Flexible pressure sensor and electric device

Abstract

The application discloses a flexible pressure sensor and an electric device. The flexible pressure sensor comprises a first electrode layer and a second electrode layer. The first electrode layer comprises a first base layer and a plurality of first electrode lines arranged at the first base layer in a first direction. The second electrode layer comprises a second base layer and a plurality of second electrode lines arranged at the second base layer in a second direction. The plurality of first electrode lines and the plurality of second electrode lines are electrically connected through a plurality of cross-sensing parts. The resistance of the cross-sensing part can change with the change of force. The first electrode layer and the second electrode layer are provided with a buffer port corresponding to a variable part. When at least a part of the variable part expands or moves towards the body of a passenger through the buffer port, the buffer port expands to form a through space. The flexible pressure sensor has the advantages of accurate measurement and control, stable function, reliable mass production and application, etc.

Description

Technical Field

[0001] This application relates to the field of pressure sensor technology, and more particularly to a flexible pressure sensor and an electric device. Background Technology

[0002] As an emerging electronic device, flexible pressure sensors have gradually demonstrated enormous application potential in fields such as smart cockpits, smart healthcare, smart homes, robotics, and power tools. However, as flexible pressure sensors are applied to a wider range of electrical devices, the implementation environment and conditions for them are becoming increasingly diverse and complex, which has a certain impact on and challenges to the functional stability and reliability of the flexible pressure sensors themselves. Utility Model Content

[0003] This application discloses a flexible pressure sensor and an electric device. The flexible pressure sensor has the advantages of accurate measurement and control, stable function, and reliable mass production application.

[0004] In a first aspect, this application provides a flexible pressure sensor applied to an electric device, the electric device having a variable element corresponding to the user's contact surface, including: The first electrode layer includes a first substrate layer and a plurality of first electrode lines. The first substrate layer includes a flexible material, and the plurality of first electrode lines are arranged at intervals along a first direction in the first substrate layer. The second electrode layer includes a second substrate layer and multiple second electrode lines. The second substrate layer is made of a flexible material. The multiple second electrode lines are arranged at intervals along a second direction in the second substrate layer. The first direction and the second direction are arranged at an angle. Multiple cross-induction portions are formed between the multiple first electrode lines and the multiple second electrode lines. The multiple first electrode lines and the multiple second electrode lines are electrically connected through the multiple cross-induction portions. The resistance value of the cross-induction portions can change with the change of force. Among them, the first electrode layer and the second electrode layer are provided with buffer openings corresponding to the moving parts, so that when at least a part of the moving parts expands or moves toward the body of the occupant through the buffer openings, the buffer openings expand to form a penetration space.

[0005] In some embodiments, the buffer opening includes a first opening and a second opening, which are arranged in an intersecting manner.

[0006] In some embodiments, the buffer opening further includes a third opening, which is intersected with the first opening and the second opening.

[0007] In some embodiments, the projection of the variable member onto the contact surface is square or near square, with a first opening along one diagonal of the square or near square and a second opening along the other diagonal of the square or near square.

[0008] In some embodiments, the first electrode layer and the second electrode layer extend axially toward the buffer opening to form a fitting flap, the fitting flap including a first side and a second side, at least a portion of the first opening being disposed corresponding to the first side, and at least a portion of the second opening being disposed corresponding to the second side.

[0009] In some embodiments, the fitting flap includes a first flap and a second flap, with at least a portion of a first opening formed between the first flap and the second flap.

[0010] In some embodiments, the fitting flap further includes a third flap and a fourth flap, with at least a portion of a first opening formed between the third flap and the fourth flap; wherein at least a portion of a second opening is formed between the third flap and the second flap; or, at least a portion of a second opening is formed between the fourth flap and the first flap.

[0011] In some embodiments, a plurality of first electrode lines are embroidered at intervals along a first direction on the first electrode layer of the bonding flap, and a plurality of second electrode lines are embroidered on the second electrode layer of the bonding flap; the bonding flap further includes a resistive layer disposed between the first electrode layer and the second electrode layer, such that the first electrode lines on the bonding flap and the second electrode lines on the bonding flap are electrically connected through the resistive layer to form a plurality of cross-sensing portions.

