.

[0389] The system can be implemented such that the set of electrodes on the first sensor are linearly arranged along the length of the plate.

[0390] The system can be implemented such that the set of electrodes on the first sensor are linearly arranged along the width of the plate.

[0391] The system can be implemented such that the first sensor output is a subset of data obtained from the first sensor signal, and the second device requests the subset of data.

[0392] The system can be implemented such that the system includes an MQTT broker that facilitates the communication of the first sensor output based on the request of the second device.

[0393] The system can be implemented such that the first laminated structure is a printed circuit board.

[0394] A sensor of electrical properties is proposed, which includes a laminated structure. The laminated structure includes an insulating layer, a conductive layer, and conductive traces. The laminated structure has a first side separated from a second side by a certain thickness, and the first side has a length and a width. The sensor includes a first sensing region configured to sense a first electrical parameter value. The sensor includes a second sensing region configured to sense a second electrical parameter value, and the second sensing region is decoupled from the first sensing region. When a fluid directly contacts the first sensing region, an electric field is generated when actuated, such that a signal is measured at a receiving electrode.

[0395] The sensor can be implemented such that the first sensing region and the second sensing region are coplanar.

[0396] The sensor can be implemented such that the laminated structure includes a flexible substrate.

[0397] The sensor can be implemented such that the flexible substrate is configured to operate in a first configuration and a second configuration. In the first configuration, the first sensing region and the second sensing region are coplanar. In the second configuration, the first sensing region is parallel to the second sensing region and separated by a gap.

[0398] The sensor can be implemented such that the laminated structure is a first laminated structure including the first sensing region. A second laminated structure includes the second sensing region.

[0399] The sensor can be implemented such that the first sensing region is configured to sense the first electrical parameter value using surface sensing technology.

[0400] The sensor can be implemented such that the first sensing region is configured to be placed along the flow direction of the fluid.

[0401] The sensor can be implemented such that the laminated structure includes a hole, and the first sensing region includes a surface angled with respect to the first side and the second side, such that the sensor is configured to sense the electrical parameter value when the fluid flows through the hole.

[0402] The sensor can be implemented such that one of the first sensing region and the second sensing region is configured to be used as a transmitting electrode, a receiving electrode, or a grounding electrode.

[0403] The sensor can be implemented such that the laminated structure includes a third sensing region and a fourth sensing region.

[0404] The sensor can be implemented such that the first sensing region, the second sensing region, the third sensing region, and the fourth sensing region are coplanar with each other.

[0405] The sensor can be implemented such that the laminated structure includes a flexible substrate, and the first sensing region, the second sensing region, the third sensing region, and the fourth sensing region are curved.

[0406] The sensor can be implemented such that the catheter includes the first sensing region, the second sensing region, the third sensing region, and the fourth sensing region.

[0407] The sensor can be implemented such that the laminated structure includes the third sensing region and the fourth sensing region, and the first sensing region, the second sensing region, the third sensing region, and the fourth sensing region are configured to operate as receiving electrodes. The catheter includes the first sensing region, the second sensing region, the third sensing region, and the fourth sensing region. The transmitting electrode is spaced apart from each of the first sensing region, the second sensing region, the third sensing region, and the fourth sensing region.

[0408] The sensor can be implemented such that the receiving electrode and the transmitting electrode are arranged in an interdigitated comb structure on the first surface.

[0409] The sensor can be implemented such that the electrical characteristic value includes conductivity, impedance, or dielectric constant.

[0410] The sensor can be implemented such that the fluid is an adhesive.

[0411] The sensor can be implemented such that the first sensing region includes a first hole in the PCB, the second sensing region includes a second hole in the laminated structure, and the sensor includes a connection end, and the first hole is a first distance from the connection edge, and the second sensing region includes a second distance from the connection end, and the first distance and the second distance are different.

[0412] The sensor can be implemented such that the connection end includes an edge connector, and the first hole, the second hole, and the edge connector are collinear.

[0413] The sensor can be implemented such that the sensor includes a housing that receives the laminated structure.

[0414] The sensor can be implemented such that the laminated structure is a printed circuit board.

[0415] A sensing system for electrical properties is proposed. The sensing system for electrical properties includes a sensor configured to be in direct contact with a fluid. The sensor includes a transmitting electrode configured to generate an electric field when actuated, and a receiving electrode configured to generate an electrical parameter signal of the fluid. The system includes a communication component configured to: receive the electrical parameter signal, generate a signal analysis based on the electrical parameter signal, and generate a feedback signal based on the electrical parameter signal, the feedback signal being generated in real time.

