A fabric-based pressure sensor, its fabrication method, and wearable devices

Abstract

This invention provides an all-fabric-based pressure sensor, its fabrication method, and a wearable device, comprising: providing an insulating textile fabric as an upper electrode substrate, a lower electrode substrate, and an isolation layer; providing a pressure-sensitive fabric as a sensitive layer; forming upper / lower electrode patterns on the upper / lower electrode substrates using conductive threads; creating a sensing area in the isolation layer by opening windows according to the sensing requirements of the upper / lower electrode patterns; sequentially stacking the lower electrode layer, the sensitive layer, and the upper electrode layer, with the isolation layer located between the lower electrode layer and the sensitive layer and / or between the sensitive layer and the upper electrode layer; and obtaining the all-fabric-based pressure sensor through an integration process. Because all materials used are fabrics, the resulting pressure sensor exhibits excellent flexibility; the isolation layer effectively reduces signal crosstalk and improves sensing accuracy; the entire manufacturing process is simple, reducing manufacturing costs and solving the problem of how to improve the flexibility of a pressure sensor while ensuring its sensing performance at a low cost.

Description

Technical Field

[0001] This invention relates to the field of sensor technology, and in particular to an all-fabric-based pressure sensor, its preparation method, and wearable devices. Background Technology

[0002] With the rapid development of wearable devices, human-computer interaction, and intelligent monitoring, the market has placed higher demands on the flexibility, lightweight design, wearability, and mass production capabilities of pressure sensors. Designers are continuously committed to optimizing the wearing comfort, durability, and compatibility with various carriers of pressure sensors to broaden their application scenarios and improve user experience. Traditional pressure sensors often rely on rigid substrates (such as printed circuit boards, PCBs) or semi-flexible composite materials. These materials are not only difficult to mold, resulting in irregular surfaces that cannot conform to the human body's curves, but also have complex manufacturing processes and high costs, making large-scale mass production difficult. Furthermore, traditional pressure sensors suffer from poor material compatibility, easily experiencing performance degradation or structural damage under stretching, bending, and other deformation scenarios, severely limiting their application in wearable clothing, flexible input devices, and other fabric-based products. In addition, while some flexible pressure sensors use flexible materials, they still suffer from cumbersome component integration, poor compatibility between the core sensitive layer and electrodes, and high manufacturing complexity, failing to balance practicality and production efficiency. Summary of the Invention

[0003] The purpose of this invention is to provide an all-fabric-based pressure sensor and its preparation method, as well as a wearable device, to solve the problem of how to improve the flexibility of the pressure sensor while ensuring its sensing performance at a low cost.

[0004] To address the aforementioned technical problems, this invention provides a method for fabricating an all-fabric-based pressure sensor, comprising: Insulating textile fabrics are provided as the upper electrode substrate, lower electrode substrate, and insulating layer; Pressure-sensitive fabric is provided as a sensitive layer; Using conductive wires, an upper electrode pattern is formed on the upper electrode substrate to obtain an upper electrode layer, and a lower electrode pattern is formed on the lower electrode substrate to obtain a lower electrode layer. Based on the sensing requirements of the upper and lower electrode patterns, windows are opened on the isolation layer to form a sensing area. The lower electrode layer, the sensitive layer, and the upper electrode layer are stacked sequentially from bottom to top, with the isolation layer located between the lower electrode layer and the sensitive layer, and / or the isolation layer located between the sensitive layer and the upper electrode layer. By integrating the lower electrode layer, sensitive layer, upper electrode layer and isolation layer into one unit through an integrated process, a full-fabric-based pressure sensor can be obtained.

[0005] Optionally, in the method for preparing the all-fabric-based pressure sensor, the insulating textile fabric includes cotton cloth, polyester cloth, and silk cloth.

[0006] Optionally, in the method for preparing the all-fabric-based pressure sensor, the conductive filaments include surface filaments and bottom filaments; the surface filaments include conductive filaments, and the bottom filaments include conventional filaments and / or conductive filaments.

[0007] Optionally, in the method for preparing the all-fabric-based pressure sensor, the conductive wire includes at least one of silver fiber conductive wire, carbon fiber conductive wire, and stainless steel fiber conductive wire, and the diameter of the conductive wire is 0.04mm~1mm; the conventional thread includes at least one of nylon thread, polypropylene thread, and cotton thread.

[0008] Optionally, in the method for preparing the all-fabric-based pressure sensor, the resistance of the conductive wire is 0.5Ω / cm to 50Ω / cm.

[0009] Optionally, in the method for preparing the all-fabric-based pressure sensor, the pressure-sensitive cloth is a high-resistance conductive fabric made of carbon fiber or copper-nickel metal fiber combined with polyester or cotton cloth, and the resistance of the pressure-sensitive cloth changes with the change of external stress or tension.