[0012] In some embodiments, reinforcing stitches are embroidered on the fitting flap, at least a portion of which passes through the first electrode layer and the second electrode layer; wherein, the reinforcing stitches are disposed in the region between the first side and any portion of the first electrode line on the fitting flap; or, the reinforcing stitches are disposed in the region between the first side and any portion of the second electrode line on the fitting flap; or, the reinforcing stitches are disposed in the region between the second side and any portion of the first electrode line on the fitting flap; or, the reinforcing stitches are disposed in the region between the second side and any portion of the second electrode line on the fitting flap.

[0013] In some embodiments, the variable element includes at least one of an airbag, rollers, massage head, support, and heating head.

[0014] In some embodiments, at least a portion of a plurality of cross-sensing portions are formed on the periphery of the buffer opening; or, the buffer opening includes two opposing sides, with at least a portion of the plurality of cross-sensing portions disposed on one side of the buffer opening and at least a portion of the plurality of cross-sensing portions disposed on the other side of the buffer opening.

[0015] Secondly, this application provides an electric device, which includes at least one of a massage chair, a car seat, a massage bed, and a massager, and the electric device includes a flexible pressure sensor as described in any embodiment of this application.

[0016] The aforementioned flexible pressure sensor and electric device, in a first aspect, through the overlapping and crossing arrangement of the first and second electrode lines, allows for the continuous replication of multiple cross-sensing parts by setting multiple first and second electrode lines from different directions within the flexible pressure sensor, thereby enabling the formation of a large-area, high-density sensing and control point array using a reliable and simple mass production process. Furthermore, combined with the flexible characteristics of the substrate layer, this flexible pressure sensor can reliably and stably measure the force distribution at flexible interfaces of skin, soft tissue, electric devices, and smart beds through this array; in a second aspect, through the first… The buffer openings provided on the electrode layer and the second electrode layer, and the positions of the buffer openings around the cross-sensing array, allow for the rapid formation of a penetration space corresponding to the moving or expanding component. This enables at least a portion of the moving component to penetrate the user's contact surface, thereby providing stress buffering and other protective functions for the cross-sensing array, the first electrode layer, and the second electrode layer. This prevents deformation, displacement, torsion failure, and breakage failure of the first electrode layer, the second electrode layer, and the cross-sensing array of the flexible pressure sensor, thereby improving the measurement and control accuracy, functional stability, and mass production reliability of the flexible pressure sensor.

[0017] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of a flexible pressure sensor and an electric device according to an embodiment of this application; Figure 2 This is a schematic diagram of the structure of an electric device provided in one embodiment of this application; Figure 3 yes Figure 1 The diagram shows the structural schematic of the stress buffer structure. Figure 4 yes Figure 1 The diagram shows the first working condition of the stress buffer structure. Figure 5 yes Figure 1 The diagram shows the second working condition of the stress buffer structure. Figure 6 This is a schematic diagram of a stress buffer structure provided in one embodiment of this application; Figure 7 This is a schematic diagram of a stress buffer structure provided in one embodiment of this application; Figure 8 This is an exploded structural diagram of a flexible pressure sensor provided in one embodiment of this application; Figure 9 This is an exploded structural diagram of a flexible pressure sensor provided in one embodiment of this application; Figure 10 This is an exploded structural diagram of a flexible pressure sensor provided in one embodiment of this application; Figure 11 This is a schematic diagram of the structure of a first electrode layer provided in an embodiment of this application; Figure 12 This is a cross-sectional view of a first electrode layer provided in an embodiment of this application; Figure 13 This is a schematic diagram of the structure of a first electrode layer provided in an embodiment of this application; Figure 14 This is a schematic diagram of the structure of a second electrode layer provided in an embodiment of this application; Figure 15 This is a partial structural schematic diagram of a first electrode layer provided in an embodiment of this application; Figure 16 This is a partial structural schematic diagram of a first electrode layer provided in an embodiment of this application; Figure 17 This is a partial structural schematic diagram of a first electrode layer provided in an embodiment of this application; Figure 18 This is a schematic block diagram of the structure of an electric device provided in one embodiment of this application.

