A flexible high-density bite force thin film pressure sensor

Abstract

The utility model discloses a kind of flexible high-density occlusal force film pressure sensor. Upper substrate and lower substrate are composed of occlusal part and coplanar extension part;The outside of occlusal part is coated with medical dye layer;The inside of upper substrate, lower substrate is respectively printed with column function layer, row function layer, column function layer includes column electrode array and several lead and contact, row function layer includes row electrode array and several lead and contact;All contacts are set in extension part, and contact is electrically connected with electrode through lead;The inside of upper substrate is also printed with column induction layer and column insulation layer, and the inside of lower substrate is also printed with row induction layer and row insulation layer, column electrode array and row electrode array are orthogonally arranged in occlusal part, and are covered by column induction layer and row induction layer respectively;The lead of upper substrate and lower substrate is covered by column insulation layer and row insulation layer respectively.The utility model fuses medical dye and film pressure sensing structure, and can obtain occlusal digital data and actual occlusal trace simultaneously.

Description

Technical Field

[0001] This utility model relates to the field of pressure sensors, specifically to a flexible high-density bite force thin film pressure sensor. Background Technology

[0002] With the development of sensor technology, flexible sensors are being used more and more widely in the field of dentistry. They have evolved from pressure-sensitive test strips to flexible high-density matrix sensors, which enable real-time dynamic detection and analysis of the occlusal process. They can accurately acquire dynamic and static data and three-dimensional pressure images of patients' oral occlusion, providing rich data and vivid imaging information for diagnosis.

[0003] Currently, most dental hospitals and clinics in China typically use traditional occlusal papers or digital occlusal analysis systems to assess occlusion. Both testing methods have the following drawbacks:

[0004] 1. Traditional occlusal paper cannot observe changes in occlusal pressure and state throughout the entire occlusal process in real time and dynamically; it cannot test specific occlusal force data and cannot perform quantitative analysis; the data obtained is isolated and cannot be saved for later review and verification.

[0005] 2. Because digital occlusion analysis systems cannot leave occlusion imprints on patients' teeth, the data presentation is not intuitive enough. Summary of the Invention

[0006] This invention provides a method for manufacturing a flexible, high-density, flexible oral occlusal force film pressure sensor, offering a solution for acquiring dynamic information about the oral occlusal process. Due to its unique piezoresistive characteristics, this patent provides a sensor for accurately testing occlusal force. It also provides an ultra-thin, sensitive, and flexible array-type pressure sensor. By raising and lowering the sensor contacts, the size of the contact area is significantly reduced, making the entire back-end testing equipment more portable.

[0007] The technical solution adopted in this utility model is:

[0008] The flexible high-density occlusal force film pressure sensor includes an upper substrate and a lower substrate. The upper and lower substrates are identical in shape, each consisting of an occlusal portion and a coplanar extension. The outer surface of the occlusal portion serves as the occlusal surface of the teeth and is coated with a medical staining agent layer. The inner surfaces of the upper and lower substrates are respectively printed with column functional layers and row functional layers. The column functional layers mainly consist of a column electrode array and several leads and contacts, while the row functional layers mainly consist of a row electrode array and several leads and contacts. All contacts are located in the extension and are electrically connected to the column or row electrodes via leads. The inner surface of the upper substrate is also printed with a column sensing layer and a column insulating layer, and the inner surface of the lower substrate is also printed with a row sensing layer and a row insulating layer. The column electrode array and row electrode array are orthogonally arranged in the occlusal portion and are respectively covered by the column sensing layer and the row sensing layer. The leads of the upper and lower substrates are respectively covered by the column insulating layer and the row insulating layer.

[0009] Both the column electrode array and the row electrode array are printed with conductive silver paste, and both the column sensing layer and the row sensing layer are printed with semiconductor carbon paste. The printed areas of the column electrode array and the row electrode array are horseshoe-shaped, and the column sensing layer and the row sensing layer respectively cover the printed areas of the column electrode array and the row electrode array. The insulating layer covers the remaining areas except for the sensing layer and the contact printing area.