[0010] Optionally, in the method for preparing the all-fabric-based pressure sensor, the thickness of the pressure-sensitive fabric is between 0.05 mm and 1.5 mm.

[0011] Optionally, in the fabrication method of the all-fabric-based pressure sensor, the upper electrode pattern includes a plurality of up-sensing electrodes, the lower electrode pattern includes a plurality of lower sensing electrodes, the up-sensing electrodes and the lower sensing electrodes correspond one-to-one to form sensing points; and the area on the isolation layer corresponding to the sensing points is windowed to form the sensing area.

[0012] Optionally, in the method for preparing the all-fabric-based pressure sensor, the integration process includes at least one of embroidery, sewing, hot melt adhesive film bonding, or glue bonding.

[0013] Optionally, in the method for fabricating the all-fabric-based pressure sensor, when the integration process is hot melt adhesive film bonding, the method further includes: Provide hot melt adhesive film; Based on the sensing requirements of the upper and lower electrode patterns, windows are opened on the hot melt adhesive film to form a sensing area. The lower electrode layer, hot melt adhesive film, sensitive layer, hot melt adhesive film, and upper electrode layer are stacked sequentially from bottom to top. When the insulating layer is located between the lower electrode layer and the sensitive layer, a hot melt adhesive film is placed between the lower electrode layer and the insulating layer, and a hot melt adhesive film is placed between the insulating layer and the sensitive layer. When the insulating layer is located between the sensitive layer and the upper electrode layer, a hot melt adhesive film is placed between the upper electrode layer and the insulating layer, and a hot melt adhesive film is placed between the insulating layer and the sensitive layer. Using a hot-pressing process, the stacked lower electrode layer, hot melt adhesive film, sensitive layer, hot melt adhesive film, upper electrode layer and isolation layer are integrally hot-pressed, so that the hot melt adhesive film melts and bonds the lower electrode layer, sensitive layer, upper electrode layer and isolation layer into one piece, resulting in an all-fabric-based pressure sensor.

[0014] Optionally, in the method for preparing the all-fabric-based pressure sensor, the hot melt adhesive film is a TPU film, and the temperature of the hot pressing process is 80~180℃.

[0015] Optionally, in the method for fabricating the all-fabric-based pressure sensor, the method further includes: An upper interface is provided on the upper electrode layer, and the upper interface is electrically connected to the upper electrode pattern. A lower interface is provided on the lower electrode layer, and the lower interface is electrically connected to the lower electrode pattern. Configure the upper and lower interfaces so that the sensing signals of the all-fabric-based pressure sensor can be transmitted to external devices through the upper and lower interfaces.

[0016] To solve the above-mentioned technical problems, the present invention also provides an all-fabric-based pressure sensor, which is manufactured using the all-fabric-based pressure sensor preparation method described in any of the above claims. The all-fabric-based pressure sensor includes a lower electrode layer, a sensitive layer, and an upper electrode layer stacked from bottom to top. An isolation layer is provided between the lower electrode layer and the sensitive layer, and / or an isolation layer is provided between the upper electrode layer and the sensitive layer. The lower electrode layer includes an insulating textile fabric and a lower electrode pattern formed on the insulating textile fabric, the lower electrode pattern including a plurality of lower sensing electrodes; the upper electrode layer includes an insulating textile fabric and an upper electrode pattern formed on the insulating textile fabric, the upper electrode pattern including a plurality of upper sensing electrodes; the upper sensing electrodes correspond one-to-one with the lower sensing electrodes to form sensing points; the isolation layer includes an insulating textile fabric and a sensing area formed by opening windows in the insulating textile fabric; the sensing area corresponds to the sensing points to realize the transmission of sensing signals.

[0017] Optionally, in the all-fabric-based pressure sensor, the upper electrode layer is further provided with an upper interface, which is electrically connected to the upper electrode pattern; the lower electrode layer is further provided with a lower interface, which is electrically connected to the lower electrode pattern.

[0018] Optionally, in the all-fabric-based pressure sensor, a hot melt adhesive film is provided between the lower electrode layer, the sensitive layer, the upper electrode layer, and the isolation layer, so that the lower electrode layer, the sensitive layer, the upper electrode layer, and the isolation layer are bonded together by melting the hot melt adhesive film through a hot pressing process.

[0019] To address the aforementioned technical problems, the present invention also provides a wearable device, including an all-fabric-based pressure sensor as described in any of the preceding claims.

