System and method for quality verification of mixture

Abstract

An electrical characteristic sensor for a low conductivity fluid includes a laminate structure including a conductive layer, an insulating layer, and a conductive trace, the laminate structure having a first face 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 laminate, the first aperture and the second aperture each including a receive electrode and a transmit electrode. An electrical characteristic signal of the low conductivity fluid is received when the fluid flows through the first aperture and an electric field is generated.

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. Users of the mixtures may not easily recognize that the composition is no longer consistent. Summary of the Invention

[0002] An electrical property sensor for a low-conductivity fluid is proposed. The electrical property sensor includes a laminated structure, which includes a conductive layer, an insulating 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 also includes 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 the second side of the laminated structure. Each of the first hole and the second hole includes a receiving electrode and a transmitting electrode. When the fluid flows through the first hole and an electric field is generated, an electrical property signal of the low-conductivity fluid is received.

[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 problems are occurring or possibly before the problems occur), so that less material is wasted and the dispensing can be more accurate.

[0004] The foregoing summary of the disclosure is not intended to describe every disclosed embodiment or every implementation of the 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 cited lists are only used as representative groups and should not be construed as exclusive lists. Therefore, the scope of the disclosure should not be limited to the specific exemplary structures described herein, but should extend at least 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 expressly included in the claims or excluded from the claims in any combination as needed. 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 an 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 embodiments described herein can be implemented.

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

[0008] Figure 4A and Figure 4B Illustrated is a material measurement flow sensor in use according to an embodiment herein.

[0009] Figures 5A to 5D Illustrated is an example implementation of a dispensing system equipped with a sensor system according to an embodiment herein.

[0010] Figure 6 Illustrated is a stir bar configured to provide in-situ conductivity measurements of a mixture.

[0011] Figure 7 Illustrated is an elongate sensor according to an embodiment herein.

[0012] Figures 8A to 8B Illustrated is a sensor having electrodes in a series configuration according to an embodiment herein.

[0013] Figures 9A to 9C Illustrated is a sensor configuration for bubble detection according to an embodiment herein.

[0014] Figures 10A to 10E Illustrated is a flexible sensor configuration according to an embodiment herein.

[0015] Figures 11A to 11B Illustrated is a sensor configuration according to an embodiment herein.

[0016] Illustrated is a method for detecting and correcting quality issues in a mixture according to an embodiment herein.

[0017] Figures 12A to 12E Illustrated is a signal received from a sensor according to an embodiment herein.

[0018] Figures 13A to 13D Illustrated is an example of a doped fluid mixture according to an embodiment herein.

[0019] Figure 14 Illustrated is an example simulated conductivity response according to an embodiment herein.

[0020] Figure 15 Illustrated is an example simulation of conductivity response over time as can be seen in an embodiment herein.

[0021] Figure 16 Illustrates an ideal response to conductive nanoparticle loading according to an embodiment of the present disclosure.

[0022] Figure 17 Illustrates a method for quality control of a material dispensing system according to an embodiment of the present disclosure.

[0023] Figure 18 Illustrates a quality control system according to an embodiment of the present disclosure.

[0024] Figure 19 Illustrates a method for receiving real-time sensor signals according to an embodiment of the present disclosure.

[0025] Figures 20A to 20C Illustrates a conductivity measurement system in an exemplary network architecture.

[0026] Figures 21A to 24 D Illustrates a control system for an electrical parameter sensor according to an embodiment of the present disclosure.

[0027] Figure 22 Illustrates an exemplary dispensing system according to an embodiment of the present disclosure.

[0028] Figures 23 to 25 Illustrates an exemplary computing device that can be used in embodiments of the present disclosure. Detailed Description

[0029] 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, operating conditions of a mixture (e.g., changing pressure, temperature, mixing ratio, etc.) can be adjusted or compositional consistency (e.g., remixing, exhaust gas, etc.) can be improved before or during operation.

[0030] Many industrial processes use mixtures, such as, for example, liquid adhesives, liquid food ingredients, liquid coolants, or liquid reaction products. Some properties of such liquids change over time: dispersions or emulsions can separate, oils can become less viscous as the temperature rises, and 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 the painting operation. Solving these problems requires detailed chemical knowledge, time, and elimination of other causes. For many operations, troubleshooting takes time that cannot be saved.

[0031] A co-pending international application IB2021 / 056362, filed on July 14, 2021, discloses a property sensor for determining a property value of a liquid. The property sensor includes 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 the material mixture. Embodiments herein provide systems and methods for effectively and accurately measuring material information for mixture quality control.

[0032] Sensors and sensor systems for measuring electrical properties of fluids are described herein. Broadly speaking, the sensors herein operate by using a provided current or voltage through an emitting electrode that generates an electric field. When the fluid flows between the emitting 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 that calculates the electrical properties of the fluid based on the sensor signal.

[0033] 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 dielectric constants can also be determined from impedance measurement results. As shown herein, conductivity or dielectric constants can be relevant for determining the relevant functionality of a dispensing system or the quality of the fluid flowing therein.

[0034] 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. Although some delay due to processing is inevitable, "real-time" is intended to encompass 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 the system and subsequently the data is input and is essentially immediately available for viewing or editing.

[0035] 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 encompass liquids with low viscosity, liquids with high viscosity, semi-solid materials, suspensions, molten materials, or other flowable materials.

[0036] As used herein, electrical parameters can be detected by an electrode pair. A fluid can flow between or across the electrode pair. When a voltage or current is applied, the emitting electrode can generate an electric field, and the receiving electrode receives a 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.

[0037] The sensor is 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 can extend completely through the thickness of the sensor along part or all of its length. The hole can have a bevel along part or all of its perimeter. The hole can be elongated, such as a slot, or can be shaped, such as a circular or oval aperture. The hole can have one or more corners or edges, or can 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 can include any number of terminals and conductors that allow voltage to be applied to the emitting electrode and allow current to be emitted from the receiving electrode. Alternatively, the PCB can also be configured to allow current to be applied and voltage to be emitted. The PCB can 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 can be used to form the conductive layer. Any suitable insulating material can be used to form the insulating layer.

[0038] The property sensors described herein can be used to sense the properties of a fluid resulting from a mixing process. These property sensors can also be used to sense the properties of an input fluid 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 the 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 the 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 specification of its properties.

[0039] 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.

[0040] 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 have been previously changed 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 the 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 the properties of the 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 the properties of the fluid from the actually measured response impedance.

[0041] Fluids have 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.

[0042] 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.

[0043] According to the present disclosure, the term "properties" of a fluid is not particularly limited. For example, as described in the embodiments herein, one property of interest is the mixing ratio of two or more components of the 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.

[0044] In other embodiments, the property of interest is the degree of aging or aging state. In certain of these embodiments, the fluid is an aged fluid, i.e., a fluid in which certain properties change over time once the aged fluid is produced. 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 aged fluid before aging and at certain times after aging. The property sensor can thereby determine the degree of aging or aging state of the fluid.

[0045] 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 to more than just numerical property values. The property "degree of curing", for example, 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.

[0046] "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, for example, particulates in a liquid. 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.

[0047] 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, where 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.

[0048] Figure 2 Illustrated is an exploded view of a paint gun in which the embodiments described herein can be implemented. The paint gun 200 includes a container 202 that houses the fluid to be dispensed, etc. However, while a container 202 coupled to a nozzle using fasteners 204 is illustrated, it is explicitly contemplated that a larger container can supply fluid to the paint gun 200, for example, using a pump. For example, the paint gun can be actuated when a trigger 208 is pulled.

[0049] Figures 3A to 3B Illustrated is a material measurement flow sensor according to an embodiment herein. Figure 3A Illustrated is a PCB material measurement flow sensor 300. As Figure 3AAs illustrated, the sensing system 300 includes a PCB board 302 having one or more ground portions 330 and TX contacts 440. The TX contacts supply 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 adjusted to ground potential. In some embodiments, the regulator action for 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).

[0050] 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 explicitly contemplated that there may be more or fewer electrode pairs depending on the available area on the PCB board and the sensing requirements.

[0051] Each of these electrode pairs is decoupled from adjacent electrode pairs, thereby receiving four separate conductivity measurement results, where one conductivity measurement result 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 simultaneously generate four different signals with respect to a single material flow, thereby providing a picture that better reflects whether the mixing ratio (or other measurement parameter) is consistent across the sensing region.

[0052] Compared with previous 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.

[0053] Figure 3A An embodiment is 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.

[0054] As further described herein, electrodes 310, 320 can be formed by metallizing the inner surfaces of carriers 352, 354, 356, 358 using, for example, copper. This metallization process can connect electrode 320 to electrode 410. Therefore, a decoupling or disconnecting step is required. This can be accomplished by disconnecting the connection, for example, by drilling holes 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.

[0055] The systems and methods of the present disclosure can be used with 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 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 sensors. 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 particulates (such as suspensions, for example), the particle size must be less than the width of slots 352 to 358. Additionally, the systems of the present disclosure can be limited to solvents that do not cause corrosion or otherwise damage PCB 302 or electrodes 310, 320.

[0056] Figure 3B Another embodiment of sensing system 360 is illustrated, which includes a built-in temperature sensor 370. 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 the embodiment of, there are also four impedance or conductivity sensor slots 380, each slot connected to ground signal 382. However, it should be noted that in Figure 3B the embodiment of, 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 pair of electrodes.

[0057] Many mixing processes rely at least in part on temperature, and material properties such as viscosity change 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 3BIn 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.

[0058] Particularly for analyzing the results of conductivity and permittivity measurements, it is important to have accurate temperature measurement results because the correlation between such parameters and the mixing ratio can be temperature-sensitive.

[0059] Figures 3A to 3B An embodiment is illustrated where slots 352 to 358, 370, and 380 are shaped as 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.

[0060] Although Figures 3A to 3C An embodiment is illustrated where each of slots 352 to 358 includes a single electrode terminal. However, it is explicitly contemplated that in some embodiments, one or more of slots 352 to 358 can accommodate multiple electrode terminals, for example, 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 the electrical parameters in the fluid flowing through slots 352 to 358.

[0061] Figures 3C to 3D An embodiment of a housing for a sensor according to some embodiments herein is illustrated. 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 in configuration 394.

[0062] 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, where sensor 396 has already been installed therein. In some embodiments, sensor 396 can be sealed to housing 390 such that the dispensing system receives housing 390.

[0063] Using the systems and methods described herein, multiple parameters related to the quality of a mixture can be monitored 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 relevant quality indicators. The sensor systems and methods of use herein can provide indications of mixing ratios, curing (e.g., open time, cure rate, temperature change), and can provide in-situ process indications 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 indications for correcting the quality issues can be provided such that corrections 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 the 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 perform the techniques of the present disclosure.

[0066] When running an actual measurement of the quality control parameters of the mixture, the measured impedance response (MIR) can be recorded in the control system, 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 a set of calibration impedance response triples 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 easily performed by using a parameterized multi-dimensional polynomial that models multiple triples of multiple data sets, i.e., (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 frequency used for calibration will generally also be used for measurement. However, a mixing ratio may occur in the measurement where the calibration impedance response is not determined during calibration. Thus, between the triples in the calibration dataset, there may not be an exact match between the sensing frequency and the response impedance. In such a case, interpolation between two appropriately chosen calibration triples that contain 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 software on the control system 220 using a parameterized multi-dimensional polynomial.

[0069] The results of interpolation and differentiation are the values of the mixing ratio of components A and B as the mixture passes through the PCB sensor during measurement.

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

[0071] The control system may record the value of the mixing ratio with a timestamp to ensure quality. The mixing ratio derived during actual measurement can be continuously checked against the desired mixing ratio. If the deviation of the mixing ratio derived during 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 4A to 4B Illustrated is a flow sensor for measuring materials in use according to an embodiment herein. As illustrated in the two images, a sensor according to an embodiment herein can 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 measurement of the mixing ratio than other methods that do not allow direct contact between the sensor and the material. However, as Figure 4A and Figure 4BAs illustrated, the sensor is coated with a material after use. It can be beneficial to be able to discard the sensor after use in scenarios where the material of interest is corrosive, highly viscous, or curable.