[0020] Figure label: A. Stress buffer structure; B. Sensing area; X, first direction; Y, second direction; 100. Flexible pressure sensor; 200. Electrical device; 210. Variable component; 201. Airbag; 202. Massage head; 220. Foam; 230. Contact surface; 10. First electrode layer; 11. First substrate layer; 12. First electrode wire; 131. First penetration point; 132. Second penetration point; 141. First segment; 142. Second segment; 20. Second electrode layer; 21. Second substrate layer; 22. Second electrode wire; 231. Third penetration point; 232. Fourth penetration point; 241. Third segment; 242. Fourth segment; 25. Cross-induction section; 30. Buffer opening; 31. Through-hole; 321. First opening; 322. Second opening; 323. Third opening; 33. Adhesive flap; 331. First side; 332. Second side; 341. First flap; 342. Second flap; 343. Third flap; 344. Fourth flap; 35. Resistive layer; 36. Reinforcing suture; 40. Insulating layer; 41. Penetrating space; 42. Hot melt adhesive; 50. Fixed line; 51. First line; 52. Second line.

[0021] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Detailed Implementation

[0022] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0023] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the order described. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0024] It should be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0025] It should be understood that, in order to clearly describe the technical solutions of the embodiments of this application, the terms "first" and "second" are used in the embodiments of this application to distinguish identical or similar items with substantially the same function and effect. For example, "first data" and "second data" are only used to distinguish different data and do not limit their order. Those skilled in the art will understand that the terms "first" and "second" do not limit the quantity or execution order, and the terms "first" and "second" are not necessarily different.

[0026] It should also be further understood that the term "or" as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0027] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0028] The inventors discovered that with the continuous improvement of flexible pressure sensors, users and manufacturers have shown great interest in applying them to electric devices such as smart massage chairs to achieve accurate and reliable pressure distribution measurement. However, because flexible pressure sensors used in massage chairs generally need to be integrated with structures such as heating heads, massage rollers, and massage airbags, especially when dealing with structures that provide massage and support airbags, flexible pressure sensors often struggle to simultaneously achieve good stress buffering performance and stable pressure detection accuracy. Under prolonged use and complex stress environments, problems such as large fluctuations in detection data, circuit damage and failure, and damage and tearing of the substrate layer can easily occur, affecting the overall user experience, massage effect, and long-term reliability of the smart massage chair. Furthermore, simply creating openings to accommodate the movement of the adjustable components can prevent pressure measurement at those locations. Since massage adjustable components are often concentrated in core areas such as the waist, shoulders, back, and hips, these are precisely the measurement locations crucial for smart seats to measure occupant pressure distribution and determine occupant posture. Blindly leaving openings can lead to these areas losing their pressure measurement capability over a long period, reducing the overall performance of the smart seat and creating a technological bottleneck where stability, reliability, measurement accuracy, and the comfort of electric devices are mutually constrained. Therefore, developing a stress-buffering structure that effectively solves these problems is of significant practical importance.

[0029] To address the aforementioned problems, this application proposes a flexible pressure sensor applicable to electric devices, which have a variable element disposed on the user's contact surface. It should be understood that the electric device may include at least one of a massage chair, car seat, massage bed, or massager. By distributing the flexible pressure sensor on the user's contact surface, the force distribution on the contact surface when the user contacts the device can be measured. Based on the force distribution, the user's body posture characteristics and pressure concentration areas can be measured, thereby enabling functions such as gear adjustment, strategy optimization, angle control, comfort detection, zero-gravity function, and fatigue detection. It should be further understood that the user's contact surface includes the surface in contact with the user, as well as a surface preset by the user for contacting a target object, such as the contact surface of a robot's dexterous hand for contacting a preset item.

[0030] Please see Figure 1 and Figure 2 , Figure 1 This is a schematic diagram of the structure of a flexible pressure sensor according to an embodiment of this application. Figure 2This is a schematic diagram of the structure of an electric device according to an embodiment of this application. The electric device 200 can be a backrest of a car seat. The electric device 200 can be provided with a variable element 210 on the user contact surface 230. The contact surface 230 can be a occupant support surface. The variable element 210 can include at least one of an airbag 201, rollers, a massage head 202, a support bracket, and a heating head.