[0020] The present invention provides an all-fabric-based pressure sensor, its fabrication method, and a wearable device, comprising: providing an insulating textile fabric as an upper electrode substrate, a lower electrode substrate, and an isolation layer; providing a pressure-sensitive fabric as a sensitive layer; forming an upper electrode pattern on the upper electrode substrate using conductive threads to obtain an upper electrode layer, and forming a lower electrode pattern on the lower electrode substrate to obtain a lower electrode layer; opening windows in the isolation layer to form a sensing area according to the sensing requirements of the upper and lower electrode patterns; stacking the lower electrode layer, the sensitive layer, and the upper electrode layer sequentially from bottom to top, with the isolation layer located between the lower electrode layer and the sensitive layer, and / or between the sensitive layer and the upper electrode layer; and integrating the lower electrode layer, the sensitive layer, the upper electrode layer, and the isolation layer into a single unit through an integration process to obtain an all-fabric-based pressure sensor. Because the upper electrode layer, lower electrode layer, isolation layer, and sensitive layer are all made of fabric, and the electrode pattern is formed by conductive threads, the resulting pressure sensor has excellent flexibility and can conform to various curved surfaces. By separating the upper electrode layer, lower electrode layer, and sensitive layer through the isolation layer, signal crosstalk can be effectively reduced and sensing accuracy can be improved. The entire manufacturing process can be achieved using simple processes such as cutting, embroidery, and sewing, which reduces manufacturing costs and solves the problem of how to improve the flexibility of the pressure sensor while ensuring its sensing performance at a low cost. Attached Figure Description

[0021] Figure 1 A flowchart illustrating the fabrication method of the all-fabric-based pressure sensor provided in this embodiment; Figure 2 This is an exploded view illustrating the hierarchical structure of the all-fabric-based pressure sensor provided in this embodiment; Figure 3 An exploded view illustrating the hierarchical structure of the all-fabric-based pressure sensor with a hot melt adhesive film provided in this embodiment. The labels in the attached figures are explained as follows: 110 - Lower electrode layer; 111 - Lower electrode pattern; 112 - Lower sensing electrode; 113 - Lower interface; 120 - Sensitive layer; 130 - Upper electrode layer; 131 - Upper electrode pattern; 132 - Upper sensing electrode; 133 - Upper interface; 210 - Isolation layer; 211 - Sensing area; 220 - Hot melt adhesive film; 221 - Sensing area. Detailed Implementation

[0022] The following detailed description, in conjunction with the accompanying drawings and specific embodiments, provides a more comprehensive overview of the all-fabric-based pressure sensor, its fabrication method, and wearable device proposed in this invention. It should be noted that the drawings are all in a very simplified form and use non-precise scales, intended only to facilitate and clarify the illustration of the embodiments of the invention. Furthermore, the structures shown in the drawings are often part of the actual structures. In particular, different figures may emphasize different aspects and may sometimes use different scales.

[0023] It should be noted that the terms "first," "second," etc., used in the specification, claims, and drawings of this invention are used to distinguish similar objects in order to describe embodiments of the invention, and are not used to describe a specific order or sequence. It should be understood that such uses of terminology are interchangeable where appropriate. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0024] This embodiment provides a method for fabricating an all-fabric-based pressure sensor, such as... Figure 1 As shown, it includes: S1 provides an insulating textile fabric as the upper electrode substrate, lower electrode substrate, and insulating layer; S2 provides pressure-sensitive fabric as a sensitive layer; S3. Using conductive wires, an upper electrode pattern is formed on the upper electrode substrate to obtain an upper electrode layer, and a lower electrode pattern is formed on the lower electrode substrate to obtain a lower electrode layer. S4. According to the sensing requirements of the upper electrode pattern and the lower electrode pattern, a window is opened on the isolation layer to form a sensing area. S5, the lower electrode layer, the sensitive layer and the upper electrode layer are stacked sequentially from bottom to top, with the isolation layer located between the lower electrode layer and the sensitive layer, and / or the isolation layer located between the sensitive layer and the upper electrode layer; S6 integrates the lower electrode layer, sensitive layer, upper electrode layer and isolation layer into one unit through an integrated process to obtain an all-fabric-based pressure sensor.

[0025] The fabrication method of the all-fabric-based pressure sensor provided in this embodiment has excellent flexibility and can conform to various curved surfaces because the upper electrode layer, lower electrode layer, isolation layer and sensitive layer are all made of fabric and the electrode pattern is formed by conductive threads. The isolation layer separates the upper electrode layer, lower electrode layer and sensitive layer, which can effectively reduce signal crosstalk and improve sensing accuracy. The entire manufacturing process can be achieved by simple processes such as cutting, embroidery and sewing, which reduces manufacturing costs and solves the problem of how to improve the flexibility of pressure sensor while ensuring the sensing performance of pressure sensor at low cost.

[0026] It should be noted that in practical applications, step S2 can be placed before step S1, or after step S3 or step S4. Adjusting the order of steps does not affect the overall implementation of the solution. Solutions with adjusted step order, provided they do not violate the spirit of this application, should also fall within the scope of protection of this application.

[0027] Specifically, in this embodiment, step S1 involves providing an insulating textile fabric as an upper electrode substrate, a lower electrode substrate, and an insulating layer.