[0074] Figures 5A to 5D An example embodiment of a dispensing system equipped with a sensor system according to an embodiment herein is illustrated.

[0075] Figures 5A to 5D The placement of the sensor within the conduit is illustrated. Figure 5A The sensor 710 within the conduit 700 is illustrated. The 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 the sensor 710, contacting each electrode pair, and the sensed conductivity measurement results are transmitted to the control system, for example, through the edge connector 712. A change in the conductivity measurement results between one electrode slot and another can indicate a change in the mass consistency of the mixture.

[0076] Figure 5B A perspective view 700 of the conduit 722 is illustrated. The conduit 722 can be coupled to another part of the dispensing system or the fluid delivery system. The conduit 722 can be coupled to another part of the fluid flow system using threads 726 or another suitable fastening system.

[0077] Figure 5C and Figure 5D A cross-sectional view of the conduit is illustrated. In Figure 5C Overmolded plastics 744, 740, 760 are used as seals to hold the PCB sensor in place. Such seals can 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 can include barbs to maintain the connection.

[0078] In Figure 5D A different seal configuration is illustrated, and an O-ring can be used. Corresponding recesses can be machined in the conduit to receive the O-ring 764 to stabilize the sensor against the pressure of the fluid flow.

[0079] In some embodiments, the illustrated conduit can 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 5A to 5DThe exemplary embodiments illustrated relate to a PCB-based impedance sensor that can 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 compatibility of the PCB sensor with many dispensing systems.

[0081] 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 expressly contemplated that the same or similar sensors can be used to evaluate mixtures in containers. For example, a paint spraying operation typically involves mixing different fluids or mixtures into a container before coupling the container to a dispenser.

[0082] 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.

[0083] Figure 6 An embodiment of a stir bar is illustrated that is configured to provide in-situ conductivity measurements of a mixture. Schematic 900 illustrates stir bar 910, which can be used with a container such as paint mixing cup 920. However, stir bar 910 can also be suitable for other containers and other mixtures.

[0084] Stir bar 910 provides sensor 916, which can be moved through the mixture (or placed in a flowing mixture). Window 914 is included in stir bar 910 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 retention features that help couple the edge connectors of sensor 916 to the wire leads.

[0085] 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 expressly contemplated that sensor 916 and / or stir bar 910 can be single-use products such that they are discarded between uses.

[0086] 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.

[0087] Stir bar 910 is configured such that when it is moved relative to the mixture, the mixture is forced to flow through slots in sensor 916.

[0088] Figure 7 Illustrates an extended sensor according to an embodiment of the present disclosure. Sensor 1000 is illustrated in Figure 7 as having a separation length 1030 between an electrode portion 1020 and an edge connector 1010. The edge connector 1010 should not come into contact with 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).

[0089] Figure 8A Through FIGS. 8D illustrate sensors with 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.

[0090] Figure 8B Illustrates a scenario 1130 that shows the use of a sensor 1100 in an incomplete mixture in a container 1140. The arrangement of the sensors in a 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 a depth 1132 at the lowest depth. The electrode pair 1144 at the second lowest depth measures a second conductivity at a depth 1134. The conductivity at depth 1132 will be different from the conductivity at depth 1134 because of the different compositions. Similarly, the conductivity measured by the electrode pair 1146 at a depth 1136 will be different from the conductivity measured by the electrode pair 1148 at a depth 1138 because of the different concentrations.

[0091] Although Figure 8A and Figure 8B illustrate a sensor 1100 having four electrode pairs arranged in a vertical stack on a PCB, it is explicitly 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.

[0092] In some embodiments, sensor 1100 includes only one pair of electrodes. One pair of electrodes can be used, for example, to measure an ongoing mixing process.

[0093] Sensors such as sensor 1100 can be particularly useful for containers that hold dispersions or emulsions that currently require continuous rotation or constant motion to prevent sedimentation or emulsion stratification. However, the resulting mixing quality is unproven. Sensor 1100 can be used to measure the current dispersion / emulsion consistency or built into a stir bar or other mixing tool such that an in-situ mixing indicator can be provided to ensure that the mixture is well mixed, but the time is not wasted on overmixing.

[0094] Figures 9A to 9C A sensor configuration is illustrated that can be particularly useful for detecting the aggregation of bubbles or droplets of a second phase formed prior to phase separation.

[0095] Figure 9A An inclinometer sensor is illustrated that can be particularly useful for detecting bubbles or droplets in a mixture. The sensor includes four pairs of electrodes in four different-sized slots 1302, 1304, 1306, and 1308. 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 envisioned. Similarly, while four coplanar pairs of electrodes are illustrated, all coplanar pairs of electrodes 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.

[0096] Slots 1302 through 1308 are designed to both detect bubbles or droplets and provide an indication of size. Generally speaking, a consistent mixture without bubbles or droplets provides an insulating effect and a consistent conductivity is maintained across all pairs of electrodes. 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.

[0097] Figure 9A The illustrated design is shown as having 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.

[0098] However, it is explicitly envisioned that some embodiments may require smaller or larger slot sizes. For example, the thinnest slot can 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 can be thinner than 500 μm. One or more slots can be thinner than 1 mm. For other applications, such as a stirrer for larger measurement operations, such as checking the mixture quality in a 50-gallon drum.

[0099] In addition to changes in width, the slots can also be changed 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 selected width to allow flow-through without sacrificing signal strength. For example, for a sensor with a length in meters, the size can be 10 cm long and 1 cm wide.

[0100] For example, when a droplet (or bubble) reaches a diameter as wide or wider than the narrowest slot 1308, it connects the two electrodes within slot 1308, thus generating a conductivity spike only for the 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 or wider than slot 1306. Once the bubble (or droplet) passes through slot 1308, the conductivity will return to the baseline of the mixture. Depending on the number of droplets (bubbles) in the mixture, the conductivity spike frequency changes.

[0101] Sensor 1300 also includes a temperature sensor 1310, which is illustrated as running along the electrode pairs 1302 to 1308. It is explicitly envisioned that the temperature sensor 1310 can be positioned in another suitable location. Additionally, it is envisioned that for some embodiments, such as for mixtures that do not significantly change viscosity within the operating temperature range, the temperature sensor 1310 may not be required.

[0102] Sensor 1300 is also illustrated as having a length 1312 that separates the edge connector 1314 from the electrode pairs 1302 to 1308. However, if sensor 1300 is used as an in-line flow sensor, such as installed in a conduit as Figure 7 illustrated from A to Figure 6 D, then the length 1312 may not be necessary.

[0103] Figure 9B and Figure 9C illustrates the sensor connected to the wire leads 1340 and how the length 1312 provides additional separation from the electrode pairs 1302 to 1308 when used in a container 1350.

[0104] So far, this document has described many sensor configurations, where (e.g., in the horizontal configuration of FIGS. 3 to 5, or in a vertical configuration such as Figures 8A to 8B ) a single row of parallel electrodes is illustrated. However, it is explicitly contemplated that arrangements combining features of both configurations are possible. For example, a grid of electrode pairs can be used to simultaneously detect consistency and blend 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.

[0105] So far, this document has described embodiments of sensors formed from a PCB that are designed to receive a fluid flow through holes therein. However, it is explicitly contemplated that the sensors herein can take other shapes and configurations.

[0106] Figures 10A to 10E A flexible sensor configuration that can be used in the embodiments herein is illustrated.

[0107] Figure 10A An embodiment is illustrated 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.

[0108] Figure 10B An embodiment is illustrated of 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 10B illustrated, 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.

[0109] Figures 10C to 10DAnother flexible sensor configuration is illustrated. 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 explicitly 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. Such configurations may be applicable to static mixers.

[0110] Figure 10E Another flexible sensor configuration is illustrated. The sensing surface 1642 of the sensor 1640 may utilize surface sensing technology to provide electrical characteristic signals to a reader using edge connector 1646. Although the edge connector 1646 is illustrated, other data transfer mechanisms such as NFC or RFID tags are contemplated.

[0111] Annotation 1648 illustrates a simplified view 1648 of an 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 create an electric field on the surface of the sensor 1640, and the receiving portions sense the signal, which is reported to the signal reader by the edge connector 1646. However, although the edge connector is illustrated, it is explicitly contemplated that other suitable data transfer options may be used.

[0112] Figures 10A to 10E A flexible sensor is illustrated. The flexible sensor may be formed using a variety of suitable techniques. Printing techniques may be used to print patterns on many flexible or rigid material substrates such as thin film transistors, capacitors, coils, resistors, etc. Printed electronics presents significant opportunities for low-cost electronics with simpler manufacturing. However, printed electronics may only be suitable for applications where low performance is acceptable.

[0113] Although Figures 10A to 10E Several embodiments of a surface sensing sensor configuration are illustrated, but it is explicitly contemplated that other sensor configurations are possible. For example, the surface sensing regions may be arranged such that a cylinder is formed by a plurality of sensing regions, where at least one of the sensing regions is capable of acting as a transmitting electrode or a receiving electrode. In such a configuration, for example, in any of the configurations described in more detail in FIGS. 1 to 9 of PCT / IB2023 / 062401 and the associated description, the sensor may operate using tomographic sensing technology. Figure 7 to any of the configurations described in more detail in FIGS. 1 to 9 and the associated description, the sensor may operate using tomographic sensing technology.

[0114] Another potentially suitable technology is in-mold electronics. Electronic devices 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 electronic devices (e.g., a single surface sensing device or two body sensing devices) are formed, sensors are assembled such that a voltage or current can be applied to the emitting electrodes and signals can be received from the receiving electrodes.

[0115] The laminate structure consists of at least one non-conductive or insulating layer. In embodiments where electronic devices are integrated onto the surface of a standard component (e.g., a molded material, a composite material, 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 a conductive material.

[0116] As described herein, the laminate structure can be formed of a variety of suitable materials. In some embodiments, additive or subtractive manufacturing techniques are used to form the laminate structure. Such "printed" materials can allow the embodiments herein to be implemented in a variety of additional configurations.

[0117] In some embodiments, classical additive manufacturing techniques (e.g., fused filament fabrication, SLA, IJ) can be used to form the laminate 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.

[0118] According to the embodiments herein, the conductive materials for the laminate structure can include a substrate material with a surface finish. The substrate material can be, for example, copper. The surface finish material can include nickel or gold. Liquid inks can be used, and the liquid inks can contain silver or graphite materials. 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. The 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.

[0119] Dielectric inks may be used in some embodiments herein to print dielectric layers, conformal coatings, and / or encapsulations. Non-conductive dielectric inks may insulate multi-layer circuits to allow for circuit crossing and multi-layer applications. Dielectric inks provide flexibility, moisture resistance, and improved strength.

[0120] According to some embodiments herein, resistive inks may be used. Resistive inks may be based on blends of silver, carbon, and non-conductive pigments to adjust the resistance levels of printed resistors, potentiometers, and heating elements.

[0121] In some embodiments herein, 3D electronic printing techniques are used, such as piezo / valve jetting, aerosol-based jetting, multi-nozzle inkjet, 3D dispensing, print / laser ablation, pneumatic spraying, and / or US spraying.

[0122] Using 3D printing techniques, the sensors described in the embodiments herein may be directly formed on surfaces in contact with fluids, such as into catheters, dispensers, mixing units, containers, etc. A greater range of functional elements (such as flexibility) is possible. Depositing electro-functional inks on a substrate creates active or passive devices.

[0123] For example, a catheter may be formed with a conductive pattern that allows for the measurement of electrical parameters. The catheter may include a plurality of sensing regions along its length to track electrical parameters as fluid passes through each sensing region.

[0124] Printed electronics may be directly printed into housings, catheters, containers, 2K cartridges, static mixers, etc. For example, a housing may be formed of two parts, one part having a transmitting electrode and the other part having a receiving electrode. One part or the other may include edge connectors or another suitable data transmitter.