[0010] In the upper substrate, column electrodes are arranged along the front-to-back direction. Two columns of contacts are symmetrically printed in the center of the extension. The axis of symmetry of the two columns of contacts is arranged along the front-to-back direction. The number of contacts is the same as the number of column electrodes and they correspond one-to-one. Each contact is connected to the rear end of the corresponding column electrode through a lead wire. In the lower substrate, row electrodes are arranged along the left-to-right direction. Two columns of contacts are printed on both sides of the inner surface of the extension. The total number of contacts is the same as the total number of rows of row electrodes. For two row electrodes located on the two wings of the horseshoe-shaped printing area but in the same row, the opposite ends of the two row electrodes are connected by a lead wire. The other end of one row electrode is connected to the corresponding contact through a lead wire.

[0011] In the lower substrate, for adjacent row electrodes, the contact connection ends are arranged alternately on the left and right.

[0012] The upper and lower substrates are polyethylene terephthalate substrates, polyimide substrates, or polyethylene naphthalate substrates.

[0013] An encapsulation adhesive layer is provided between the two insulating layers, and the upper and lower substrates are fixedly connected by the encapsulation adhesive layer.

[0014] The beneficial effects of this utility model are as follows:

[0015] 1. The flexible high-density bite force sensor in this utility model, when used with a data acquisition device, can generate real-time dynamic bite force images and data;

[0016] 2. The flexible high-density bite force sensor in this utility model not only presents the pressure distribution profile but also obtains an accurate pressure value.

[0017] 3. The flexible high-density biting force sensor in this utility model can be manufactured by combining screen printing, achieving low-cost, pollution-free, and environmentally friendly additive manufacturing; and by patterning the arrangement of leads and contacts, the final thickness of the sensor can reach 60~100um.

[0018] 4. The flexible high-density bite force sensor in this utility model optimizes the interface from the original large, circular contact points (φ5mm) staggered arrangement to a small, strip-shaped arrangement by applying high-resolution screen printing technology, thereby miniaturizing the sensor and making the back-end data acquisition equipment portable. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the flexible high-density biting force thin film pressure sensor of this utility model;

[0020] Figure 2 This is a schematic diagram illustrating the working principle of the thin-film pressure sensor of this utility model.

[0021] In the figure: 1. Upper surface medical dye layer, 2. Upper substrate, 3. Column sensing layer, 4. Column functional layer, 5. Column insulating layer, 6. Encapsulation adhesive layer, 7. Row insulating layer, 8. Row functional layer, 9. Row sensing layer, 10. Lower substrate, 11. Lower surface medical dye layer. Detailed Implementation

[0022] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] The structure of the thin-film pressure sensor in this invention is as follows: Figure 1 As shown.

[0024] It includes an upper base 2 and a lower base 10. The upper base 2 and the lower base 10 have the same shape, both consisting of an occlusal portion and a coplanar extension. The outer surfaces of the occlusal portions of the upper base 2 and the lower base 10 serve as the occlusal surfaces of the teeth, and are coated with medical staining agent layers to form an upper surface medical staining agent layer 1 and a lower surface medical staining agent layer 11.

[0025] The lower surface of the upper substrate 2 is sequentially printed with a column sensing layer 3, a column functional layer 4, and a column insulating layer 5. The upper surface of the lower substrate 10 is sequentially printed with a row sensing layer 9, a row functional layer 8, and a row insulating layer 7.

[0026] Specifically, the inner surface of the upper substrate 2 and the inner surface of the lower substrate 10 are respectively printed with column functional layer 4 and row functional layer 8. The column functional layer 4 is mainly composed of column electrode array and several leads and contacts. The row functional layer 8 is mainly composed of row electrode array and several leads and contacts. All contacts are located in the extension and are electrically connected to the column electrode or row electrode through the leads.

[0027] Specifically, the inner surface of the upper substrate 2 is also printed with a column sensing layer 3 and a column insulating layer 5, and the inner surface of the lower substrate 10 is also printed with a row sensing layer 9 and a row insulating layer 7. The column electrode array and the row electrode array are orthogonally arranged in the interlocking part and are respectively covered by the column sensing layer 3 and the row sensing layer 9, so that after the upper substrate 2 and the lower substrate 10 are bonded together, the intersection of each column electrode and the row electrode constitutes a sensing unit; the leads of the upper substrate 2 and the lower substrate 10 are respectively covered by the column insulating layer 5 and the row insulating layer 7.