[0028] In practical applications, the insulating textile fabric can include conventional fabrics such as cotton, polyester, and silk, as long as they have insulating properties, to ensure that the electrode patterns subsequently formed on the upper and lower electrode substrates will not short-circuit with the substrate fabric, thus ensuring that the sensing signal is not interfered with.

[0029] To reduce manufacturing costs, the insulating textile fabrics used for the upper electrode substrate, lower electrode substrate, and insulating layer can be the same, for example, all made of cotton. Of course, the fabrics for the upper electrode substrate, lower electrode substrate, and insulating layer can be selected according to actual needs. For example, when the lower electrode layer is to be in close contact with the skin, a silk fabric with a good skin-friendly feel can be chosen as the lower electrode substrate; when the upper electrode layer is to be in frictional contact with the outside, a wear-resistant Oxford cloth can be chosen as the upper electrode substrate. This application does not restrict the specific selection of the base fabrics for the upper electrode substrate, lower electrode substrate, and insulating layer.

[0030] Furthermore, in this embodiment, step S2 involves providing a pressure-sensitive fabric as a sensitive layer.

[0031] In practical applications, the pressure-sensitive cloth is a high-resistance conductive fabric made of carbon fiber or copper-nickel metal fiber and polyester or cotton cloth. The resistance of the pressure-sensitive cloth changes with the external stress or tension, thereby providing accurate pressure sensing.

[0032] Preferably, in this embodiment, the thickness of the pressure-sensitive fabric is between 0.05mm and 1.5mm. This ensures sensing accuracy while providing good flexibility and portability, making it easy to wear.

[0033] Furthermore, in this embodiment, in step S3, an upper electrode pattern is formed on the upper electrode substrate using conductive wires to obtain an upper electrode layer, and a lower electrode pattern is formed on the lower electrode substrate to obtain a lower electrode layer.

[0034] Specifically, in this embodiment, embroidery or sewing techniques can be used to weave conductive wires onto insulating textile fabric to form a pattern with conductive properties, thereby obtaining an upper electrode layer with an upper electrode pattern and a lower electrode layer with a lower electrode pattern.

[0035] like Figure 2 As shown, the lower electrode layer 110 has a lower electrode pattern 111 formed by braiding conductive wires. The lower electrode pattern 111 includes a plurality of lower sensing electrodes 112, which are electrically connected through conductive wires to achieve the transmission of sensing signals. Similarly, the upper electrode layer 130 has an upper electrode pattern 131 formed by braiding conductive wires. The upper electrode pattern 131 includes a plurality of upper sensing electrodes 132, which are electrically connected through conductive wires to achieve the transmission of sensing signals. The upper sensing electrodes 132 correspond one-to-one with the lower sensing electrodes 112 to form sensing points.

[0036] In practical applications, the conductive thread includes a top thread and a bottom thread; the top thread includes conductive filaments, and the bottom thread includes conventional threads and / or conductive filaments. The conductive filaments include at least one of silver fiber conductive threads, carbon fiber conductive threads, and stainless steel fiber conductive threads, wherein silver fiber conductive threads, carbon fiber conductive threads, and stainless steel fiber conductive threads refer to conductive threads made by combining materials such as silver fiber, carbon fiber, and stainless steel fiber with fiber fabrics such as nylon and cotton. The conventional threads include at least one of nylon threads, cotton threads, and cotton threads.

[0037] To ensure the sensing performance and bending resistance of the conductive wire, in this embodiment, the diameter of the conductive wire is 0.04mm to 1mm, and the resistance of the conductive wire is 0.5Ω / cm to 50Ω / cm.

[0038] Furthermore, in this embodiment, in step S4, a window is opened on the isolation layer to form a sensing area according to the sensing requirements of the upper electrode pattern and the lower electrode pattern.

[0039] Specifically, in this embodiment, such as Figure 2As shown, the sensing area 211 is formed by opening a window in the region corresponding to the sensing point on the isolation layer 210. This allows the sensing electrode 132 on the upper electrode layer 130 to contact the sensitive layer 120 through the sensing area 211 exposed by the isolation layer 210, and the lower sensing electrode 112 on the lower electrode layer 110 to contact the sensitive layer 120 through the sensing area 211 exposed by the isolation layer 210, thus achieving a complete pressure sensing path. Simultaneously, the conductive wires used to connect the sensing electrodes are insulated from the sensitive layer 120 due to the presence of the isolation layer 210, thereby avoiding signal crosstalk and improving sensing accuracy and stability.

[0040] In practical applications, windows can be created in the isolation layer to form a sensing area by means of cutting or laser cutting. The specific implementation methods for creating windows in the isolation layer to form a sensing area are well known to those skilled in the art, and will not be described in detail here.

[0041] Furthermore, in this embodiment, in step S5, the lower electrode layer, the sensitive layer, and the upper electrode layer are stacked sequentially from bottom to top, with the isolation layer located between the lower electrode layer and the sensitive layer, and / or the isolation layer located between the sensitive layer and the upper electrode layer.