[0031] Please see Figure 3 , Figure 4 and Figure 5 The flexible pressure sensor 100 can be disposed on the occupant support surface of the electric device 200, and a buffer opening 30 is provided corresponding to the variable member 210. The buffer opening 30 expands to form a passage space 31 when at least a portion of the variable member 210 expands or moves towards the user through the buffer opening 30, or the buffer opening 30 shrinks to reduce the passage space 31 when at least a portion of the variable member 210 contracts or moves away from the user through the buffer opening 30. For example, the car seat can form a placement position for the variable member 210 using foam 220, with the variable member 210 disposed within the placement position and corresponding to the buffer opening 30, so that the buffer opening 30 expands to form a passage space 31 when at least a portion of the variable member 210 expands or moves towards the user through the buffer opening 30.

[0032] It should be understood that the penetration space 31 formed by the buffer opening 30 when the variable member 210 does not expand or move towards the user is less than or equal to the penetration space 31 formed when the variable member 210 expands or moves towards the user. For example, the buffer opening 30 may not form a penetration space 31 when the variable member 210 does not expand or move towards the user. Or, the buffer opening 30 may be merely a crack when the variable member 210 does not expand or move towards the user, forming only a small, gap-like penetration space 31.

[0033] It should be further understood that, in addition to massage, the electric device 200 often has other functions that require force distribution detection. The buffer port 30 of the flexible pressure sensor 100, by reducing the penetration space 31 when the variable element 210 does not expand or move towards the user, can effectively retain the pressure distribution measurement area of ​​the electric device 200 on the contact surface 230 when not in a scenario that enables the variable element 210, such as massage. This ensures that other functions of the electric device 200, such as posture detection, zero-gravity seat, fatigue detection, and safety detection, can be performed normally, accurately, safely, stably, and reliably.

[0034] In some embodiments, the electric device 200 may have a plurality of agitators 210 on the contact surface 230, and the flexible pressure sensor 100 may form a plurality of buffer openings 30 corresponding to the plurality of agitators 210. It should be understood that the electric device 200 may have a plurality of agitators 210 corresponding to at least one of the waist, shoulder, arm, hip, and back, and correspondingly, a plurality of buffer openings 30 may be provided corresponding to the plurality of agitators 210. Depending on the morphological, dimensional, positional, and layout relationships between the buffer openings 30 and the agitators 210, one buffer opening 30 may correspond to a plurality of agitators 210, or one agitator 210 may correspond to a plurality of buffer openings 30, or one buffer opening 30 may correspond to one agitator 210.

[0035] In some embodiments, please refer to Figure 8 , Figure 9 and Figure 10 The flexible pressure sensor 100 may include a first electrode layer 10 and a second electrode layer 20. The first electrode layer 10 includes a first substrate layer 11 and multiple first electrode lines 12. The first substrate layer 11 is made of a flexible material, and the multiple first electrode lines 12 are arranged at intervals along a first direction on the first substrate layer 11. The second electrode layer 20 includes a second substrate layer 21 and multiple second electrode lines 22. The second substrate layer 21 is made of a flexible material, and the multiple second electrode lines 22 are arranged at intervals along a second direction on the second substrate layer 21. The first direction and the second direction are arranged at an angle. Multiple cross-sensing portions 25 are formed between the multiple first electrode lines 12 and the multiple second electrode lines 22. The multiple first electrode lines 12 and the multiple second electrode lines 22 are electrically connected through the multiple cross-sensing portions 25, and the resistance value of the cross-sensing portions 25 can change with the force applied. This configuration allows the sensor to detect pressure by the resistance change of the cross-sensing portions 25, and due to the flexible material of the electrode layers, the sensor can adapt to contact surfaces 230 of different shapes and sizes. It should be understood that by overlapping and intersecting the first electrode line 12 and the second electrode line 22, multiple intersecting sensing parts 25 can be continuously replicated in the flexible pressure sensor 100 by setting multiple first electrode lines 12 and multiple second electrode lines 22 from different directions, thereby enabling the formation of a large-area, high-density array of sensing and control points using a reliable and simple mass production process. Furthermore, combined with the flexible characteristics of the substrate layer, the flexible pressure sensor 100 can reliably and stably measure the force distribution of the skin, soft tissue, electric device 200, and flexible interface of the smart bed through this array.

[0036] Typically, but not limitingly, the absolute value of the angle between the first and second directions can be 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, 85°, 90°, or a range of any two values.