[0125] The sensors and sensing systems herein may be used in a variety of quality control applications for moving materials or static materials. Equipment has points of failure, and as components wear due to use, the risk of equipment failure increases. When a failure occurs, maintenance is required.

[0126] When a failure is not detected, reactive maintenance is needed to repair or replace the failed component. When signs of failure are detected before the failure occurs, predictive maintenance may be taken. Predictive maintenance may be performed before damage occurs.

[0127] 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 materials, sealants, fillers, materials that separate the battery cells, etc. In one embodiment, the housing may include thermoformed sensors (similar to those described herein) that may form an electronic circuit when the housing is sealed, and the electronic circuit may be used to detect the conductivity of any material contacting the housing. Alternatively, a sensor with a flexible backing may be placed inside the housing where fluid will contact the sensor. If the sensor signal is not as expected, errors in manufacture may be corrected before the battery is placed in the vehicle. Additionally, sensors placed inside the installed battery may report signals during use and may be used as a way to determine whether a recall is needed or whether maintenance is required. The sensor may have a data transmitting device that operates wirelessly and associates the sensed signal with a vehicle ID. Health monitoring may also be useful for applications outside of electric vehicles, such as in aerospace manufacturing, etc.

[0128] So far, the sensor systems described herein are based on a single PCB board. Such systems are relatively inexpensive, and thus their use and replacement offer high cost-effectiveness. However, one drawback of the designs described so far is the large stray fields compared to the main fields present between each pair of electrodes. The stray field effect is caused by the short distance between the input and output ends of the material flow, such as the thickness of the PCB. One way to reduce the stray field effect is to solder multiple PCBs into a PCB stack, where each PCB has holes that contain electrodes.

[0129] Figures 11A to 11B Sensors according to embodiments of the present disclosure are illustrated. It is illustrated herein that multiple electrode slots may 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 multiple electrode slots may be organized in columns such that each slot has a different distance from the connection end. It is also explicitly contemplated that in some embodiments, the electrode slots may be organized in both rows and columns. Sensors 1800, 1830 may provide Figures 8A to 8B and Figures 9A to 9C desired features of two sensor configurations.

[0130] Figure 11A A sensing setup 1800 is illustrated, where sensor 1810 is partially submerged in solution 1820. Sensor 1810 includes electrode slots of a first dimension 1802 and a second dimension 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.

[0131] Figure 11AIllustrates a uniform solution 1820, while Figure 18 Example B illustrates a solution 1850 that has undergone sedimentation, which may be a sign of material aging. 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 solution 1850.

[0132] 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. Quality may decrease as the separation increases.

[0133] Additionally, it is desirable to have a sensor that can handle materials over 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.

[0134] It should be noted that Figure 18 A to Figure 18 B only illustrates one sensor 1810, 1830. However, it is explicitly contemplated that the sensitivity can be increased by stacking sensors 1810, 1830.

[0135] Figures 12A to 12E Illustrates the results of calculating the mixing ratio of silicone obtained using the sensors of the present disclosure. Silicones are generally not conductive. However, they are typically dispensed as mixtures. Like other mixtures discussed herein, the mixing quality affects performance. Therefore, systems and methods for measuring and identifying the mixing ratio are needed.

[0136] Figure 12A Illustrates graphs 1900 of conductivity, dielectric constant, and temperature over time for a two-part sealant mixed in a 2:1 ratio.

[0137] Conductivity 1908 and temperature 1902 of the mixed components of the silicone sealant over time. Each of these components is passed through a dispenser to identify the dielectric constant of the component. Two dielectric constants 1904, 1906 are measured. The dielectric constant of the first material (Part A) is measured to be 4.53. The dielectric constant of the second material (Part B) is measured to be 2.97. Then the two components are mixed together, and the mixture 1904 of the two components results in a detected dielectric constant of 3.42. As illustrated in graph 1900, the dielectric constant of each material component of the mixture can be measured over time. As discussed herein, the electrical parameter values can be measured and analyzed in real time or substantially in real time such that corrective action can be taken quickly with minimal waste of product or components.

[0138] Figure 12B A graph 1920 of both the base part fraction 1924 and the dielectric constant 1922 of the silicone sealant over time is illustrated on the left. The number of data points collected at each base part fraction is represented by the bars in the upper halves on the left and right. In the lower right, a fit between the base part fraction and the dielectric constant is illustrated. The filter used is data with f = 16384 Hz, where the signal-to-noise ratio is less than 0.09.

[0139] Figure 12C is an enlarged view of the dielectric constant relative to the base part fraction, with a linear fit.

[0140] Figure 12D and Figure 12E illustrates a similar analysis of the silicone foam. Graph 1950 illustrates a graph of the base part fraction 1954 and the dielectric constant 1952 over time. Graph 1960 illustrates the data points 1962 received at three different base part fractions. Graph 1960 is generated using the same filter with f = 16384 Hz. The raw data and ratio interpretation are performed using the dielectric constant measured in real time. Also illustrated is the measurement 1964 of the base part fraction relative to the dielectric constant. Figure 12E Illustrates an enlarged graph 1980 of the dielectric constant relative to the base part fraction, which shows a good correlation between the dielectric constant and the base part fraction.

[0141] The noise in the dielectric constant data 1952 is an artifact illustrating metering pump overpressure. In a real-time monitoring scenario, the received dielectric constant signal can indicate pump overpressure.

[0142] Figures 13A to 13BAn example of a doped fluid mixture according to an embodiment of the present disclosure is illustrated. The systems and methods discussed so far have focused on detecting and / or calculating the electrical parameters inherent in a fluid or mixture. However, it is expressly contemplated that in some embodiments of the present disclosure, the electrical parameters of a fluid or mixture can be altered without significantly changing other parameters, such as adhesive cure time, flow rate, etc.

[0143] In some embodiments of the present disclosure, one or more portions of the mixture are loaded with conductive nanoparticles. As used herein, the term "nanoparticle" encompasses particles having a longest dimension less than 999 nm. In some embodiments of the present disclosure, the holes in the sensor body (e.g., PCB) can be as small as 10 μm. Thus, it is desirable that the size of the particles loaded into the fluid be sized so as not to interfere with the electrical features of the sensor. In some embodiments, the nanoparticles loaded into one or more portions of the mixture have a longest dimension less than about 500 nm. In some embodiments, the nanoparticles loaded into one or more portions of the mixture have a longest dimension less than about 400 nm. In some embodiments, the nanoparticles loaded into one or more portions of the mixture have a longest dimension less than about 300 nm. In some embodiments, the nanoparticles loaded into one or more portions of the mixture have a longest dimension less than about 100 nm. In some embodiments, the nanoparticles loaded into one or more portions of the mixture have a longest dimension less than about 100 nm. In some embodiments, the nanoparticles loaded into one or more portions of the mixture have a longest dimension less than about 80 nm. Larger and / or sharp particles may pose a risk of clogging or other damage to the sensor body. Sharp particles in particular can cause increased shear on the sensor body, damaging its electronics. While smaller sized particles can be used, this may require the use of increasingly high frequencies.

[0144] The nanoparticles used in the embodiments of the present disclosure are provided to the fluid in a concentration that is at least sufficient to enable the sensor to pick up an electrical parameter reading. The required concentration can vary depending on the fluid being loaded.

[0145] According to an embodiment of the present disclosure, one or more portions of the fluid are loaded with one or more types of conductive nanoparticles. In some embodiments, only a single portion of the mixture is loaded. In some embodiments, multiple portions of the mixture are loaded, each of which has a different type of conductive nanoparticle or a different density of conductive nanoparticles.

[0146] In some embodiments, the conductive nanoparticles may be loaded at a concentration sufficient to modify the density of one or more portions of the mixture. However, it is explicitly contemplated that the concentration of the nanoparticles must be low enough so as not to affect the performance of the fluid in its intended application. According to the embodiments herein, nanoparticles are selected that are inert to the fluid as well as any other fluids in the potential mixture. For example, in an A-B mixture, portion A may be loaded with a first type of nanoparticle. The first type of nanoparticle must be selected that is inert to portion A as well as portion B and mixture AB and any reaction by-products thereof. In some applications, a small amount of nanoparticle oxidation is acceptable. However, it is desirable that no bubbles or weak bonds are formed between the nanoparticles and portion A, portion B, or mixture AB and any by-products. According to the embodiments herein, the nanoparticles are dispersed throughout the fluid, thereby providing a uniform reading.

[0147] According to the embodiments herein, a sensor can be used to measure or calculate the electrical parameters of a nanoparticle-loaded fluid as described herein. Any of the illustrated sensor embodiments and other suitable sensor configurations can be used to sense the electrical parameters based on the electric field generated by the nanoparticles while providing a current or voltage to the emitting electrode in contact with the fluid.

[0148] Once loaded with nanoparticles, the fluid has a specific set of electrical properties that can be made unique to the fluid and / or mixture. As the fluid and / or mixture changes (e.g., cures, ages, mixes, etc.), the electrical properties will change in a measurable manner.

[0149] Figure 13A The components of a two-part mixture are illustrated. Portion A is loaded with first nanoparticles 2810, and portion B is loaded with second nanoparticles 2820. The particles 2810 and 2820 are shown as being different in size, with particle 2820 being larger than particle 2810. However, it is explicitly noted that this is merely an example. The particles 2810 may be similar to or different from the particles 2820 in many respects (size, concentration, material, etc.).

[0150] In Figure 13A the simulated example, the size of the dots represents the different "effective sizes" of the nanoparticles. In this case, the "effective size" can refer not only to the physical size and shape of the nanoparticle structure but also to the impact on the electrical properties. Thus, if both adhesive A and adhesive B have the same concentration of nanoparticles, adhesive B will have a larger nanoparticle "effective size". This may mean that the nanoparticles in B are more conductive, magnetic, metallic, etc., and thus more strongly affect the electrical properties.

[0151] Figure 13BThree different mixtures 2830, 2840, and 2850 are illustrated. Each mixture has a different combination of parts A and B. Mixture 2830 contains 7 parts A and 3 parts B. Mixture 2840 contains 3 parts A and 7 parts B. Mixture 2850 contains equal parts A and parts B. Since nanoparticle 2810 is different from nanoparticle 2820, each of mixtures 2830 to 2850 will produce a different electrical characteristic signal.

[0152] Figure 13C A graph 2840 illustrating the simulated conductivity over time is shown. Part B is illustrated as having a significantly higher conductivity response 2842 than the conductivity response of part A 2844. The filler material may also be present as part of a mixture that also has a conductivity response 2846.

[0153] Figure 13D A graph of the conductivity of different mixtures of part A and part B is shown, illustrating how the mixing ratio can be determined based on the sensed electrical parameter. Conductivity response 2860 is associated with a mixture having 7 parts A and 3 parts B. Conductivity response 2858 is associated with a mixture having 6 parts A and 4 parts B. Conductivity response 2856 is associated with a mixture having equal parts A and parts B. Conductivity response 2854 is associated with a mixture having 4 parts A and 6 parts B. Conductivity response 2852 is associated with a mixture having 3 parts A and 7 parts B.

[0154] Figure 14 is illustrated Figures 13A to 13D The simulated example conductivity response 2900 of the simulated two - part mixture described in

[0155] Figure 15Illustrates a simulated example of the conductivity response over time as seen in the embodiments herein. The simulated conductivity response 3000 illustrates the simulated operation over time of an extruder for running a two-part adhesive in an dispensing application. The sensing system measures the sensor. The desired mixing ratio is between the limits 3010 and 3020. Fault indications are illustrated at points 3002, 3004, and 3006, where the mixing ratio is no longer in the proper position and where corrective action needs to be taken. Any time spent outside the red bar is a fault mode, and the adhesive pumped in that state is effectively wasted. For the customer, this increases waste and defective products.

[0156] In a manufacturing environment, a two-part adhesive extruder may allow variable dispensing rates. The simulation results 3000 can be used to modify the dispensing rate in real time to correct the mixing ratio.