[0042] In practical applications, an isolation layer can be placed only between the lower electrode layer and the sensitive layer, or only between the sensitive layer and the upper electrode layer, to reduce the overall thickness of the all-fabric pressure sensor and lower manufacturing costs. Of course, to achieve better low crosstalk performance and further improve the sensing accuracy of the all-fabric pressure sensor, an isolation layer 210 can be placed between the lower electrode layer 110 and the sensitive layer 120, and simultaneously between the sensitive layer 120 and the upper electrode layer 130, such as... Figure 2 As shown.

[0043] Furthermore, in this embodiment, in step S6, the lower electrode layer, the sensitive layer, the upper electrode layer, and the isolation layer are integrated into one unit through an integration process to obtain an all-fabric-based pressure sensor.

[0044] Specifically, in this embodiment, the integration process includes at least one of embroidery, sewing, hot melt adhesive film bonding, or glue bonding.

[0045] In practical applications, when combining the lower electrode layer, sensitive layer, upper electrode layer, and isolation layer into a single unit using embroidery or sewing, conventional insulating threads, such as cotton thread, can be used to sew them together. Of course, to ensure sensing performance, in addition to sewing the edges of the lower electrode layer, sensitive layer, upper electrode layer, and isolation layer together, the surface areas of the lower electrode layer, sensitive layer, upper electrode layer, and isolation layer can also be sewn according to the stitching lines of the sensing electrodes and lower sensing electrodes and conductive wires in the upper and lower electrode patterns. This ensures that the fit of each area and layer meets the sensing requirements.

[0046] Furthermore, in practical applications, when the lower electrode layer, sensitive layer, upper electrode layer, and isolation layer are combined into one unit using adhesive bonding, flexible adhesive can be applied to the upper electrode pattern, lower electrode pattern, and the sensing area. The lower electrode layer, sensitive layer, upper electrode layer, and isolation layer are then aligned and bonded sequentially. After the adhesive cures, a fully fabric-based pressure sensor is obtained. Because flexible adhesive is used, the fully fabric-based pressure sensor retains good flexibility and tactile feel even after the adhesive cures.

[0047] Furthermore, in practical applications, when the lower electrode layer, sensitive layer, upper electrode layer, and insulating layer are combined into one unit using a hot melt adhesive film bonding method, a hot melt adhesive film needs to be provided first. Then, according to the sensing requirements of the upper electrode pattern 131 and the lower electrode pattern 111, windows are opened in the hot melt adhesive film 220 to form a sensing area 221, such as... Figure 3 As shown, the sensing area can be formed by cutting or laser cutting. Then, from bottom to top, the lower electrode layer, hot melt adhesive film, sensitive layer, hot melt adhesive film, and upper electrode layer are stacked sequentially. When the isolation layer is located between the lower electrode layer and the sensitive layer, a hot melt adhesive film is placed between the lower electrode layer and the isolation layer, and between the isolation layer and the sensitive layer. When the isolation layer is located between the sensitive layer and the upper electrode layer, a hot melt adhesive film is placed between the upper electrode layer and the isolation layer, and between the isolation layer and the sensitive layer. In other words, a hot melt adhesive film must be placed between each pair of the lower electrode layer, isolation layer, upper electrode layer, and sensitive layer to fix adjacent layers. Finally, a hot-pressing process is used to heat-press the stacked lower electrode layer, hot melt adhesive film, sensitive layer, hot melt adhesive film, upper electrode layer, and isolation layer together, so that the hot melt adhesive film melts and bonds the lower electrode layer, sensitive layer, upper electrode layer, and isolation layer into a single unit, resulting in a fully fabric-based pressure sensor.

[0048] Specifically, when the hot melt adhesive film is a TPU film, the temperature of the hot pressing process is 80~180℃. In practical applications, to ensure the structural stability and reliability of the all-fabric-based pressure sensor, the hot melt adhesive film can be hot-pressed layer by layer for fixation. For example, the lower electrode layer, the hot melt adhesive film, and the isolation layer are first hot-pressed to fix the lower electrode layer and the isolation layer. Then, the fixed lower electrode layer and the isolation layer are treated as a whole, and the hot melt adhesive film and the sensitive layer are placed on top of it and hot-pressed to fix the sensitive layer to the surface of the isolation layer. This process of hot pressing is repeated multiple times to complete the fabrication of the all-fabric-based pressure sensor. Of course, in practical applications, the order of hot pressing can be flexibly adjusted, as long as the final layer structure of the all-fabric-based pressure sensor meets the distribution of the lower electrode layer, the sensitive layer, and the upper electrode layer. This application does not limit the specific hot pressing process.