[0037] In some embodiments, the flexible pressure sensor 100 may include a resistive layer 35, the resistance value of which may change with the force applied. The resistive layer 35 may be disposed between the first electrode layer 10 and the second electrode layer 20. The first electrode line 12 and the second electrode line 22 may be electrically connected through the resistive layer 35 to form a plurality of cross sensing portions 25.

[0038] In other embodiments, at least one of the first electrode line 12 and the second electrode line 22 can be a force-sensitive electrode. This force-sensitive electrode may include a conductor and a conductive layer applied to the conductor. The resistance of the conductor can change with the applied force. The other electrode line can be directly connected to the conductor, electrically connected to the first electrode line 12, and form multiple cross-sensing portions 25. Specifically, the conductor can be linear, and the conductive layer is applied to the conductor by extrusion. This configuration eliminates the need for a resistive layer 35 between the first electrode layer 10 and the second electrode layer 20, simplifying the process and structure.

[0039] In some embodiments, buffer openings 30 are provided on the first electrode layer 10 and the second electrode layer 20 corresponding to the moving member 210. When at least a portion of the moving member 210 expands or moves toward the user through the buffer openings 30, the buffer openings 30 expand to form a penetration space 31. It should be understood that the buffer openings 30 provided on the first electrode layer 10 and the second electrode layer 20, combined with the position of the buffer openings 30 on the periphery of the cross sensing part 25 array, allow the penetration space 31 to be quickly formed corresponding to the moving member 210 when it moves or expands. This enables at least a portion of the moving member 210 to penetrate the user's contact surface 230, thereby providing stress buffering and other protective functions for the cross sensing part 25 array, the first electrode layer 10, and the second electrode layer 20. This prevents the first electrode layer 10, the second electrode layer 20, and the cross sensing part 25 array of the flexible pressure sensor 100 from deforming, shifting, twisting, or breaking, thereby improving the measurement and control accuracy, functional stability, and mass production application reliability of the flexible pressure sensor 100. It should be further understood that when a resistor layer 35 is provided between the first electrode layer 10 and the second electrode layer 20, the resistor layer 35 may also be provided with a buffer port 30 corresponding to the variable element 210.

[0040] Specifically, at least a portion of a plurality of cross-sensing portions 25 can be formed around the periphery of the buffer port 30. Alternatively, the buffer port 30 can include two opposing sides, with at least a portion of the plurality of cross-sensing portions 25 disposed on one side of the buffer port 30 and at least a portion of the plurality of cross-sensing portions 25 disposed on the other side of the buffer port 30. This arrangement provides a richer data source for the sensor's signal processing. By analyzing the resistance changes of the cross-sensing portions 25 on both sides, the direction, magnitude, and distribution of the force on the variable element 210 can be determined more accurately. For example, when the resistance change of the cross-sensing portion 25 on one side is significantly greater than that on the other side, it can be determined that the force on the variable element 210 is mainly concentrated on that side, thereby providing more accurate information for subsequent signal processing and equipment control.

[0041] It should be further understood that by providing buffer ports 30 on the first electrode layer 10 and the second electrode layer 20, and combining the cross sensing portions 25 on both sides of the buffer ports 30, the flexible pressure sensor 100 can not only effectively buffer the stress brought by the moving parts 210 and protect the key components of the sensor, but also provide more accurate pressure monitoring data, thereby significantly improving the sensor's measurement and control accuracy, functional stability and reliability for mass production applications.

[0042] In some embodiments, to further optimize sensor performance, the first electrode line 12 and the second electrode line 22 can be made of materials with good conductivity, such as at least one of stainless steel, silver nanowires, conductive polymer fibers, tin-plated copper, and carbon fibers, wherein the carbon fibers may include graphene fibers or carbon nanotube fibers. These materials not only have excellent conductivity but also maintain the flexibility of the electrode lines, thereby ensuring that the sensor can function normally under pressure. Furthermore, by adjusting the spacing and arrangement density of the electrode lines, the sensitivity and resolution of the sensor can be adjusted to meet the needs of different application scenarios.

[0043] In some embodiments, the flexible pressure sensor 100 can be connected to the control unit of the electric device 200. When the sensor detects a pressure change, the resistance value of the cross-sensing portion 25 changes accordingly. These changes can be converted into electrical signals by a signal processing circuit and transmitted to the control unit. The control unit can analyze and process these signals according to a preset algorithm, thereby achieving intelligent control of the electric device 200. For example, in a massage chair, when the sensor detects uneven pressure distribution on the user's lower back, the control unit can automatically adjust the massage intensity or massage position to provide a more comfortable massage experience.