[0028] Specifically, both the column electrode array and the row electrode array are printed with conductive silver paste, and both the column sensing layer 3 and the row sensing layer 9 are printed with semiconductor carbon paste. The printing areas of the column electrode array and the row electrode array are horseshoe-shaped, and the column sensing layer 3 and the row sensing layer 9 cover the printing areas of the column electrode array and the row electrode array, respectively. The insulating layer covers the remaining areas except for the sensing layer and the contact printing area.

[0029] Among them, conductive silver paste has advantages over other electrode ink materials, such as excellent conductivity and good adhesion to the substrate.

[0030] In practice, semiconductor carbon paste is typically prepared by grinding polymer resin binders (epoxy resin, polyester, polyacrylic resin, etc.), a small amount of graphene (natural graphite exfoliated graphene, chemical vapor deposition graphene, etc.), a small amount of carbon nanotubes (carboxylated carbon nanotubes, aminated carbon nanotubes, etc.), and conductive carbon black (surface-modified carbon black). This type of semiconductor functional ink possesses characteristics such as good mechanical strength and strong adhesion.

[0031] Specifically, in the upper substrate 2, column electrodes are arranged along the front-to-back direction, and two columns of contacts are symmetrically printed in the center of the extension. The axis of symmetry of the two columns of contacts is arranged along the front-to-back direction. The number of contacts is the same as the number of column electrodes and they correspond one-to-one. Each contact is connected to the rear end of the corresponding column electrode through a lead wire. In the lower substrate 10, row electrodes are arranged along the left-to-right direction, and two columns of contacts are printed on both sides of the inner surface of the extension. The total number of the two columns of contacts is the same as the total number of rows of row electrodes. For two row electrodes that are located on the two wings of the horseshoe-shaped printing area but are located in the same row, the opposite ends of the two row electrodes are connected by a lead wire, and the other end of one row electrode is connected to the corresponding contact through a lead wire.

[0032] Preferably, in the lower substrate 10, for row electrodes of adjacent rows, the contact connection ends are arranged alternately on the left and right.

[0033] Optionally, the upper substrate 2 and the lower substrate 10 are polyethylene terephthalate substrates, polyimide substrates, or polyethylene naphthalate substrates.

[0034] Preferably, the insulating layer is made of silica sol.

[0035] Specifically, an encapsulation adhesive layer 6 is provided between the two insulating layers, and the upper and lower substrates 10 are fixedly connected by the encapsulation adhesive layer 6.

[0036] Preferably, the encapsulation adhesive layer 6 is an encapsulation adhesive, which is an acrylic self-adhesive or a hot melt adhesive bonded by low-temperature hot pressing.

[0037] In one embodiment of this utility model, a fabrication process for a flexible high-density bite force thin-film pressure sensor is provided. In this embodiment, the fabrication process involves screen printing followed by high-temperature curing. Figure 1 As shown, the sensor is divided into rows and columns. All components are supported by a substrate, and other components are printed onto it using a screen printing process. The entire sensor includes:

[0038] 1) Apply a medical staining agent coating to the outer side of the substrate;

[0039] 2) The electrode material for the row and column functional layers 4 is conductive silver paste;

[0040] 3) The row and column sensing layers 3 are formed by printing and drying semiconductor carbon paste;

[0041] 4) The insulating layer is made of silica sol;

[0042] 5) The encapsulation adhesive layer 6 uses encapsulation adhesive.

[0043] The production process includes the following steps:

[0044] First, conductive silver paste is screen-printed onto the upper substrate 2 and the lower substrate 10 according to a pre-drawn array pattern to form the column functional layer 4 and the row functional layer 8.

[0045] Next, carbon paste is printed onto column functional layer 4 and row functional layer 8 according to the pre-drawn edge shape. After drying, column sensing layer 3 and row sensing layer 9 are formed.

[0046] Subsequently, silica sol is applied onto column functional layer 4 and row functional layer 8 according to the pre-drawn edge shape to form column insulating layer 5 and row insulating layer 7.

[0047] Subsequently, encapsulating adhesive is applied to the column insulating layer 5 and the row insulating layer 7, and the upper substrate 2 and the lower substrate 10 are aligned and bonded together for encapsulation.

[0048] Finally, a surface medical staining agent is applied to the outer surface of the occlusal portion of the upper base 2 and the lower base 10, and then dried to produce the final flexible sensor.