[0157] Figure 16 Illustrates the ideal response to conductive nanoparticle loading according to the embodiments herein. The range between the bars 3210 indicates the correct mixing ratio for a particular application, and the conductivity signal response (Y-axis) is the maximum per percentage change in the mixing ratio (X-axis). In this configuration, a system utilizing the sensor will have the maximum signal resolution to ensure proper mixing ratio.

[0158] If the first and second nanoparticles of part A and part B have an interaction effect with each other to produce a non-linear response, this idealized curve can be achieved. In some embodiments, this can be achieved through a moderately high Q (0.5 to 5) resonance frequency. For example, if one part is loaded with metal nanoparticles and the other part is loaded with capacitive or ferrite-based nanoparticles. The interaction of the two loaded adhesives will produce a second-order response and thus a non-linear region between the red bars.

[0159] Suitable nanoparticles can include metal-based nanoparticles, carbon-based nanoparticles, ferrite or magnetoresponsive nanoparticles, resonant structures, or other suitable compositions. Some suitable resonant structures can include conductive or semiconductive metal materials. In some embodiments, split S-shaped metamaterials or split ring resonators may be suitable.

[0160] In some embodiments, one or more portions of a fluid or mixture are loaded with metal-based nanoparticles. The metal-based nanoparticles can increase the electrical conductivity of the fluid. They can also be applicable to inductive or magnetic sensing, causing eddy currents that will detune the sensing circuit, thereby shifting the resonance frequency, reducing the Q, and reducing the net impedance. According to embodiments herein, any suitable metal-based nanoparticles can be used. Additionally, in some embodiments, metal oxides can be used. For example, copper and / or gold flakes can be used. Alumina and / or aluminum oxide can also be applicable in some embodiments herein. However, while some examples are listed here, it is expressly contemplated that other metal or metal oxide options may be suitable.

[0161] In some embodiments, one or more portions of a fluid or mixture are loaded with carbon-based nanoparticles. Any suitable conductive carbon nanoparticles can be used, including but not limited to buckyball structures, nanotubes, graphene, carbon black, etc. The increased loading of the carbon-based nanoparticles increases the electrical conductivity of the fluid. The carbon-based nanoparticles can also be applicable to inductive or magnetic sensing, causing eddy currents that will detune the sensing circuit, thereby shifting the resonance frequency, reducing the Q, and reducing the net impedance.

[0162] In some embodiments, the nanoparticles can be composed of ferrites or other magnetoresponsive materials. Such materials may not significantly increase the electrical conductivity, however, the eddy currents will respond to the magnetic flux, thereby shifting the resonance frequency, changing the Q, and changing the net impedance. If polarized, such nanoparticles can give an orientation or flow of the material at a mixing ratio. However, while ferrites are described as one material, it is expressly contemplated that other suitable materials can be used, such as other iron-containing materials.

[0163] In some embodiments, the nanoparticles can be composed of resonance structures (structures that experience a resonance peak at a specific frequency when a frequency is applied). When the mixing ratio deviates, the frequency shifts unidirectionally in a detectable manner. Such materials may not significantly increase the electrical conductivity response of the fluid, however, they will produce a resonance frequency that can vary in a measurable manner as the mixing ratio changes.

[0164] While electrical conductivity is exemplified and described as the electrical parameter of interest, it is expressly contemplated that other electrical parameters can be sensed or calculated. For example, a current can be applied through an emitting electrode, and the voltage can be detected and plotted over time.

[0165] Figure 17 A method for detecting and correcting quality issues in a mixture according to embodiments herein is exemplified. Method 2000 can be implemented using a sensor system (such as those described herein), their combination, or other suitable sensors.

[0166] In block 2010, inconsistencies in the guiding mixture are detected. The inconsistencies can be entrained air, mixing ratio drift, inconsistent mixing (droplet formation, precipitation, emulsion stratification), or another inconsistency from normal flow. Detection can be accomplished by detecting spikes in the sensed electrical parameters by one or more electrode pairs on the PCB sensor, as illustrated in block 2002. Detection can also be achieved by detecting changes in the sensed values 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.

[0167] 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 through different electrode pairs. The sensor can also or alternatively include a plurality of sensing regions arranged in a straight 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 through the sensing regions.

[0168] In block 2020, the detected inconsistencies are corrected. Correction can include further mixing 2022 the mixture, for example to ensure a consistent concentration, correcting the detected mixing ratio drift, reducing the risk of phase separation, and / or stabilizing the dispersion or emulsion. Correction can also include degassing 2024 the mixture to remove detected bubbles or entrained air introduced during the remixing step. Degassing can be accomplished using, for example, a vacuum or by purging a portion of the mixture containing entrained air. Other suitable correction measures 2028 (such as correcting the mixture composition), such as purging, can also be used.

[0169] In some embodiments, detected bubbles can be mitigated without purging, for example by sending a signal to the motor controlling the fluid flow to increase the speed and dispense an amount of material required 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.

[0170] 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 the conductivity spikes (e.g., reducing the severity and / or number) or by confirming that the conductivity difference in 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.

[0171] Figure 18Illustrates 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 analysis tool for the contained fluid), or in a dynamic environment (e.g., in a fluid flow conduit), where the fluid moves through an electrode pair in a PCB board.

[0172] Some systems or methods herein may benefit from using relative thresholds instead of absolute thresholds. A reference level may be important for measuring to have a more accurate relative threshold. 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 purification or reduce the time wasted in attempting to correct inconsistencies that may not exist or may not be at a level requiring correction.

[0173] 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 the fluid flows between them or such that the fluid contacts their surfaces. The electrode pairs 2132 can be part of a printed circuit board, for example, 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.

[0174] 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.

[0175] 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 the signal values retrieved from the same batch of materials or material mixture within a recent time period. For example, the values retrieved within the previous few seconds or minutes may be important. In some embodiments, the signal values may drift over a longer time period due to temperature changes, material aging, mixture ratio fluctuations, etc. However, the inconsistencies can be detected as a rapid change in conductivity or the difference between conductivity measurements in the sensing system from each other. In some embodiments, the threshold generator 2160 periodically or continuously generates a relative threshold 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.

[0176] 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 communicates the command to the device 2180 using the command communicator 2166.

[0177] In some embodiments, the device 2180 can include a display component, and the generated command can be an update to the 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, a remix command, a degassing command, etc.

[0178] The system 2150 can include other features 2168.

[0179] In some embodiments, the threshold generator includes a machine learning model to predict future conductivity time series data based on historical data. The prediction can include a so-called confidence interval. The 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.

[0180] 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.

[0181] 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.

[0182] While conductivity is discussed herein as the value of interest, it is explicitly contemplated that other material parameters (such as current flow, relative permittivity (er)) or impedance may alternatively or also be used in the detection algorithm.

[0183] Measuring conductivity can provide valuable information about the quality of the mixture. For example, as described herein and in the Examples 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.

[0184] 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.

[0185] In block 2210, one or more components to be dispensed are provided to the sensing area. The sensing area can be a material dispenser, a transfer line to the material dispenser, before a nozzle, atomizer, or other delivery mechanism or container within a fluid system. For example, the material dispenser can dispense a liquid 2212, particles 2214 in a suspension, 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 before dispensing.

[0186] In block 2220, the mixture passes through a sensing system, for example, before being dispensed, stored, or removed from storage. Passing through the sensing system may require passing a portion of the sensing body such that the material (e.g., mixture or component) is in direct contact with the sensor. The direct contact between the material and the electrode pair ensures accurate measurement. By sensing

[0187] In block 2230, conductivity measurements are received from the sensing system. The sensing system may 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. Sensor measurements can be made continuously, for example, receiving a signal every second, or more frequently. Measurements can also be made in parallel, for example, from each of the 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.

[0188] 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 the acceptable range, and thus the mixing rate should be changed, or an increase in instability is tending towards phase separation. Similarly, conductivity readings can indicate that a curable component is curing.

[0189] The feedback can also indicate the need for corrective actions. For example, an emulsion or dispersion experiencing separation may need to be stabilized 2242 (e.g., remixed, heated, etc.). The feedback can also indicate the 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.

[0190] In some embodiments, as illustrated herein, providing feedback may also include providing conductivity readings, material characterization 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.

[0191] Figure 23 A through Figure 23 C illustrate conductivity measurement systems in a system network according to embodiments herein.

[0192] In Figure 23 the example shown in A, some items are similar to those shown in the previous figures. Figure 23 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.

[0193] Figure 20A It is also contemplated 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 connectivity service residing at a remote location. Additionally, the data can be substantially stored in any location and intermittently accessed by interested parties or forwarded to interested parties. For example, a physical carrier can be used instead of an electromagnetic wave carrier, or in addition to an electromagnetic wave carrier. This can allow the user 2350 to interact with the system 2310 through their computing device 2360 to initiate a seal inspection process.

[0194] It will also be noted that 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.

[0195] A conductivity measurement system can be any suitable system configured to use the systems and methods herein to collect conductivity measurements, perform analysis, and provide the analysis to a receiving device, storage device, or graphical user interface generator. The Figure 16 operation of such systems is described in PCT / US22 / 52343 and is incorporated herein by reference.

[0196] 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. The 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.

[0197] The conductivity measurement system 2310 may receive the sensor signal as a conductivity signal or a dielectric constant signal or an impedance signal. In embodiments where the received signal is an impedance signal, the conductivity value may be calculated based on the impedance signal. Similarly, the dielectric constant may be calculated based on the received impedance signal. Based on the received sensor signal, calculations and / or predictions may be made as described herein. The blend ratio may be calculated based on calibration data stored in the data repository 2360, which may indicate conductivity data from pure components and / or known mixtures of components. As described above, the 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 required where trend information is particularly relevant.

[0198] Systems and methods using machine learning algorithms are described herein. Machine learning models may be preferred because they can better handle noisy data, make predictions about future signal trends, and make adjustments before the blend quality changes significantly. The systems and methods described herein may calculate the blend ratio in real time. Using machine learning techniques, the blend ratio may be predicted in advance. This allows for faster adjustments, thus keeping the blend 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 blend ratio is detected, the materials already in the mixer will continue to have an incorrect blend ratio for at least the adhesive value of the mixer, and thus, identifying blend ratio problems earlier may save materials and potential purging.

[0199] 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, and the like. In some embodiments, multiple machine learning models are used simultaneously, with each machine learning model being used by a separate system such that the model for each system can learn and improve the overall model. However, it is expressly contemplated that non-machine learning models can also be used.

[0200] The sensing system herein is described as having the functionality to send and receive communicable information to and from other devices. This can be done through an application programming interface, such that, for example, system 2310 can receive and communicate with a pump controller, a line 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 mixtures being generated, and the like.

[0201] In embodiments using machine learning models, the data repository can also include an analyzer that learns 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, purge frequency, dispensing pattern, replacement of sensors, and the like can be collected and used to train the model to more accurately predict trends and provide corrective actions.

[0202] 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 one of data repositories 2330 to 2360. The information can be updated passively or an alert or notification can be provided upon update. For example, current status information can be presented and an alert (visual, audio, or tactile) can be provided if the mixing ratio drifts out of an acceptable range. Additionally or alternatively, a notification can be provided when a device command is generated or when operator intervention is required.

[0203] 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.

[0204] 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 component A, the pressure on the cartridge containing component A is decreased and the pressure on the cartridge containing component B is increased.

[0205] The regressor can then obtain the encoded signal and generate a mixing ratio signal. The regressor can be a machine learning-based algorithm that can be trained in any suitable manner.

[0206] 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.

[0207] 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 step includes 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.

[0208] 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 the weighted combination in the backward pass.

[0209] Alternating or combined training can provide the following benefits: learning the representation of the signal in a way that has a positive effect on the performance of the regressor, which can lead to lower errors when estimating the mixing ratio. Learning the representation of the signal 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.

[0210] Different from systems that only use a single signal from the mixed material, this novel method allows adaptation to the between-batch variations of the raw materials, where for the same mixing ratio, a variation in one of the parts can lead to a change 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.