[0416] The sensing system may include a housing configured to receive the sensor and configured to interact with a sensing area.

[0417] The sensing system may be implemented such that the sensing area includes static fluid.

[0418] The sensing system may be implemented such that the sensing area receives a fluid flow.

[0419] The sensing system may be implemented such that the sensor is a first sensor, and the sensing system further includes a second sensor.

[0420] The sensing system may be implemented such that the sensing system includes a laminated structure including an insulating layer, a conductive layer, and conductive traces, and the laminated structure includes the first sensor and the second sensor.

[0421] The sensing system may be implemented such that the first sensor and the second sensor are coplanar with respect to the laminated structure.

[0422] The sensing system may be implemented such that the laminated structure is flexible.

[0423] The sensor may be implemented such that the sensing system includes a first laminated structure and a second laminated structure, and the first laminated structure includes the transmitting electrode, and the second laminated structure includes the receiving electrode.

[0424] The sensing system may be implemented such that the receiving electrode is a first receiving electrode, and the sensing system includes a second receiving electrode.

[0425] The sensing system may be implemented such that the first receiving electrode, the second receiving electrode, and the transmitting electrode of the sensing system form part of a conduit.

[0426] The sensing system may be implemented such that the fluid flows through the conduit.

[0427] The sensing system may be implemented such that the feedback signal includes a mixing ratio, a purification signal, detected bubbles, or an unstable mixture.

[0428] The sensing system can be implemented such that the electrical parameter is conductivity, impedance, or permittivity.

[0429] The sensing system can be implemented such that the sensing system is incorporated into a dispenser that has a pressure sensor, and the sensing system further includes a processing circuit and a memory configured to: receive a pressure signal, receive the value of the electrical parameter, and determine a required setting change for the dispenser based on the pressure signal and the value of the electrical parameter.

[0430] The sensing system can be implemented such that the communication component conveys the setting change to a user of the dispenser.

[0431] The sensing system can be implemented such that the communication component generates a command to change the setting.

[0432] The sensing system can be implemented such that the laminated structure includes a printed circuit board.

[0433] An electrical parameter sensing system is provided that includes: a laminated structure including an insulating layer, a conductive layer, and conductive traces, the laminated structure including a plurality of sensing regions configured to be in direct contact with a fluid; an edge connector electrically coupled to each of the plurality of sensing regions; a signal reader configured to receive a sensed electrical parameter from the edge connector and configured to change the configuration of the plurality of sensing regions from a first configuration to a second configuration. The first configuration includes a first sensing region as a transmitting electrode or a ground electrode and a second sensing region as a receiving electrode, and the second configuration includes the first sensing region as a receiving electrode and the second sensing region as a transmitting electrode or a ground portion. The system includes a communication component configured to convey a sensed value of the electrical parameter, the parameter value being sensed by the receiving electrode when an electric field is generated by the transmitting electrode.

[0434] The sensing system can include a housing having a conduit for a fluid flow, and the sensing regions form part of the housing.

[0435] The sensing system can be implemented such that the sensing regions are along the direction of the fluid flow.

[0436] The sensing system can be implemented such that the signal reader includes a multiplexer that periodically changes the configuration of the plurality of sensing regions.

[0437] The sensing system can include a signal analyzer, and based on a signal, the receiving electrode generates a feedback signal.

[0438] The sensing system can be implemented such that the feedback signal includes a mixing ratio, a purification signal, or a detected inconsistency.

[0439] The sensing system can be implemented such that the feedback signal includes a correction indication.

[0440] The sensing system can be implemented such that the signal reader includes the signal analyzer.

[0441] The sensing system can be implemented such that the sensing area senses the electrical parameter using surface sensing technology.

[0442] The sensing system can be implemented such that the device includes the signal reader, the signal analyzer, and a display configured to display the sensed electrical parameter value.

[0443] The sensing system can be implemented such that the sensing area senses the electrical parameter using body sensing technology.

[0444] The sensing system can be implemented such that the laminated structure is flexible.

[0445] The sensing system can be implemented such that the laminated structure includes a molded material.

[0446] The sensing system can be implemented such that the laminated structure is a printed circuit board.

[0447] A method for detecting an inconsistency in a fluid is proposed, the method including using a signal reader to receive a sensed electrical parameter from a sensor in direct contact with the fluid. The sensor includes a PCB having a transmitting electrode and a receiving electrode, and the electrical parameter is sensed by the receiving electrode when the transmitting electrode is actuated. The method includes: using a signal analyzer to detect an inconsistency in the fluid based on the sensed electrical parameter, generating a correction indication for the inconsistency, and using a communication component to convey the correction indication.