[0049] The working principle of this novel thin-film pressure sensor is as follows: Figure 2 As shown, the upper and lower substrates 10 of the thin-film pressure sensor electrode array structure are respectively provided with rows and columns of orthogonal electrodes. Each intersection point is a sensing unit. When the sensing point receives pressure, the electrode transmits the resistance change information of the sensing point in real time through the contact connected to itself, so as to detect the pressure information of the sensing point.

[0050] In summary, this invention employs both a medical staining agent similar to traditional occlusal paper and a thin-film sensor mechanism based on flexible circuits, integrating the two into a single sensor. While acquiring digital data on occlusion, it also leaves actual occlusal traces on the patient's teeth, providing more accurate and user-friendly data for subsequent occlusal relationship restoration.

[0051] The above specific embodiments are used to explain and illustrate the present utility model, and are not intended to limit the present utility model. Any modifications and changes made to the present utility model within the spirit and scope of the claims shall fall within the protection scope of the present utility model.

[0052] The above description is only a preferred embodiment of the present utility model. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present utility model patent application are included in the scope of the present utility model patent application.

Claims

1. A flexible high-density bite force thin film pressure sensor, comprising an upper substrate (2) and a lower substrate (10), characterized in that: The upper base (2) and lower base (10) have the same shape, both consisting of an occlusal portion and a coplanar extension portion; the outer surface of the occlusal portion serves as the occlusal surface of the teeth and is coated with a medical staining agent layer; the inner surfaces of the upper base (2) and lower base (10) are respectively printed with a column functional layer (4) and a row functional layer (8), the column functional layer (4) mainly consists of a column electrode array and several leads and contacts, and the row functional layer (8) mainly consists of a row electrode array and several leads and contacts; all contacts are provided with The contacts are placed in the extension section and are electrically connected to the column electrode or the row electrode via leads; the inner surface of the upper substrate (2) is also printed with a column sensing layer (3) and a column insulating layer (5), and the inner surface of the lower substrate (10) is also printed with a row sensing layer (9) and a row insulating layer (7). The column electrode array and the row electrode array are orthogonally arranged in the interlocking section and are respectively covered by the column sensing layer (3) and the row sensing layer (9); the leads of the upper substrate (2) and the lower substrate (10) are respectively covered by the column insulating layer (5) and the row insulating layer (7).

2. The flexible high-density biting force thin film pressure sensor according to claim 1, characterized in that: The column electrode array and row electrode array are both printed with conductive silver paste, and the column sensing layer (3) and row sensing layer (9) are both printed with semiconductor carbon paste. The printing areas of the column electrode array and row electrode array are horseshoe-shaped, and the column sensing layer (3) and row sensing layer (9) respectively cover the printing areas of the column electrode array and row electrode array. The insulating layer covers the remaining positions except for the sensing layer and the contact printing area.

3. The flexible high-density bite force thin film pressure sensor according to claim 2, characterized in that: In the upper substrate (2), column electrodes are arranged along the front-back direction, and two columns of contacts are symmetrically printed in the center of the extension. The axis of symmetry of the two columns of contacts is arranged along the front-back direction. The number of contacts is the same as the number of column electrodes and they correspond one-to-one. Each contact is connected to the rear end of the corresponding column electrode through a lead wire. In the lower substrate (10), row electrodes are arranged along the left-right direction. Two columns of contacts are printed on both sides of the inner surface of the extension. The total number of contacts is the same as the total number of rows of row electrodes. For two row electrodes that are located on the two wings of the horseshoe-shaped printing area but are located in the same row, the opposite ends of the two row electrodes are connected by a lead wire, and the other end of one row electrode is connected to the corresponding contact through a lead wire.

4. The flexible high-density bite force thin film pressure sensor according to claim 1, characterized in that: In the lower substrate (10), for row electrodes of adjacent rows, the contact connection ends are arranged alternately on the left and right.

5. The flexible high-density bite force thin film pressure sensor according to claim 1, characterized in that: The upper substrate (2) and the lower substrate (10) are polyethylene terephthalate substrates, polyimide substrates, or polyethylene naphthalate substrates.

6. The flexible high-density biting force thin film pressure sensor according to claim 1, characterized in that: An encapsulation adhesive layer (6) is provided between the two insulating layers, and the upper substrate (2) and the lower substrate (10) are fixedly connected by the encapsulation adhesive layer (6).

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