[0211] Data tracking collected from the sensor system can be processed to provide other information as described herein. For example, the sensor can provide signals that can be processed to indicate a need for a corrective action.

[0212] As described herein, in some embodiments, the sensor includes four electrode pairs. The time series of the conductivity can be analyzed from the 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.

[0213] 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 this is that manual thresholds typically need to be adjusted for new batches, but the ADF test can adapt.

[0214] 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 synchronized.

[0215] Once each signal is stable, these four sensors should have a high covariance. Negative covariance indicates persistent anti-correlated behavior and represents spatial non-uniformity.

[0216] Similarly, a single component of the mixture may also be non-uniform, for example, because it has settled in the barrel or has 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 taken to empty the container.

[0217] Architecture 2300 illustrates an embodiment of a particular 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. Computing resources in a remote server environment can be consolidated at a remote data center location, or they can be distributed. 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.

[0218] Figure 20B illustrates an exemplary system architecture. In Figure 20BIn an embodiment, the system is connected by wires such that it is not a wireless or open distribution solution. In embodiments where wireless connections would have slower transmission rates or would potentially be unreliable, wired communication may also be preferred. However, as discussed with respect to Figure 20A it is envisioned that a wireless system is also possible.

[0219] The electrical parameter sensor 2380 can 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 can provide the sensor signal directly to the processor 2384. The signal converter 2382 can, for example, convert impedance to conductivity, convert an analog signal to a digital signal, or can perform another suitable conversion.

[0220] The processor 2384 receives the electrical parameter indication and generates an electrical parameter value output that can be provided to one or more devices 2386. The devices 2386 can 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 can also query one or more data repositories 2388 to generate additional indications. For example, the data repository 2388 can include past conductivity sensor signals, conductivity sensor signal thresholds, commands to adjust dispensing parameters based on the conductivity signal threshold, and the like. The processor 2384 can take actions accordingly.

[0221] According to an embodiment herein, the system can 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 can convert the pressure signal from one form to another, from amperes to voltage, analog to digital, etc.

[0222] The processor 2384 or another suitable processor can generate a pressure output that can be provided to one or more devices 2386. The processor 2384 can continuously receive signals from the pressure sensor 2390 and the conductivity sensor 2380 throughout the process and can also be capable of continuously generating an output, thereby providing substantially real-time information about the dispensing system. The processor 2384 can include one or more suitable machine learning techniques, can query a look-up table, or can perform another suitable data analysis technique on the received conductivity signal or pressure signal.

[0223] 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.

[0224] 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, to data repository 2388, or to processor 2384.

[0225] 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.

[0226] 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.

[0227] Figure 20B An example shows a single processor receiving information from a single set of sensors for dispensing operations. However, it is explicitly envisioned that a production environment may have multiple dispensers operating 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 20C An example shows a configuration of a system that may be able to provide such functionality.

[0228] Figure 20C An example shows a signal analysis system that communicates with multiple devices using a cloud-based network. As Figure 20C illustrated, the signal analysis system 2400 can communicate with a local analysis system 2440, for example, as Figure 23 described in B. The signal analysis system 2400 can receive multiple sensor signal data 2410 from multiple dispensing operations, such as a pilot line 2404, any operating line 2402, and / or a laboratory setup 2406. As described in Figure 23As 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.

[0229] 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.

[0230] 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 for continuous updates to receive ongoing.

[0231] Figures 21A to 21D An example of a sensing system according to an embodiment of the present disclosure is illustrated. 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 can be detected quickly.

[0232] In some embodiments of the present disclosure, 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., fieldbus systems, sensor networks, input / output links, etc.). In some embodiments of the present disclosure, sensor signal processing is done without an external computer. The sensing system of the present disclosure provides decentralization, increased reliability, reduced cost, increased flexibility, and simplicity.

[0233] In some embodiments, the sensor systems herein include a concentrator that integrates electronic components within a single housing. In some embodiments, all electronic components are on a single 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 circuitry, including power supplies, I / O protection circuitry, signal conditioning, reset management, and / or debug circuitry 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.

[0234] 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.

[0235] Figure 21A A schematic diagram of a sensing system according to an embodiment herein is illustrated. The sensing system 2500 may be used with a sensor as described, for example, 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 that includes 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 an I / O device 2506 and / or another wired or wireless communication protocol 2508. A 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.

[0236] Figure 21B An example interface 2520 of the concentrator is illustrated, which 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.

[0237] Figure 21CAnother interface 2530 is illustrated, which can receive the coupling of an input / output device. Power can be provided, for example, using port 2434. Data can be communicated from the concentrator using computer link 2436.

[0238] Figure 21D Illustrated is a component diagram of a sensing system 2540 according to an embodiment herein. One or more sensors 2542 provide sensor signals received by one or more receivers 2544 coupled to or included in housing 2570. In some embodiments, system 2540 includes an analog front end, which may include filter 2548 and / or analog multiplexer 2546. There may be a converter, e.g., a DA converter or a DC converter 2549. Concentrator 2550 may include non-volatile memory 2552, flash memory 2554, or another suitable information storage device. Temperature sensor 2556 may be incorporated into concentrator 2350 or receive a temperature signal from a temperature sensor. Concentrator 2550 may include a clock 2558. Concentrator 2562 may also include reset functionality 2562.

[0239] Sensor analyzer 2570 may include calibration data and / or functionality 2572. A real-time operating system 2573 may manage the functionality. Sensor analyzer 2570 may include a Fourier transformer 2576. 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, curing progress, etc. Sensor analyzer 2570 may also include an identifier 2574 that identifies the sensor type.

[0240] Concentrator 2550 may include a power management system 2560, which includes or accesses a power source 2566. Power quality 2568 may be monitored. Energy consumption 2569 may be tracked. Conversion input and output ranges 2564 may be stored. Symmetric voltage 2567 may be used.

[0241] Figure 22 Illustrated is a dispensing system according to an embodiment herein. Many dispensing operations are performed with a portable handheld system. If the material quality or machine settings are incorrect, it may result in dispensing errors or adhesive failure. For example, an incorrect mixing ratio or incorrect pressure settings may produce unacceptable products. There is a desire for a handheld dispensing system that can provide real-time sensing and feedback to the user. Figure 24Described is an example of a system that can receive and process sensor signals without a separate computing device. 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. Dispenser 2610 is illustrated as an adhesive dispenser 2610, however other dispensers may also benefit from the systems described herein. Dispenser 2610 includes an in-line sensor 2630 that senses the electrical properties of the material being dispensed. A pressure sensor 2640 is incorporated into dispenser 2610 and monitors the pressure within the dispenser.

[0242] Dispenser 2610 also includes a signal processing system 2620. A signal receiver receives the sensed parameter signals from 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 a user, such as received from signal processing system 2620 using a communication module. Display 2650 may be integrated into dispenser 2610, or into another display visible to the dispenser operator, such as a mobile computer, a work site display, etc. However, while display 2650 is illustrated as communicating the processed information to the operator, it is expressly contemplated that in some embodiments of the present disclosure, the output from signal processing system 2620 may be presented as audio or tactile feedback.

[0243] Based on the sensed signals, 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. Signal processing system 2620 may adjust the mixing ratio by changing the pump speed of one of the components based on the sensed mixing ratio drift. Signal processing system 2620 may control the pump speed directly or indirectly such that an instruction to change the pump speed is sent to a pump controller. Signal processing system 2620 may also communicate the mixing ratio drift, for example, via display 2650. In some embodiments, 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, dispenser parameters are automatically adjusted in real time based on signals from sensors 2630, 2640.

[0244] Information regarding expected process parameters (such as mixing ratio, dispensing pressure) can be detected in any suitable manner. In some embodiments, the dispenser receives the expected process parameters from an NFC tag, an RFID tag, or other information storage system on the material to be dispensed.

[0245] Figures 23 to 25Illustrates an example device that can be used in the embodiments shown in the previous figures. Figure 23 Illustrates an example mobile device that can 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 can be used as, for example, a worker device or a supervisor / safety officer device, in which the present system (or a part thereof) can be deployed. For example, the mobile device can be deployed in the operator's compartment of a computing device for generating, processing, or displaying data.

[0246] Figure 23 Provides a general block diagram of the components of a mobile cellular device 2716 that can 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 allowing communication via one or more communication protocols, such as wireless services for providing cellular access to a network, and protocols for providing a local wireless connection to a network.

[0247] In other examples, an application can be received on a removable Secure Digital (SD) card connected to interface 2715. Interface 2715 and communication link 2713 communicate along bus 2719 with a processor 2717 (which can also embody the processor), which is also connected to a memory 2721 and input / output (I / O) components 2723, as well as a clock 2725 and a location system 2727.

[0248] In one embodiment, I / O components 2723 are provided to facilitate input operations and output operations, and device 2716 can 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 can also be used.

[0249] The clock 2725 illustratively includes a real-time clock component that outputs time and date. The clock can also provide a timing function for the processor 2717.

[0250] Exemplarily, the location system 2727 includes components that output the current geographical location of the output device 2716. The location system may include, for example, a Global Positioning System (GPS) receiver, a LORAN system, a dead reckoning system, a cellular triangulation system, or other positioning systems. The location system may also include, for example, mapping software or navigation software that generates desired maps, navigation routes, and other geographical functions.

[0251] The memory 2721 stores an operating system 2729, network settings 2731, applications 2733, application configuration settings 2735, a data repository 2737, a communication driver 2739, and communication configuration settings 2741. The 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). The memory 2721 stores computer-readable instructions that, when executed by the processor 2717, cause the processor to perform computer-implemented steps or functions in accordance with the instructions. The processor 2717 may also be activated by other components to facilitate its functionality. It should be explicitly contemplated that while the 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.

[0252] Figure 24 It is shown that the device may also be a smart phone 2871. The smart phone 2871 has a touch-sensitive display 2873 that displays icons or tiles or other user input mechanisms 2875. The mechanism 2875 may be used by the user to run applications, make phone calls, perform data transfer operations, etc. Generally, the smart phone 2871 is built on a mobile operating system and provides higher computing power and connectivity than a non-smart phone. Note that other forms of devices are possible.

[0253] However, although Figure 24 an embodiment is illustrated in which the device 2800 is a smart phone 2871, it should be explicitly contemplated that a display may be presented on another computing device.

[0254] Figure 25 is an example of a computing environment in which elements or portions thereof (e.g.) of the systems and methods described herein may be deployed. Refer to Figure 25, Example systems for implementing some embodiments include a general-purpose computing device in the form of a computer 2910. The components of 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 with respect to the systems and methods herein may be deployed in Figure 25 the corresponding part of.

[0255] Computer 2910 typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by computer 2910 and includes both volatile / non-volatile media and removable / non-removable media. By way of example and not limitation, computer-readable media can 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 devices, magnetic tape cartridges, magnetic tape, magnetic disk storage devices or other magnetic storage devices, or any other media that can be used to store the desired information and can be accessed by computer 2910. Communication media can embody computer-readable instructions, data structures, program modules, or other data in a conveyance medium 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.

[0256] 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. The basic input / output system 2933 (BIOS), which contains basic routines that help transfer information between elements within the computer 2910 (such as during startup), is typically stored in the ROM 2931. The RAM 2932 typically contains data and / or program modules that are immediately accessible by and / or currently being operated on by the processing unit 2920. By way of example and not limitation, FIG. 26 illustrates an operating system 2934, application programs 2935, other program modules 2936, and program data 2937.

[0257] 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 disks 2952, an optical disk drive 2955, and non-volatile optical disks 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.

[0258] 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 (FPGA), application specific integrated circuits (e.g., ASIC), application specific standard products (e.g., ASSP), system on a chip (SOC), complex programmable logic devices (CPLD), etc.

[0259] The drives and their associated computer storage media discussed above and illustrated in FIG. 26 provide storage means for computer readable instructions, data structures, program modules, and other data for the computer 2910. In FIG. 29, for example, the 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.