[0044] In some embodiments, please refer to Figures 3 to 5The performance of the buffer port 30 can be further improved by optimizing its design. The buffer port 30 can be adjusted according to the shape and position of the variable element 210 to ensure good contact and pressure transmission between the sensor and the variable element 210. For example, the buffer port 30 or the through space 31 formed by its expansion can be designed to match the shape of the variable element 210, such as circular, elliptical, or rectangular, to adapt to the pressure distribution requirements of different parts. At the same time, the size and layout of the buffer port 30 can also be adjusted according to the actual application to ensure that the sensor can maintain stable performance under different pressures.

[0045] In some embodiments, please refer to Figure 3 , Figure 5 , Figure 6 and Figure 7 The buffer port 30 may include a first opening 321 and a second opening 322, which are arranged at an angle. Specifically, the first opening 321 or the second opening 322 may be arc-shaped, strip-shaped, chamfered rectangle, star-shaped, rhomboid, etc. The first opening 321 and the second opening 322 may be arranged in a T-shape, a cross (X-shape), or an L-shape. Through the opening structure of the buffer port 30, the flexible pressure sensor 100 can be provided with multi-directional deformation space to accommodate the expansion or movement of the moving part 210 in different directions. It should be understood that the multi-directional opening design is particularly suitable for situations where the moving part 210 may deform in multiple directions. For example, when a human body moves on a massage device, the waist, shoulders, and other parts may experience multi-directional pressure changes. Through the multi-directional opening design, the flexible pressure sensor 100 can more flexibly disperse and buffer stress when facing complex mechanical environments, thereby further improving the stability and reliability of the sensor.

[0046] Typically, but not limitingly, the absolute value of the angle between the first opening 321 and the second opening 322 can be 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, 85°, 90°, or any range of two values. Specifically, in different scenarios of electric devices such as massage chairs and smart mattresses, different angle settings can be selected according to the pressure distribution characteristics of different parts of the human body. For example, for areas with relatively uniform pressure distribution, such as the waist and back, a larger angle (such as 60° or 75°) can be selected. Conversely, for areas with more complex pressure variations, such as the shoulders and hips, a smaller angle (such as 30° or 45°) can be selected.

[0047] Specifically, when the variable component 210 expands or moves towards the user, the angled structure between the first opening 321 and the second opening 322 can guide the stress to be dispersed in multiple directions. For example, when the first opening 321 and the second opening 322 are arranged in a T-shape or a cross shape, the stress can be effectively dispersed in the vertical and horizontal directions, reducing stress concentration. This structure is particularly suitable for situations where the variable component 210 may deform in multiple directions, such as the multi-directional pressure changes in the waist, shoulders, and other parts of the body when the human body moves on the massage device.

[0048] It should be further understood that the multi-directional opening design also enhances the adaptability of the flexible pressure sensor 100. When the variable element 210 generates pressure changes in different directions, the opening structure of the buffer port 30 can automatically adjust the stress dispersion path according to the direction of the pressure, thereby achieving more efficient stress buffering. This adaptability enables the flexible pressure sensor 100 to maintain stable performance in dynamic environments, accurately detecting pressure distribution even under frequent pressure changes and complex mechanical conditions.

[0049] In some embodiments, the buffer port 30 further includes a third opening 323, which is angled to the first opening 321 and angled to the second opening 322. Specifically, the first opening 321, the second opening 322, and the third opening 323 can be arranged in a triangular star shape. It should be understood that the triangular star-shaped opening layout can guide stress to be dispersed in three main directions, thereby reducing stress concentration. When the variable member 210 expands or moves towards the user, the stress can be effectively dispersed in different directions through the three openings, avoiding deformation, twisting, or breakage of the first electrode layer 10, the second electrode layer 20, or the cross-sensing part 25 due to stress concentration. This multi-directional stress buffering capability is particularly important for coping with dynamic and complex mechanical environments, such as in massage devices, where the waist, shoulders, and other parts of the human body may experience multi-directional pressure changes during massage.