[0049] Preferably, considering that the TPU film is an insulating material, in order to further reduce costs, the TPU film can be used as an isolation layer, thereby eliminating the isolation layer originally made of insulating textile fabric. That is, the all-fabric-based pressure sensor at this time includes a lower electrode layer, a TPU film, a sensitive layer, another TPU film, and an upper electrode layer arranged sequentially from bottom to top.

[0050] Furthermore, to facilitate the transmission of signal data between the all-fabric-based pressure sensor and external devices, in this embodiment, the fabrication method of the all-fabric-based pressure sensor further includes: setting an upper interface on the upper electrode layer, the upper interface being electrically connected to the upper electrode pattern; setting a lower interface on the lower electrode layer, the lower interface being electrically connected to the lower electrode pattern; configuring the upper interface and the lower interface so that the sensing signal of the all-fabric-based pressure sensor is transmitted to the external device through the upper interface and the lower interface.

[0051] like Figure 2 or Figure 3 As shown, the lower interface 113 is electrically connected to the lower electrode pattern 111 via a conductive wire, and the upper interface 133 is electrically connected to the upper electrode pattern 131 via a conductive wire, thereby enabling communication with external devices through the upper interface 133 and the lower interface 113.

[0052] The fabrication method of the all-fabric pressure sensor provided in this embodiment uses an all-fabric substrate to construct the sensor. This method can effectively reduce signal crosstalk and improve sensing accuracy, while ensuring that the pressure sensor has excellent flexibility and lightweight, fits various curved surfaces, and is highly adaptable to human wearable scenarios.

[0053] The fabric-based pressure sensor manufacturing method provided in this embodiment only requires simple processes such as cutting, embroidery, sewing, hot melt adhesive film bonding and / or glue bonding. It has high manufacturing efficiency, low cost, and is easy to achieve large-scale mass production.

[0054] This embodiment also provides an all-fabric-based pressure sensor, which is manufactured using the all-fabric-based pressure sensor fabrication method described above. Figure 2 As shown, the all-fabric-based pressure sensor includes a lower electrode layer 110, a sensitive layer 120, and an upper electrode layer 130 stacked from bottom to top; an isolation layer 210 is provided between the lower electrode layer 110 and the sensitive layer 120, and / or an isolation layer 210 is provided between the upper electrode layer 130 and the sensitive layer 120. The lower electrode layer 110 includes an insulating textile fabric and a lower electrode pattern 111 formed on the insulating textile fabric. The lower electrode pattern 111 includes a plurality of lower sensing electrodes 112. The upper electrode layer 130 includes an insulating textile fabric and an upper electrode pattern 131 formed on the insulating textile fabric. The upper electrode pattern 131 includes a plurality of upper sensing electrodes 132. The upper sensing electrodes 132 correspond one-to-one with the lower sensing electrodes 112 to form sensing points. The isolation layer 210 includes an insulating textile fabric and a sensing area 211 formed by opening windows in the insulating textile fabric. The sensing area 211 corresponds to the sensing points to realize the transmission of sensing signals.

[0055] Specifically, in this embodiment, such as Figure 2 As shown, the upper electrode layer 130 is also provided with an upper interface 133, which is electrically connected to the upper electrode pattern 131; the lower electrode layer 110 is also provided with a lower interface 113, which is electrically connected to the lower electrode pattern 111.

[0056] When using hot melt adhesive film bonding to fabricate an all-fabric-based pressure sensor, such as Figure 3 As shown, a hot melt adhesive film 220 is provided between the lower electrode layer 110, the sensitive layer 120, the upper electrode layer 130 and the isolation layer 210, so that the lower electrode layer 110, the sensitive layer 120 and the upper electrode layer 130 and the isolation layer 210 are bonded together by melting the hot melt adhesive film through a hot pressing process.

[0057] In practical applications, when the all-fabric pressure sensor deforms or receives pressure, the resistance of the corresponding area of ​​the sensitive layer 120 changes, thereby generating a corresponding sensing signal between the upper sensing electrode 132 and the lower sensing electrode 112 in contact with this area, and recording this change. By analyzing and processing the sensing signals generated by all sensing electrodes on the all-fabric pressure sensor, the deformation or pressure value received in each area of ​​the all-fabric pressure sensor can be obtained, thus realizing pressure sensing.

[0058] Furthermore, this embodiment also provides an electronic device, including the all-fabric-based pressure sensor described above.

[0059] In practical applications, electronic devices can include, but are not limited to, smart gloves, health monitoring mattresses, smart wearables, smart textiles, humanoid robots, and elderly care monitoring systems. Furthermore, electronic devices can also include computers, memory devices, and other equipment to process or store the sensing signals obtained from the all-fabric-based pressure sensors.