[0260] The user can type 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, gamepad, satellite receiver, or scanner, etc. These input devices and other input devices are generally 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 the monitor, the computer may also include other peripheral output devices such as speakers 2997 and a printer 2996, which may be connected through an output peripheral interface 2995.

[0261] The computer 2910 operates in a networked environment using a logical connection (such as a local area network (LAN) or a wide area network (WAN)) with one or more remote computers such as the remote computer 2980.

[0262] When used in a LAN networked environment, the computer 2910 is connected to the LAN 2971 through a network interface or adapter 2970. When used in a WAN networked environment, the computer 2910 typically includes a modem 2972 or other components for establishing communication through a WAN 2973 (such as the Internet). In a networked environment, program modules may be stored in a remote memory storage device. FIG. 29 illustrates, for example, that a remote application 2985 may reside on the remote computer 2980.

[0263] In the detailed description of the preferred embodiments, reference is made to the accompanying drawings, which illustrate specific embodiments in which the present invention may be practiced. The illustrated embodiments are not intended to enumerate all embodiments according to the present 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 present invention. Therefore, the following detailed description should not be considered limiting, and the scope of the present invention is defined by the appended claims.

[0264] Unless otherwise specified, all numbers expressing feature sizes, amounts, and physical properties used in this specification and the claims should be understood to be modified in all cases by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the above specification and the appended claims are approximations that may vary depending on the desired properties sought to be obtained by those skilled in the art using the teachings disclosed herein.

[0265] Unless the context otherwise requires, as used in the specification and the appended claims, the singular forms "a", "an", and "the" encompass embodiments having plural referents. Unless the context otherwise requires, as used in the specification and the appended claims, the term "or" is generally employed in its sense including "and / or".

[0266] If spatial - related terms are used herein, including but not limited to "proximal", "distal", "lower", "upper", "below", "beneath", "above", and "on top of", they are used for convenience in describing the spatial relationship of one or more elements relative to another element. Such spatial - related 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 figure is flipped or inverted, a portion previously described as below or beneath other elements would then be above or on top of those other elements.

[0267] As used herein, for example, when an element, component, or layer is described as forming a "conformal interface" with, "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, 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 with" 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, various features can be implemented as an integrated circuit device (such as an integrated circuit chip or chipset). Additionally, although this 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.

[0268] If implemented in software, the techniques may be realized, at least in part, by a computer-readable medium comprising instructions that, when executed in a processor, perform one or more of the methods described above. The computer-readable medium may include a tangible computer-readable storage medium and may form part of a computer program product that may include packaging material. The computer-readable storage medium may 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, and magnetic or optical data storage media, among others. The computer-readable storage medium may also include non-volatile storage devices, such as hard disks, magnetic tapes, compact discs (CDs), digital versatile discs (DVDs), Blu-ray discs, holographic data storage media, or other non-volatile storage devices.

[0269] As used herein, the term "processor" may refer to any one of the foregoing structures or any other structure suitable for the specific implementation of the techniques described herein. Additionally, in some aspects, the functionality described herein may be provided within a dedicated software module or hardware module 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 computer described herein may define a specific machine capable of performing the specific 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).

[0270] An electrical property sensor for a low-conductivity fluid is proposed. The electrical property sensor includes a laminated structure that includes a conductive layer, an insulating layer, and conductive traces. The laminated structure has a first face separated from a second face by a certain thickness, and the first face 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 extending from the first face of the laminated structure to the second face of the laminated structure. Each of the first hole and the second hole includes a receiving electrode and a transmitting electrode. When a fluid flows through the first hole and an electric field is generated, an electrical property signal of the low-conductivity fluid is received.

[0271] The sensor may be implemented such that the first hole is parallel to the length and perpendicular to the width.

[0272] The sensor may be implemented such that the first hole is at a first distance from an edge connector of the laminated structure, and the second hole is parallel to the first hole. The distance of the second center of the second hole from the edge connector is similar to the distance of the first center of the first hole from the edge connector.

[0273] The sensor 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.

[0274] The sensor 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.

[0275] The sensor can be implemented such that the second width is less than 4 mm.

[0276] The sensor can be implemented such that the second width is less than 1 mm.

[0277] The sensor can be implemented such that the second width is less than 0.5 mm.

[0278] The sensor can be implemented such that the second width is less than 300 μm.

[0279] The sensor can be implemented such that the first width is at least 50 μm.

[0280] The sensor can be implemented such that the first width is at least 100 μm.

[0281] The sensor can be implemented such that the fluid flows through the first hole such that the fluid directly contacts the receiving electrode.

[0282] The sensor can be implemented such that the fluid flow is a first part of the 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.

[0283] 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.

[0284] The sensor can be implemented such that the sensor is part of a stack of sensors consisting of an impedance sensor and a second impedance sensor.

[0285] The sensor can include a temperature sensor.

[0286] The sensor can be implemented such that the temperature sensor is electrically isolated from the fluid flow.

[0287] 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.

[0288] The sensor can be implemented such that the length of the laminated structure is more than twice the length of the first hole.

[0289] The sensor can be implemented such that the length of the laminate structure is more than three times the length of the first hole.

[0290] The sensor can be implemented such that the length of the laminate is more than four times the length of the first hole.

[0291] The sensor can be implemented such that the laminate structure includes a laminate structure.

[0292] The sensor can be implemented such that the low-conductivity fluid is silicone.

[0293] The sensor can be implemented such that the electrical property signal includes a dielectric constant.

[0294] The sensor can be implemented such that the laminate structure includes a printed circuit board.

[0295] The sensor can be implemented such that the viscosity of the low-conductivity fluid is less than 100 K centipoise.

[0296] The sensor can be implemented such that the viscosity of the low-conductivity fluid is higher than 50 K centipoise.

[0297] The sensor can be implemented such that the low-conductivity fluid has a conductivity less than 10 -6 Siemens.

[0298] The sensor can be implemented such that the low-conductivity fluid has a conductivity less than 10 -7 Siemens.

[0299] The sensor can be implemented such that the low-conductivity fluid has a conductivity less than 10 -8 Siemens.

[0300] The sensor can be implemented such that the fluid includes oil, grease, rubber, resin, caulking, filler, microspheres, polysulfides, or silica.

[0301] A sensing system for a mixture includes: a sensing zone that contains the mixture; and a sensor within the sensing zone. The sensor includes a laminated structure that includes a conductive layer, an insulating layer, and conductive traces. The sensor includes a first sensing region and a second sensing region within the laminated structure, and each of the first sensing region and the second sensing region includes a receiving electrode spaced apart from a transmitting electrode. The mixture is in direct contact with the transmitting electrode and the receiving electrode of each of the first hole and the second hole. When an electric field is generated by the transmitting electrode, an electrical parameter signal is received at the receiving electrode of each of the first hole and the second hole. The sensing system includes communication components that communicate a first calculated electrical parameter for the mixture from the first hole from the first electrical parameter signal, and a second calculated electrical parameter for the mixture from the second hole from the second electrical parameter signal.

[0302] The system can be implemented such that the sensing zone is a container that holds the mixture.

[0303] 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.

[0304] The system can be implemented such that the instability indicates precipitation, emulsion stratification, entrained air, droplet formation, or inconsistent mixing in the mixture.

[0305] The system can be implemented such that a controller generates an inconsistency correction plan based on the instability.

[0306] 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.

[0307] The system can be implemented such that the sensing zone is a conduit through which the mixture flows.

[0308] The system can be implemented such that, to detect 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.

[0309] 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.

[0310] The system can be implemented such that the sensing zone includes a mixing chamber that receives a first component stream and a second component stream.

[0311] The system can be implemented such that the sensing region is within a dispenser configured to dispense the mixture.

[0312] The system can be implemented such that the electrical parameter is impedance, conductivity, or permittivity.

[0313] The system can be implemented such that the electrical parameter indicates a mixing ratio.

[0314] The system can be implemented such that the electrical parameter is an indication of fluid aging.

[0315] The system can be implemented such that the electrical parameter indicates a curing progress.

[0316] The system can be implemented such that the emitting electrode is perpendicular to the surface of the laminate structure.

[0317] 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.

[0318] The system can be implemented such that the second hole is parallel to the first hole.

[0319] The system can be implemented such that the length of the laminate structure is more than twice the length of the first hole.

[0320] The system can be implemented such that the length of the laminate structure is more than three times the length of the first hole.

[0321] The system can be implemented such that the length of the laminate structure is more than four times the length of the first hole.

[0322] 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.

[0323] 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.

[0324] 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.

[0325] The system can be implemented such that the sensor is a first sensor, and the system further includes a second sensor.

[0326] The system can be implemented such that the laminated structure is a first laminated structure, and the sensor includes: a second laminated structure, a second hole within the second laminated structure including a second receiving electrode spaced apart from a second transmitting electrode, and the fluid flows through the second hole and directly contacts the second transmitting electrode and the second receiving electrode.

[0327] The system can be implemented such that the second hole is positioned such that the fluid first flows through the first hole and then through the second hole.

[0328] The system can be implemented such that the second laminated structure is coupled to the first laminated structure.

[0329] The system can be implemented such that the laminated structure includes a temperature sensor.

[0330] The system can include a housing that receives the sensor at an angle with respect to the fluid passage.

[0331] The system can be implemented such that the angle is less than 90°.

[0332] The system can be implemented such that the angle is less than 75°.

[0333] The system can be implemented such that the angle is less than 60°.

[0334] The system can be implemented such that the angle is less than 45°.

[0335] The system can be implemented such that the angle is less than 30°.

[0336] The system according to claim 1, wherein the low-conductivity fluid has a viscosity lower than 100 K centipoise.

[0337] The system according to claim 1, wherein the low-conductivity fluid has a viscosity higher than 50 K centipoise.

[0338] The system according to claim 1, wherein the low-conductivity fluid has a conductivity less than 10 -6 Siemens.

[0339] The system can be implemented such that the low-conductivity fluid has a conductivity less than 10 -7 Siemens.

[0340] The system can be implemented such that the low-conductivity fluid has a conductivity less than 10 -8 Siemens.

[0341] The system can be implemented such that the fluid includes oil, grease, rubber, resin, caulking compound, filler, microsphere, polysulfide, or silica.

[0342] The system can be implemented such that the first calculated electrical parameter includes the dielectric constant.

[0343] The system can be implemented such that the communication component is further configured to communicate a base fraction of the calculation, the base fraction of the calculation being calculated based on the dielectric constant.

[0344] The system can include: a fluid identifier configured to identify the mixture; a controller configured to, based on the fluid identifier: retrieve the electrical parameter distribution of the mixture; compare the first calculated electrical parameter with the electrical parameter distribution; and generate a mixture indication based on the comparison.

[0345] The system can be implemented such that the mixture includes a component doped with a conductive material, and the electrical parameter distribution includes the expected electrical parameter values of the mixture at the mixing ratio.

[0346] The system can be implemented such that the electrical parameter distribution includes a range of acceptable electrical parameter values.

[0347] The system can be implemented such that the electrical parameter distribution includes a first component electrical parameter distribution and a second component electrical parameter distribution.

[0348] The system can be implemented such that the fluid identifier identifies the mixture based on a scan of the packaging material of the mixture.

[0349] The system can be implemented such that the scan includes reading a barcode, analyzing an image, receiving an RFID signal, or receiving an NFC signal.

[0350] The system can be implemented such that analyzing the image includes detecting and reading a barcode, detecting alphanumeric text indicating the fluid identity, or detecting symbols or colors indicating the fluid identity.

[0351] The system can be implemented such that the fluid identifier receives the fluid identity from an I / O device.

[0352] The system can be implemented such that the I / O device includes a keyboard, a touch screen, a mouse, or other computer peripherals.

[0353] A dispensing system for a mixture includes: a mixing unit configured to receive a first fluid stream and a second fluid stream and produce the mixture; a sensor within the fluid flow stream of the dispensing system. The sensor includes a laminate structure that includes a sensing region that includes a transmitting electrode and a receiving electrode, and the laminate structure includes an insulating layer, a conductive layer, and conductive traces. The sensor is configured such that fluid directly contacts the sensing region as it flows through the fluid flow stream, and the sensor generates a sensor signal indicative of the fluid. The system includes: a dispenser configured to dispense the mixture; and a communication component configured to convey the sensor signal.