[0448] The method can be implemented such that conveying includes: conveying the correction indication to a device having a display such that the correction indication is presented on the display.

[0449] The method can be implemented such that the device includes the signal reader and the signal analyzer.

[0450] The method can be implemented such that the device includes a multiplexer.

[0451] The method can be implemented such that the sensor includes a second receiving electrode, the transmitting electrode, the receiving electrode, and the second receiving electrode are electrically coupled to an edge connector, and the signal reader receives the edge connector.

[0452] The method can be implemented such that the second receiving electrode, the transmitting electrode, and the receiving electrode are along the fluid flow such that the fluid flow contacts the surface of the laminated structure during flow.

[0453] The method can be implemented such that the receiving, detecting, and generating steps are performed in real time.

[0454] The method can be implemented such that the inconsistencies include: curing amount, mixing ratio, entrained air, or mixing instability.

[0455] The method can be implemented such that the correction indication includes: dispensing parameter change or purification indication.

[0456] The method can be implemented such that the correction indication includes a command for the dispenser to automatically implement the correction indication.

[0457] The method can be implemented such that the sensor uses a somatosensory technology to sense the value of the electrical parameter.

[0458] The method can be implemented such that the sensor uses a surface sensing technology to sense the electrical parameter.

[0459] The method can be implemented such that the laminated structure is flexible.

[0460] The method can be implemented such that the laminated structure includes more receiving electrodes than transmitting electrodes.

[0461] The method can be implemented such that the laminated structure includes holes, and the holes include the transmitting electrode and the receiving electrode.

[0462] The method can be implemented such that the sensed electrical parameter includes impedance, conductivity, or permittivity.

[0463] The method can be implemented such that the fluid is an adhesive.

[0464] The method can be implemented such that the laminated structure is a printed circuit board.

[0465] A fluid parameter sensor is proposed, which includes a flexible laminated structure, the flexible laminated structure includes an electrode pair, and the electrode pair includes a transmitting electrode and a receiving electrode. When the fluid directly contacts the receiving electrode and when the transmitting electrode is actuated, an indication is sensed at the receiving electrode. The sensor includes: a signal analyzer that generates a fluid parameter value based on the indication; and a communication component that is configured to convey the sensed fluid parameter value.

[0466] The fluid parameter sensor can be implemented such that the electrode pair is a first electrode pair, and the flexible laminated structure includes a second electrode pair decoupled from the first electrode pair.

[0467] The fluid parameter sensor can be implemented such that the second electrode pair includes the transmitting electrode and a second receiving electrode different from the receiving electrode.

[0468] The fluid parameter sensor can be implemented such that the flexible laminate structure includes a third pair of electrodes, the third pair of electrodes including the emitting electrode and a third receiving electrode.

[0469] The fluid parameter sensor can be implemented such that the second pair of electrodes includes a second emitting electrode and a second receiving electrode.

[0470] The fluid parameter sensor can be implemented such that the emitting electrode and the receiving electrode are printed onto the laminate structure such that the direct contact includes the fluid contacting the surface of the laminate structure.

[0471] The fluid parameter sensor can be implemented such that the emitting electrode is printed on a first portion of the laminate structure and the receiving electrode is printed on a second portion of the laminate structure such that the laminate structure is configured to receive a fluid flow between the emitting electrode and the receiving electrode.

[0472] The fluid parameter sensor can be implemented such that the laminate structure is configured to fold from a flat configuration to a configuration configured to receive the fluid flow.

[0473] The fluid parameter sensor can include an edge connector.

[0474] The fluid parameter sensor can be implemented such that a signal receiver receives the edge connector.

[0475] The fluid parameter sensor can include a near field communication tag.

[0476] The fluid parameter sensor can include a radio frequency identification tag.

[0477] The fluid parameter sensor can be implemented such that the emitting electrode and the receiving electrode are arranged in an interdigitated comb structure.

[0478] The fluid parameter sensor can be implemented such that the receiving electrode senses the indication through a surface sensing technique.

[0479] The fluid parameter sensor can be implemented such that the receiving electrode senses the indication through a body sensing technique.

[0480] The fluid parameter sensor can be implemented such that the laminate structure is a printed circuit board.

[0481] Example

[0482] These examples are for illustrative purposes only and are not intended to unduly limit the scope of the appended claims. While the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in the corresponding testing measurements. At the very least, and without attempting to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the reported significant digits and by application of ordinary rounding.