[0050] Furthermore, the triangular opening layout enhances the sensor's sensitivity and accuracy. Because stress is distributed in three directions, the cross-sensing element 25 can perceive pressure changes more evenly, providing more accurate pressure distribution data. This design makes the sensor perform better in high-precision pressure monitoring applications, such as medical rehabilitation equipment or high-precision smart mattresses, enabling more accurate monitoring of the body's pressure distribution and providing more reliable data support for the device's intelligent control.

[0051] In some embodiments, the projection of the variable element 210 onto the contact surface 230 can be square or near-square. A first opening 321 is provided along one diagonal of the square or near-square, and a second opening 322 is provided along the other diagonal of the square or near-square, with the first opening 321 and the second opening 322 intersecting. The square can be rectangular or square, and the near-square can be approximately square, for example, a square with at least one rounded corner, or a parallelogram with one corner angle of 75°-89°. It should be understood that massage seats and car seats sometimes include variable elements 210 such as airbags 201, rollers, massage heads 202, support brackets, and heating heads, whose projections onto the contact surface 230 can be square or near-square. By providing the first opening 321 and the second opening 322 along the diagonals, stress can be effectively dispersed, reducing stress concentration caused by the corner positions of the square or near-square shape. This design helps reduce the risk of mechanical damage such as scratches and cuts caused by contact and relative movement between corner surfaces. Specifically, the diagonally intersecting opening layout can guide stress to be dispersed along the diagonal direction, so that when the variable part 210 expands or moves, the stress can be more evenly distributed in all parts of the buffer opening 30, rather than concentrated at the corner position.

[0052] It should be understood that in applications such as massage chairs and car seats, the moving parts 210, such as airbags 201, rollers, massage heads 202, support brackets, and heating heads, may expand, move, or rotate during operation. These movements may cause stress impacts on the flexible pressure sensor 100, especially at the corners of the moving parts 210, where abrupt changes in geometry can easily create stress concentration areas. Stress concentration can lead to fatigue damage to the sensor material, thereby affecting the sensor's performance and lifespan.

[0053] By placing the first opening 321 and the second opening 322 diagonally, the shape and layout of the buffer opening 30 can better adapt to the expansion or movement path of the variable component 210. This design not only effectively disperses stress but also provides sufficient deformation space for the variable component 210, reducing direct contact and friction between the variable component 210 and the sensor. For example, when the airbag 201 inflates, the diagonally intersecting openings allow the inflation force of the airbag 201 to be evenly distributed along the diagonal direction, preventing the corners of the airbag 201 from directly pressing on the sensor, thereby reducing local stress on the sensor. Furthermore, this diagonally intersecting opening design can also improve the reliability and durability of the sensor. During long-term use, the repeated movements of the variable component 210 may cause cumulative mechanical damage to the sensor. By optimizing the design of the buffer opening 30, the risk of such damage can be significantly reduced, thereby extending the sensor's lifespan and ensuring stable performance in various application scenarios.

[0054] In some embodiments, the first electrode layer 10 and the second electrode layer 20 extend axially toward the buffer opening 30 to form a fitting flap 33. The fitting flap 33 includes a first side 331 and a second side 332. At least a portion of the first opening 321 is provided corresponding to the first side 331, and at least a portion of the second opening 322 is provided corresponding to the second side 332. It should be understood that, through the design of the fitting flap 33, the pressure distribution of the user on the moving member 210 can be measured when at least a portion of the moving member 210 passes through the contact surface 230. In particular, by utilizing the structural advantages of the fitting flap 33, the flexible pressure sensor 100 can more accurately capture multi-directional pressure changes when the moving member 210 expands or moves, rather than just the pressure perpendicular to the contact surface 230. Combined with the aforementioned design of the buffer opening 30, the fitting flap 33 not only enhances the expansion capability and stress dispersion capability of the buffer opening 30 with a reliable structure and retaining existing materials, saving costs and improving reliability, but also improves the sensor's sensing accuracy for complex pressure distributions, further optimizing the performance of the flexible pressure sensor 100 in complex dynamic curved surface applications.