[0354] The system can be implemented such that the sensor is downstream of the mixing unit and the fluid is the mixture.

[0355] The system can be implemented such that the sensor is upstream of the mixing and downstream of a first fluid source, and the fluid is the first fluid stream or the second fluid stream.

[0356] The system can be implemented such that the sensor is printed inside the dispensing system.

[0357] The system can be implemented such that the laminate structure is positioned within the fluid flow stream such that the fluid contacts the sensing region as it flows through the dispensing system.

[0358] The system can be implemented such that the laminate structure is perpendicular to the fluid flow.

[0359] The system can be implemented such that the sensor is a first sensor positioned downstream of the mixer, and the dispensing system includes a second sensor positioned upstream of the mixer.

[0360] 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 contacts both the first component fluid flow and the second component fluid flow.

[0361] The system can be implemented such that the sensor includes a second sensing region that includes a second transmitting electrode and a second receiving electrode, the first fluid contacts the sensing region, and the second fluid flow contacts the second sensing region.

[0362] The system can include a housing that houses the sensor and physically separates the first fluid flow from the second fluid flow.

[0363] 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 the second fluid stream upstream of the mixer.

[0364] The system can be implemented such that the sensing region includes a first hole, and the laminate structure includes a second hole having a second transmitting electrode and a second receiving electrode.

[0365] The system can be implemented such that the transmitting electrode is parallel to the length of the hole and parallel to the receiving electrode.

[0366] The system can include an analyzer that receives the sensor signal and provides an indication.

[0367] The system can be implemented such that the indication includes aging of the first fluid.

[0368] The system can be implemented such that the analyzer determines the indication by comparing the sensor signal with a stored sensor signal.

[0369] The system can be implemented such that the indication includes an indication of the curing progress of the mixture.

[0370] The system can be implemented such that the indication includes a mixing ratio.

[0371] The system can be implemented such that the analyzer provides a mixing ratio indication based on the received sensor signal.

[0372] The system can be implemented such that the analyzer provides a batch quality indication based on the received sensor signal.

[0373] The system can be implemented such that the analyzer provides an aging indication based on the received sensor signal.

[0374] The system can be implemented such that the indication includes the mixing quality across the cross-section of the fluid flow.

[0375] The system can be implemented such that the analyzer determines the indication by applying a prediction model to the sensor signal.

[0376] The system can be implemented such that the indication includes a bubble indication.

[0377] The system can be implemented such that a control signal is generated based on the indication to purify the fluid flow.

[0378] The system can be implemented such that in response to the sensor signal, the controller is configured to generate a control signal that is provided to a motor to adjust the motor speed of the motor.

[0379] The system can be implemented such that in response to the sensor signal, the controller is configured to automatically initiate purification.

[0380] The system further includes a display component configured to receive the sensed signal and provide a visual indication of the sensed signal.

[0381] The system can be implemented such that the visual indication is a hybrid quality indication.

[0382] The system can be implemented such that the communication component provides the sensed signal to a data repository.

[0383] The system can be implemented such that the sensor includes a temperature sensor.

[0384] The system can be implemented such that the sensor is coplanar with the receiving electrode and the transmitting electrode.

[0385] The system can be implemented such that the temperature sensor is isolated from the fluid flow.

[0386] 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, the coupling including a conductive material.

[0387] The system can be implemented such that the sensor is a four-layer laminate structure.

[0388] The system can be implemented such that the second sensor is a two-layer laminate structure.

[0389] The system can be implemented such that the laminate structure is at a non-orthogonal angle with respect to the fluid flow.

[0390] The system can include a pressure sensor that detects a pressure indication at an outlet of a reservoir or a pump associated with the first fluid flow or the second fluid flow.

[0391] The system can be implemented such that the sensor signal includes conductivity, voltage, or permittivity.

[0392] The system can be implemented such that the communicated sensor signal is converted from the sensed signal.

[0393] The system can be implemented such that the laminate sensor is printed on an inner surface of the dispenser.

[0394] The system can be implemented such that the viscosity of the low-conductivity fluid is less than 100K centipoise.

[0395] The system can be implemented such that the viscosity of the low-conductivity fluid is greater than 50K centipoise.

[0396] The system can be implemented such that the low-conductivity fluid has a conductivity less than 10 -6 Siemens.

[0397] The system can be implemented such that the low-conductivity fluid has a conductivity less than 10 -7 Siemens.

[0398] The system can be implemented such that the low-conductivity fluid has a conductivity less than 10 -8 Siemens.

[0399] The system can be implemented such that the fluid includes oil, grease, rubber, resin, caulking, filler, microspheres, polysulfide, or silica.

[0400] The system can be implemented such that the first calculated electrical parameter includes the dielectric constant.

[0401] The system can be implemented such that the communication component is further configured to communicate a calculated base fractional part that is calculated based on the dielectric constant.

[0402] The system can include: a fluid identifier configured to identify the mixture; and a controller configured to, based on the fluid identifier: retrieve the electrical parameter distribution of the mixture; compare the first calculated electrical parameter with the electrical parameter distribution; and generate a mixture indication based on the comparison.

[0403] The system can be implemented such that the mixture includes components doped with a conductive material, and the electrical parameter distribution includes the expected electrical parameter values of the mixture at the mixing ratio.

[0404] The system can be implemented such that the electrical parameter distribution includes a range of acceptable electrical parameter values.

[0405] The system can be implemented such that the electrical parameter distribution includes a first component electrical parameter distribution and a second component electrical parameter distribution.

[0406] The system can be implemented such that the fluid identifier identifies the mixture based on a scan of the packaging material of the mixture.

[0407] The system can be implemented such that the scan includes reading a barcode, analyzing an image, receiving an RFID signal, or receiving an NFC signal.

[0408] The system can be implemented such that analyzing the image includes detecting and reading a barcode, detecting alphanumeric text indicating fluid identification, or detecting symbols or colors indicating the fluid identification.

[0409] The system can be implemented such that the fluid identifier receives the fluid identification from an I / O device.

[0410] The system can be implemented such that the I / O device includes a keyboard, a touch screen, a mouse, or other computer peripherals.

[0411] A method for detecting inconsistencies in a low-conductivity fluid, the method comprising: receiving, using a signal reader, sensed electrical parameters from a sensor that is in direct contact with the fluid and that includes: a laminated structure including an insulating layer, a conductive layer, and conductive traces; an emitting electrode and a receiving electrode. When an electric field is generated at the emitting electrode, the electrical parameters are sensed by the receiving electrode. The method further comprises: detecting, using a signal analyzer, an inconsistency in the fluid based on the sensed electrical parameters; generating a correction indication for the inconsistency; and communicating the correction indication using a communication component.

[0412] The method may be implemented such that communicating includes: communicating the correction indication to a device having a display such that the correction indication is presented on the display.

[0413] The method may be implemented such that the device includes the signal reader and the signal analyzer.

[0414] The method may be implemented such that the device includes a multiplexer.

[0415] The method may be implemented such that the sensor includes a second receiving electrode, the emitting electrode, the receiving electrode, and the second receiving electrode are electrically coupled to an edge connector, and the signal reader receives the edge connector.

[0416] The method may be implemented such that the sensor is a tomographic sensor.

[0417] The method may be implemented such that the second receiving electrode, the emitting electrode, and the receiving electrode are along the fluid flow such that the fluid flow contacts the surface of the laminated structure during flow.

[0418] The method may be implemented such that the receiving, detecting, and generating steps are completed in real time.

[0419] The method may be implemented such that the inconsistency includes: cure amount, mixing ratio, entrained air, or mixing instability.

[0420] The method may be implemented such that the correction indication includes: dispense parameter change or purge indication.

[0421] The method may be implemented such that the correction indication includes a command for an automatic dispenser to implement the correction indication.

[0422] The method may be implemented such that the sensor uses body sensing technology to sense the electrical parameter value.

[0423] The method may be implemented such that the sensor uses surface sensing technology to sense the electrical parameter.

[0424] The method can be implemented such that the laminate structure is flexible.

[0425] The method can be implemented such that the laminate structure includes more receiving electrodes than emitting electrodes.

[0426] The method can be implemented such that the laminate structure includes holes, and the holes include the emitting electrode and the receiving electrode.

[0427] The method can be implemented such that the sensed electrical parameter includes impedance, conductivity, or permittivity.

[0428] The method can be implemented such that the fluid is silicone.

[0429] The method can be implemented such that the fluid is an adhesive.

[0430] The method can be implemented such that the laminate structure is a printed circuit board.

[0431] The method can be implemented such that the viscosity of the low-conductivity fluid is less than 100 K centipoise.

[0432] The method can be implemented such that the viscosity of the low-conductivity fluid is greater than 50 K centipoise.

[0433] The method can be implemented such that the low-conductivity fluid has a conductivity of less than 10 -6 Siemens.

[0434] The method can be implemented such that the low-conductivity fluid has a conductivity of less than 10 -7 Siemens.

[0435] The method can be implemented such that the low-conductivity fluid has a conductivity of less than 10 -8 Siemens.

[0436] The method can be implemented such that the fluid includes oil, grease, rubber, resin, caulking, filler, microspheres, polysulfide, or silica.

[0437] The method can be implemented such that the communication component is further configured to communicate a fractional basis of the calculation, which is calculated based on the sensed electrical parameter.

[0438] The method can include: identifying a low-conductivity fluid; retrieving the electrical parameter distribution of the mixture; comparing the first calculated electrical parameter with the electrical parameter distribution; and generating a mixture indication based on the comparison.

[0439] The method can be implemented such that the electrical parameter distribution includes the expected electrical parameter values of the mixture at the mixing ratio.

[0440] The method can be implemented such that the electrical parameter distribution includes a range of acceptable electrical parameter values.

[0441] The method can be implemented such that the electrical parameter distribution includes a first component electrical parameter distribution and a second component electrical parameter distribution.

[0442] The method can be implemented such that the fluid identifier identifies the mixture based on a scan of the packaging material of the mixture.

[0443] The method can be implemented such that the scan includes reading a barcode, analyzing an image, receiving an RFID signal, or receiving an NFC signal.

[0444] The method can be implemented such that analyzing the image includes detecting and reading a barcode, detecting alphanumeric text indicative of the fluid identity, or detecting symbols or colors indicative of the fluid identity.

[0445] The method can be implemented such that the fluid identifier receives the fluid identity from an I / O device.

[0446] The method can be implemented such that the I / O device includes a keyboard, a touch screen, a mouse, or other computer peripherals.

[0447] The method may include: receiving a sensed temperature.

[0448] The method can be implemented such that the sensed temperature is the sensed fluid temperature.

[0449] The method can be implemented such that the sensor includes a temperature sensor.

[0450] An electrical parameter sensor for a low-conductivity fluid includes: a laminated structure that includes an insulating layer, a conductive layer, and conductive features, the laminated structure further includes a transmitting electrode and an electrode, the sensor is configured to operate such that when actuated, the transmitting electrode generates an electric field, and the receiving electrode generates a sensor signal when in direct contact with the low-conductivity fluid. The sensor includes: a signal reader configured to detect the electrical parameter value of the low-conductivity fluid based on the sensed signal; and a signal analyzer configured to generate a mixing ratio of the low-conductivity fluid based on the electrical parameter.

[0451] The electrical parameter sensor can be implemented such that the viscosity of the low-conductivity fluid is less than 100 K centipoise.

[0452] The electrical parameter sensor can be implemented such that the viscosity of the low-conductivity fluid is greater than 50 K centipoise.

[0453] The electrical parameter sensor can be implemented such that the low-conductivity fluid has a conductivity less than 10 -6 Siemens.

[0454] The electrical parameter sensor can be implemented such that the low-conductivity fluid has a conductivity less than 10 -7 Siemens.