[0060] The all-fabric-based pressure sensor provided in this embodiment possesses excellent tensile toughness, softness, and durability, making it perfectly adaptable to human wearable scenarios and capable of being attached to various flexible or rigid carrier surfaces. Through an interface, it can transmit data with computing devices. It can be used not only to manufacture fabric-based intelligent monitoring products such as smart gloves and health monitoring mattresses, but also to form flexible input devices with multiple touch-sensitive controls. It can be widely applied in human-computer interaction, smart wearables, industrial inspection, and other fields, effectively filling the gap in the application scenarios of traditional pressure sensors in fabric-based flexible applications.

[0061] The electronic device based on the all-fabric-based pressure sensor provided in this embodiment can be configured with other functional modules according to actual needs to achieve real-time acquisition of physiological parameters such as heart rate and blood pressure, as well as real-time monitoring of data such as body posture, range of motion, respiration, and sleep quality. Because the all-fabric-based pressure sensor possesses excellent flexibility and elasticity, it can conform to the complex curves of the human body, significantly improving wearing and usage comfort, ensuring the accuracy of the acquired data, and supporting personalized customization. The acquired data can also be synchronized in real-time to external devices such as mobile phones for easy viewing and analysis.

[0062] It should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Similar or identical parts between embodiments can be referred to mutually. In addition, different parts between embodiments can also be combined with each other, and this invention does not limit this.

[0063] The all-fabric-based pressure sensor and its fabrication method, as well as the wearable device provided in this embodiment, include: providing an insulating textile fabric as an upper electrode substrate, a lower electrode substrate, and an isolation layer; providing a pressure-sensitive fabric as a sensitive layer; forming an upper electrode pattern on the upper electrode substrate using conductive threads to obtain an upper electrode layer, and forming a lower electrode pattern on the lower electrode substrate to obtain a lower electrode layer; opening windows in the isolation layer to form a sensing area according to the sensing requirements of the upper and lower electrode patterns; stacking the lower electrode layer, the sensitive layer, and the upper electrode layer sequentially from bottom to top, with the isolation layer located between the lower electrode layer and the sensitive layer, and / or between the sensitive layer and the upper electrode layer; and integrating the lower electrode layer, the sensitive layer, the upper electrode layer, and the isolation layer into a single unit through an integration process to obtain the all-fabric-based pressure sensor. Because the upper electrode layer, lower electrode layer, isolation layer, and sensitive layer are all made of fabric, and the electrode pattern is formed by conductive threads, the resulting pressure sensor has excellent flexibility and can conform to various curved surfaces. By separating the upper electrode layer, lower electrode layer, and sensitive layer through the isolation layer, signal crosstalk can be effectively reduced and sensing accuracy can be improved. The entire manufacturing process can be achieved using simple processes such as cutting, embroidery, and sewing, which reduces manufacturing costs and solves the problem of how to improve the flexibility of the pressure sensor while ensuring its sensing performance at a low cost.

[0064] The above description is merely a description of preferred embodiments of the present invention and is not intended to limit the scope of the present invention in any way. Any changes or modifications made by those skilled in the art based on the above disclosure shall fall within the protection scope of the claims.

Claims

1. A method for fabricating an all-fabric-based pressure sensor, characterized in that, include: Insulating textile fabrics are provided as the upper electrode substrate, lower electrode substrate, and insulating layer; Pressure-sensitive fabric is provided as a sensitive layer; Using conductive wires, an upper electrode pattern is formed on the upper electrode substrate to obtain an upper electrode layer, and a lower electrode pattern is formed on the lower electrode substrate to obtain a lower electrode layer. Based on the sensing requirements of the upper and lower electrode patterns, windows are opened on the isolation layer to form a sensing area. The lower electrode layer, the sensitive layer, and the upper electrode layer are stacked sequentially from bottom to top, with the isolation layer located between the lower electrode layer and the sensitive layer, and / or the isolation layer located between the sensitive layer and the upper electrode layer. By integrating the lower electrode layer, sensitive layer, upper electrode layer and isolation layer into one unit through an integrated process, a full-fabric-based pressure sensor can be obtained.

2. The method for preparing the all-fabric-based pressure sensor according to claim 1, characterized in that, The insulating textile fabrics include cotton fabric, polyester fabric, and silk fabric.

3. The method for preparing the all-fabric-based pressure sensor according to claim 1, characterized in that, The conductive wire includes a top wire and a bottom wire; the top wire includes conductive wires, and the bottom wire includes conventional wires and / or conductive wires.

4. The method for preparing the all-fabric-based pressure sensor according to claim 3, characterized in that, The conductive wire includes at least one of silver fiber conductive wire, carbon fiber conductive wire, and stainless steel fiber conductive wire, and the diameter of the conductive wire is 0.04mm to 1mm; the conventional thread includes at least one of nylon thread, polypropylene thread, and cotton thread.

5. The method for preparing the all-fabric-based pressure sensor according to claim 3, characterized in that, The resistance of the conductive wire is 0.5Ω / cm to 50Ω / cm.