[0483] Example 1: Sensor Application for Monitoring Mixing Ratio for Paint Spraying

[0484] Use a system consisting of a paint mixing cup (3M TM PPS TM Series 2.0 spray cup, available from 3M Company, St. Paul, MN) to hold a manually mixed automotive clear coat paint formulation (Standocryl VOC Xtra Clear K9560, including Clear K9560, thinner 5820, and hardener VOC 25 - 30, available from Standox GmbH, Wuppertal, Germany). The PPS TM liner is filled with a base mixture (only Clear K9250, without thinner and hardener) and tested with a sensor (as Figure 9 illustrated), which is embedded in a stir bar that moves through the mixture. The stir bar is configured to retrieve in - situ conductivity and dielectric constant signals and provide them to a connector box, where a software program acquires the signals and creates data that is plotted over time for conductivity and dielectric constant measurements.

[0485] Using the above system, a set of experiments were conducted where the mixing ratios of three components (Clear K9560, diluent 5820, and hardener VOC 25 - 30) were varied to form paint mixtures. The formulation of the clear Standocryl VOC Xtra Clear K9560 was 70.42 wt% Clear K9560, 25.35 wt% diluent 5820, and 4.23 wt% hardener VOC 25 - 30. First, half of the hardener VOC 25 - 30 was added to the base mixture (Clear K9560 only (see above)) and mixed. Conductivity and relative permittivity signals were collected and recorded in real - time and their plots against time were made as shown in Figures 26 and 27. An instantaneous drop in the solution conductivity was observed while the dielectric constant increased. Next, diluent 5820 was added to the mixture. A significant increase in the mixture conductivity and dielectric constant was observed. Finally, the other half of the hardener VOC 25 - 30 was added to the mixture. The conductivity dropped again and the dielectric constant increased.

[0486] Example 2:

[0487] A system consisting of containers was used to hold a liquid material that is low - viscosity in one state and high - viscosity in another state. The material was to be subjected to mixing by a stir bar embedded with sensors (as Figure 10 illustrated). The material would be low - viscosity in one state and high - viscosity in another state. The stir bar was configured as Figure 10 and allowed the conductivity signal to be retrieved to a connector box by a reader where a software program acquired the signal and created data that was plotted over time for conductivity measurement. The initial measurement readings in the chart would be related to readings of the measured air, and once the sensor bar was introduced into the material, spikes and increases in conductivity over time for each material state were observed. Figure 281 illustrates the retrieved data.

Claims

1. An electrical property sensor, the electrical property sensor comprising: A laminated structure, the laminated structure including an insulating layer, a conductive layer, and a conductive trace, the laminated structure having a first side separated from a second side by a certain thickness, the first side having a length and a width; A first hole and a second hole, each of the first hole and the second hole extending from the first side of the laminated structure to a second side of a printed circuit board, the first hole and the second hole each including a receiving electrode and a transmitting electrode; And Wherein when a fluid flows through the first hole and an electric field is generated at the transmitting electrode, a sensor signal indicating an electrical property is measured at the receiving electrode.

2. The sensor according to claim 1, wherein the sensor signal can be converted into an electrical property value of the fluid, and the electrical property value is conductivity, impedance, or dielectric constant.

3. The sensor according to any one of claims 1 to 2, wherein the first hole is parallel to the length and perpendicular to the width.

4. The sensor according to claim 3, wherein the first hole is at a first distance from an edge connector, the second hole is parallel to the first hole, and a distance from a second center of the second hole to the edge connector is similar to a distance from a first center of the first hole to the edge connector.

5. The sensor according to claim 4, wherein the second hole is parallel to the first hole, and the second hole is located at a second length from the edge connector, the second length being different from a first length of the first hole from the edge connector.

6. The sensor according to any one of claims 1 to 5, wherein the first hole has a first width, the second hole has a second width, and the second width is greater than the first width.

7. The sensor according to any one of claims 1 to 6, wherein the fluid flows through the first hole such that the fluid directly contacts the receiving electrode.

8. The sensor according to any one of claims 1 to 7, wherein the fluid flow is a first part of a fluid flow, and when a second part of the fluid flows through the second hole, a second impedance signal is generated using a second transmitting electrode and a second receiving electrode.

9. The sensor according to any one of claims 1 to 8, and the sensor further includes a temperature sensor.

10. The sensor according to any one of claims 1 to 9, wherein the sensor includes a housing, and the housing can be communicatively coupled to an adapter for attachment to a dispensing system.

11. The sensor according to any one of claims 1 to 10, wherein the length of the laminated structure is more than twice the length of the first hole.

12. The sensor according to claim 11, wherein the length of the laminated structure is more than three times the length of the first hole.