[0455] The electrical parameter sensor can be implemented such that the low-conductivity fluid has a conductivity less than 10 -8 Siemens.

[0456] The electrical parameter sensor can be implemented such that the fluid includes oil, grease, rubber, resin, caulking compound, filler, microsphere, polysulfide, or silica.

[0457] The electrical parameter sensor can be implemented such that the laminate structure includes more receiving electrodes than transmitting electrodes.

[0458] The electrical parameter sensor can be implemented such that the laminate structure includes an electrode that can be configured as a transmitting electrode in a first mode and as a receiving electrode in a second mode.

[0459] The electrical parameter sensor can be implemented such that the electrode can be configured as a ground electrode in a third mode.

[0460] The electrical parameter sensor can be implemented such that the laminate structure is configured to be placed in a conduit through which the fluid flows.

[0461] The electrical parameter sensor can be implemented such that the laminate structure is configured to be placed such that the receiving electrodes are substantially along the direction of the fluid flow.

[0462] The electrical parameter sensor can be implemented such that the sensor further includes a housing for the laminate structure.

[0463] The electrical parameter sensor can be implemented such that the laminate structure is sealed into the housing such that the transmitting electrode and the receiving electrode can be used to directly contact the low-conductivity fluid.

[0464] The electrical parameter sensor can be implemented such that the laminate structure is angled with respect to the direction of the fluid flow.

[0465] The electrical parameter sensor can be implemented such that the sensor includes two transmitting electrodes and two receiving electrodes arranged in two electrode pairs.

[0466] The electrical parameter sensor can be implemented such that the sensor includes connection ends, and the connection ends follow the first electrode pair and the second electrode.

[0467] The electrical parameter sensor can be implemented such that the first electrode pair is parallel to the second electrode pair, and one of the first electrode pair and the second electrode pair is offset from the center of the connection edge.

[0468] The electrical parameter sensor can be implemented such that the sensor includes a sensing area, and the transmitting electrode and the receiving electrode are printed on the sensing area.

[0469] The electrical parameter sensor can be implemented such that the laminate structure is flexible.

[0470] The electrical parameter sensor can be implemented such that the laminate structure includes a molding material.

[0471] The electrical parameter sensor can be implemented such that the laminate structure is integral with a housing for the low-conductivity fluid.

[0472] The electrical parameter sensor can be implemented such that the laminate structure is integral with a housing configured to receive a flow of the low-conductivity fluid.

[0473] The electrical parameter sensor can include a temperature sensor.

[0474] The electrical parameter sensor can be implemented such that the sensor includes the temperature sensor.

[0475] A kit of distributable mixtures includes: a first part that includes a first component including a low-conductivity fluid and a dopant selected to artificially increase the conductivity of the first part; a second part that includes a second component, wherein a mixture is formed when the first part and the second part are combined at a mixing ratio; and a mixture identifier configured to communicate an electrical parameter distribution associated with the mixture.

[0476] The kit of distributable mixtures can include a sensor including: a laminate structure including an insulating layer, a conductive layer, and conductive traces; a transmitting electrode; and a receiving electrode configured to generate an electrical signal when an electric field is generated at the transmitting electrode, and the sensor is configured to generate the electrical signal when in direct contact with a fluid.

[0477] The kit of distributable mixtures can be implemented such that the sensor includes a communication component configured to communicate electrical parameters based on the electrical signal.

[0478] The kit of distributable mixtures can be implemented such that the communication component includes an edge connector.

[0479] The kit of distributable mixtures can be implemented such that the electrical parameters are calculated based on the electrical signal.

[0480] The kit of distributable mixtures can be implemented such that the first part includes a first container configured to be received by a dispensing unit.

[0481] The distributable mixture kit can be implemented such that the packaging component of the distributable mixture kit includes the mixture identifier.

[0482] The distributable mixture kit can be implemented such that the mixture identifier is configured to enable a device interacting with the mixture identifier to retrieve the electrical parameter distribution of the mixture.

[0483] The distributable mixture kit can be implemented such that the mixture identifier includes an address for a digital database including the electrical parameter distribution.

[0484] The distributable mixture kit can be implemented such that the mixture identifier includes an RFID or NFC tag.

[0485] The distributable mixture kit can be implemented such that the mixture identifier is a barcode.

[0486] The distributable mixture kit can be implemented such that the dopant includes conductive particles having a maximum diameter of less than about 100 μm.

[0487] The distributable mixture kit can be implemented such that the dopant includes conductive particles having a maximum diameter of less than about 50 μm.

[0488] The distributable mixture kit can be implemented such that the dopant includes metal-based particles.

[0489] The distributable mixture kit can be implemented such that the dopant includes carbon-based particles.

[0490] The distributable mixture kit can be implemented such that the dopant includes magnetoresponsive particles.

[0491] The distributable mixture kit can be implemented such that the dopant includes resonant structure particles.

[0492] The distributable mixture kit can be implemented such that the dopant is substantially inert with respect to the first component, the second component, and the mixture.

[0493] The distributable mixture kit can be implemented such that the electrical parameter distribution is specific to the first component.

[0494] The distributable mixture kit can be implemented such that the second component includes a second dopant, and the electrical parameter distribution includes a first electrical parameter distribution and a second component electrical parameter distribution.

[0495] The distributable mixture kit can be implemented such that the electrical parameter distribution includes expected electrical parameter values at mixing ratios.

[0496] The distributable mixture kit can be implemented such that the expected electrical parameter values include a range of acceptable electrical parameter values.

[0497] The distributable mixture kit can be implemented such that the dopant comprises a plurality of particles, wherein a maximum diameter of each of the plurality of particles is at least about one tenth of a size of a minimum diameter of a sensor feature.

[0498] The distributable mixture kit can be implemented such that the sensor comprises a pore that includes the emission electrode on a first surface and the reception electrode on a second surface, wherein a pore width separates the emission electrode from the reception electrode, and the sensor feature is the pore width.

[0499] The distributable mixture kit can be implemented such that the sensor further comprises a temperature sensor.

[0500] The distributable mixture kit can be implemented such that the dopant concentration is not sufficient to significantly change a functional parameter of the first component or the mixture.

Claims

1. An electrical property sensor for low-conductivity fluids, the sensor comprising: A laminated structure including a conductive layer, an insulating layer, and conductive traces, the laminated structure having a first face separated by a certain thickness from a second face, the first face 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 face of the laminated structure to the second face of the laminated structure, 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, an electrical property signal of the low-conductivity fluid is received.

2. 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.

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

4. The sensor according to claim 4, wherein the second hole is parallel to the first hole, and wherein 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.

5. The sensor according to any one of claims 1 to 4, wherein the first hole has a first width, the second hole has a second width, and wherein the second width is greater than the first width.

6. The sensor according to claim 5, wherein the second width is less than 4 mm.

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 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.

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 wherein 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 any one of claims 1 to 11, wherein the low-conductivity fluid is silicone.

13. The sensor according to any one of claims 1 to 12, wherein the electrical property signal is a dielectric constant.

14. The sensor according to any one of claims 1 to 13, wherein the viscosity of the low-conductivity fluid is less than 100 K centipoise.

15. The sensor according to any one of claims 1 to 14, wherein the low-conductivity fluid has a conductivity of less than 10 -6 Siemens.

16. The sensor according to any one of claims 1 to 15, wherein the fluid comprises oil, grease, rubber, resin, caulking compound, filler, microspheres, polysulfide, or silica.

17. A kit of distributable mixtures, the kit comprising: a first part, the first part comprising a first component, the first component comprising a low-conductivity fluid and a dopant, the dopant being selected to artificially increase the conductivity of the first part; a second part, the second part comprising a second component, wherein a mixture is formed when the first part and the second part are combined in a mixing ratio; and a mixture identifier, wherein the mixture identifier is configured to convey an electrical parameter distribution associated with the mixture.

18. The kit of distributable mixtures according to claim 17, and the kit of distributable mixtures further comprises a sensor, the sensor comprising: a laminated structure, the laminated structure comprising an insulating layer, a conductive layer, and conductive traces; a transmitting electrode; a receiving electrode, the receiving electrode being configured to generate an electrical signal when an electric field is generated at the transmitting electrode; and wherein the sensor is configured to generate the electrical signal when in direct contact with a fluid.

19. The kit of distributable mixtures according to claim 18, wherein the sensor comprises a communication component, the communication component being configured to convey electrical parameters based on the electrical signal.

20. The kit of distributable mixtures according to claim 18, wherein the electrical parameters are calculated based on the electrical signal.

21. The kit of distributable mixtures according to any one of claims 17 to 20, wherein the first part comprises a first container, the first container being configured to be received by a dispensing unit.

22. The kit of distributable mixtures according to any one of claims 17 to 21, wherein a packaging component of the kit of distributable mixtures comprises the mixture identifier.

23. The kit of distributable mixtures according to any one of claims 17 to 22, wherein the mixture identifier is configured to enable a device interacting with the mixture identifier to retrieve the electrical parameter distribution of the mixture.

24. The kit of distributable mixtures according to any one of claims 17 to 23, wherein the dopant comprises conductive particles having a maximum diameter of less than about 100 μm.

25. The kit of distributable mixtures according to any one of claims 17 to 24, wherein the dopant comprises metal-based particles, carbon-based particles, magnetoresponsive particles, or resonant structure particles.

26. The kit of distributable mixtures according to any one of claims 17 to 25, wherein the dopant is substantially inert with respect to the first component, the second component, and the mixture.

27. The kit of distributable mixtures according to any one of claims 17 to 26, wherein the electrical parameter distribution is specific to the first component.

28. The kit of distributable mixtures according to claim 18, wherein the dopant comprises a plurality of particles, wherein the maximum diameter of each of the plurality of particles is at least about one-tenth of the size of the minimum diameter of a sensor feature.

29. The kit of distributable mixtures according to claim 18, wherein the sensor further comprises a temperature sensor.

30. The distributable mixture according to any one of claims 17 to 29, wherein the dopant concentration is not sufficient to significantly change the functional parameters of the first component or the mixture.

31. A method for detecting inconsistencies in a low-conductivity fluid, the method comprising: Receiving, by a signal reader, sensed electrical parameters from a sensor, wherein the sensor is in direct contact with the fluid, and wherein the sensor comprises: A laminated structure comprising an insulating layer, a conductive layer, and conductive traces; A transmitting electrode and a receiving electrode; Wherein when an electric field is generated at the transmitting electrode, the electrical parameters are sensed by the receiving electrode; detecting inconsistencies in the fluid by a signal analyzer based on the sensed electrical parameters; Generating a correction indication for the inconsistencies; and Communicating the correction indication using a communication component.

32. The method according to claim 31, wherein communicating comprises communicating the correction indication to a device having a display such that the correction indication is presented on the display.

33. The method according to claim 31 or 32, wherein the receiving, detecting, and generating steps are performed in real time.

34. The method according to any one of claims 31 to 33, wherein the inconsistency includes: The amount of curing, mixing ratio, entrained air, or mixing instability.

35. The method according to any one of claims 31 to 34, wherein the sensed electrical parameters comprise impedance, conductivity, or dielectric constant.

36. The method according to any one of claims 31 to 35, wherein the viscosity of the low-conductivity fluid is less than 100K centipoise.

37. The method according to any one of claims 31 to 36, wherein the low-conductivity fluid has a conductivity of less than 10 -6 Siemens.

38. The method according to any one of claims 31 to 37, wherein the fluid comprises oil, grease, rubber, resin, caulking, filler, microspheres, polysulfide, or silica.

39. The method according to any one of claims 31 to 38, wherein the communication component is further configured to communicate a calculated base fractional part that is calculated based on the sensed electrical parameters.

40. The method according to any one of claims 31 to 39, and the method further comprises: Identifying the low-conductivity fluid; Retrieving the electrical parameter distribution of the mixture; Comparing a first calculated electrical parameter with the electrical parameter distribution; And Generating a mixture indication based on the comparison.

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