6. The method for preparing the all-fabric-based pressure sensor according to claim 1, characterized in that, The pressure-sensitive cloth is a high-resistance conductive fabric made of carbon fiber or copper-nickel metal fiber combined with polyester or cotton cloth, and the resistance of the pressure-sensitive cloth changes with the external stress or tension.

7. The method for preparing the all-fabric-based pressure sensor according to claim 1, characterized in that, The thickness of the pressure-sensitive cloth is between 0.05mm and 1.5mm.

8. The method for preparing the all-fabric-based pressure sensor according to claim 1, characterized in that, The upper electrode pattern includes a plurality of up-sensing electrodes, and the lower electrode pattern includes a plurality of lower sensing electrodes. The up-sensing electrodes and the lower sensing electrodes correspond one-to-one to form sensing points. The area on the isolation layer corresponding to the sensing points is windowed to form the sensing area.

9. The method for preparing the all-fabric-based pressure sensor according to claim 1, characterized in that, The integrated process includes at least one of embroidery, sewing, hot melt adhesive film bonding, or glue bonding.

10. The method for preparing the all-fabric-based pressure sensor according to claim 9, characterized in that, When the integration process involves hot melt adhesive film bonding, the fabrication method of the all-fabric-based pressure sensor further includes: Provide hot melt adhesive film; Based on the sensing requirements of the upper and lower electrode patterns, windows are opened on the hot melt adhesive film to form a sensing area. The lower electrode layer, hot melt adhesive film, sensitive layer, hot melt adhesive film, and upper electrode layer are stacked sequentially from bottom to top. When the insulating layer is located between the lower electrode layer and the sensitive layer, a hot melt adhesive film is placed between the lower electrode layer and the insulating layer, and a hot melt adhesive film is placed between the insulating layer and the sensitive layer. When the insulating layer is located between the sensitive layer and the upper electrode layer, a hot melt adhesive film is placed between the upper electrode layer and the insulating layer, and a hot melt adhesive film is placed between the insulating layer and the sensitive layer. Using a hot-pressing process, the stacked lower electrode layer, hot melt adhesive film, sensitive layer, hot melt adhesive film, upper electrode layer and isolation layer are integrally hot-pressed, so that the hot melt adhesive film melts and bonds the lower electrode layer, sensitive layer, upper electrode layer and isolation layer into one piece, resulting in an all-fabric-based pressure sensor.

11. The method for preparing an all-fabric-based pressure sensor according to claim 10, characterized in that, The hot melt adhesive film is a TPU film, and the temperature of the hot pressing process is 80~180℃.

12. The method for preparing the all-fabric-based pressure sensor according to claim 1, characterized in that, The method for preparing the all-fabric-based pressure sensor further includes: An upper interface is provided on the upper electrode layer, and the upper interface is electrically connected to the upper electrode pattern. A lower interface is provided on the lower electrode layer, and the lower interface is electrically connected to the lower electrode pattern. Configure the upper and lower interfaces so that the sensing signals of the all-fabric-based pressure sensor can be transmitted to external devices through the upper and lower interfaces.

13. A full-fabric-based pressure sensor, manufactured using the method for preparing a full-fabric-based pressure sensor as described in any one of claims 1 to 12, characterized in that, The all-fabric-based pressure sensor includes a lower electrode layer, a sensitive layer, and an upper electrode layer stacked from bottom to top; an isolation layer is provided between the lower electrode layer and the sensitive layer, and / or an isolation layer is provided between the upper electrode layer and the sensitive layer; The lower electrode layer includes an insulating textile fabric and a lower electrode pattern formed on the insulating textile fabric, the lower electrode pattern including a plurality of lower sensing electrodes; the upper electrode layer includes an insulating textile fabric and an upper electrode pattern formed on the insulating textile fabric, the upper electrode pattern including a plurality of upper sensing electrodes; the upper sensing electrodes correspond one-to-one with the lower sensing electrodes to form sensing points; the isolation layer includes an insulating textile fabric and a sensing area formed by opening windows in the insulating textile fabric; the sensing area corresponds to the sensing points to realize the transmission of sensing signals.

14. The all-fabric-based pressure sensor according to claim 13, characterized in that, The upper electrode layer is further provided with an upper interface, which is electrically connected to the upper electrode pattern; the lower electrode layer is further provided with a lower interface, which is electrically connected to the lower electrode pattern.

15. The all-fabric-based pressure sensor according to claim 13, characterized in that, A hot melt adhesive film is provided between the lower electrode layer, the sensitive layer, the upper electrode layer and the isolation layer, so that the lower electrode layer, the sensitive layer, the upper electrode layer and the isolation layer are bonded together by melting the hot melt adhesive film through a hot pressing process.

16. A wearable device, characterized in that, Including the all-fabric-based pressure sensor as described in any one of claims 13 to 15.

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