13. The sensor according to claim 11, wherein the length of the laminated structure is more than four times the length of the first hole.

14. The sensor according to any one of claims 1 to 13, wherein the laminated structure is a printed circuit board.

15. A signal analysis system for multiple distribution systems, the system comprising: A first distribution system having a first sensor that detects a first sensor signal from a first sensor within the first distribution system, the first sensor including a first laminated structure; A second distribution system having a second sensor that detects a second sensor signal from a second sensor within the first distribution system, the second sensor including a second laminated structure; An analyzer that receives the first sensor signal and the second sensor signal and generates a first sensor output and a second sensor output; And Wherein the signal analysis system provides the first sensor output to a first device and provides the second sensor output to a second device.

16. The system according to claim 15, wherein the first sensor signal is received and the first output is provided in-situ.

17. The system according to claim 16, wherein the sensor signal is received using a wireless protocol.

18. The system according to any one of claims 15 to 17, wherein the first sensor includes a transmitting electrode and a receiving electrode, each electrode being coplanar with the surface of the laminated structure.

19. The system according to any one of claims 15 to 18, wherein one of the electrodes on the first sensor has a first width and a second electrode has a second width, and wherein the second width is wider than the first width.

20. The system according to claim 19, wherein the set of electrodes on the first sensor each have a first end and a second end, and each of the electrodes has a distance measured from an edge connector to the first end, wherein the set of electrodes on the first sensor includes a first electrode having a first electrode first end and a first electrode second end, a second electrode having a second electrode first end and a second electrode second end, and wherein a first distance measured from the first electrode first end and the edge connector and a second distance measured from the second electrode first end are different, and wherein the first distance and the second distance are different.

21. The system according to claim 20, wherein the set of electrodes on the first sensor are linearly arranged along the length of the plate.

22. The system according to claim 20, wherein the set of electrodes on the first sensor are linearly arranged along the width of the plate.

23. The system according to claim 20, wherein the first sensor output is a subset of data obtained from the first sensor signal, and wherein the second device requests the subset of data.

24. The system according to claim 23, wherein the system includes an MQTT broker that facilitates communication of the first sensor output based on the request of the second device.

25. The system according to any one of claims 15 to 24, wherein the first laminated structure is a printed circuit board.

26. A method for detecting an inconsistency in a fluid, the method comprising: Receiving, using a signal reader, a sensed electrical parameter from a sensor that is in direct contact with the fluid; Wherein the sensor includes a PCB having a transmitting electrode and a receiving electrode, and wherein the electrical parameter is sensed by the receiving electrode when the transmitting electrode is actuated; Detecting, using a signal analyzer, an inconsistency in the fluid based on the sensed electrical parameter; Generating a correction indication for the inconsistency; And Communicating the correction indication using a communication component.

27. The method according to claim 26, wherein communicating includes communicating the correction indication to a device having a display such that the correction indication is presented on the display.

28. The method according to claim 27, wherein the device includes the signal reader and the signal analyzer.

29. The method according to any one of claims 26 to 28, wherein the sensor includes a second receiving electrode, wherein the transmitting electrode, the receiving electrode, and the second receiving electrode are electrically coupled to an edge connector, and wherein the signal reader receives the edge connector.

30. The method according to claim 29, wherein the second receiving electrode, the transmitting electrode, and the receiving electrode are along the fluid flow such that the fluid flow contacts the surface of the laminate structure during flow.

31. The method according to claim 30, wherein the receiving, detecting, and generating steps are performed in real time.

32. The method according to any one of claims 26 to 31, wherein the inconsistency includes: Degree of curing, mixing ratio, entrained air, or mixing instability.

33. The method according to any one of claims 26 to 32, wherein the correction indication comprises: Distribution parameter change or purification indication.

34. The method according to any one of claims 26 to 33, wherein the correction indication includes a command for causing a dispenser to automatically implement the correction indication.

35. The method according to any one of claims 26 to 34, wherein the sensor uses a body sensing technique to sense the value of the electrical parameter.

36. The method according to any one of claims 26 to 35, wherein the sensor uses a surface sensing technique to sense the electrical parameter.

37. The method according to any one of claims 26 to 36, wherein the laminate structure is flexible.

38. The method according to any one of claims 26 to 37, wherein the laminate structure includes more receiving electrodes than transmitting electrodes.

39. The method according to any one of claims 26 to 38, wherein the laminate structure includes holes, and wherein the holes include the transmitting electrode and the receiving electrode.

40. The method according to any one of claims 26 to 39, wherein the sensed electrical parameter includes impedance, conductivity, or permittivity.

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