[0055] In some embodiments, the fitting flap 33 may include a first flap 341 and a second flap 342, with at least a portion of a first opening 321 formed between the first flap 341 and the second flap 342. Specifically, when the first opening 321 and the second opening 322 are arranged in a cross shape, a portion of the first opening 321 is formed between the first flap 341 and the second flap 342. When the first opening 321 and the second opening 322 are arranged in a T-shape, the first opening 321 is formed between the first flap 341 and the second flap 342. With this design, the structure of the fitting flap 33 can closely match the opening layout of the buffer port 30 and the triangular, trapezoidal, or other shapes of the variable member 210, further optimizing the stress dispersion and pressure monitoring capabilities of the flexible pressure sensor 100. When the first opening 321 and the second opening 322 are arranged in a cross shape or an L-shape, the opening design between the first flap 341 and the second flap 342 can effectively guide the stress to be dispersed in different directions, while providing sufficient space for the expansion or movement of the variable member 210. This not only reduces stress concentration but also enhances the sensor's ability to detect pressure changes in multiple directions. In particular, when the expansion direction of the variable component 210 is inconsistent with the normal of the contact surface 230, it can more accurately measure the pressure distribution in the non-directional direction.

[0056] For example, multiple first electrode lines 12 are embroidered at intervals along a first direction on the first electrode layer 10 of the bonding petal 33, and multiple second electrode lines 22 are embroidered on the second electrode layer 20 of the bonding petal 33. By setting the electrode lines on the bonding petal 33, not only are multiple cross-sensing parts 25 formed, but the characteristics of the petal structure are also utilized to facilitate and strengthen the wiring connection between the multiple cross-sensing parts 25 on the petal and other circuit patterns and control boards in the flexible pressure sensor 100.

[0057] In some embodiments, the bonding flap 33 further includes a resistive layer 35, which is disposed between the first electrode layer 10 and the second electrode layer 20, and the first electrode line 12 on the bonding flap 33 and the second electrode line 22 on the bonding flap 33 are electrically connected through the resistive layer 35 to form a plurality of cross sensing portions 25.

[0058] In some embodiments, the first opening 321, the second opening 322, and the third opening 323 can form a complete I-shape, or they can form the left or right half of an I-shape. When the first opening 321 and the second opening 322 are perpendicularly arranged, and the second opening 322 and the third opening 323 are perpendicularly arranged, the fitting flap 33 can also include a third side, which can correspond to at least a portion of the third opening 323. This design further expands the stress dispersion range and pressure monitoring dimension of the sensor. Through the multi-opening, multi-directional layout, the sensor can more uniformly disperse stress when facing complex mechanical environments, while providing more comprehensive pressure distribution data, thereby significantly improving the performance stability and measurement accuracy of the sensor. This design, combined with the stress dispersion function of the aforementioned buffer port 30, further enhances the reliability and adaptability of the sensor in dynamic applications, enabling it to better meet the needs of high-precision pressure monitoring and dynamic stress buffering in application scenarios such as massage chairs and car seats.

[0059] In some embodiments, a four-lobed structure can be formed by designing the cross (or X-shape) positional relationship between the first opening 321 and the second opening 322. Specifically, the fitting lobe 33 may further include a third lobe 343 and a fourth lobe 344, with at least a portion of the first opening 321 formed between the third lobe 343 and the fourth lobe 344. Alternatively, at least a portion of the second opening 322 may be formed between the third lobe 343 and the second lobe 342; or, at least a portion of the second opening 322 may be formed between the fourth lobe 344 and the first lobe 341. It should be understood that the four-lobed structural design further optimizes the stress dispersion and pressure monitoring capabilities of the flexible pressure sensor 100.

[0060] The inventors discovered that the connection between the first electrode layer 10 and the second electrode layer 20 is often only stitched or glued at the edge of the entire layer. The crossover between the first electrode line 12 and the second electrode line 22 inside often relies on contact connection. Furthermore, due to the setting of the buffer opening 30, it will be affected by the irregular shape of the variable part 210 itself during long-term use, causing the surrounding structures such as the bonding petal 33 to become scattered, curled, and moved, thereby damaging the structure of the cross sensing part 25 on the bonding petal 33 and the structure of the bonding petal 33 itself. Over time, this will cause problems such as decreased reliability of the buffer opening 30 and tearing of the first electrode layer 10 and the second electrode layer 20.

[0061] In some embodiments, to solve the above problems, reinforcing stitches 36 can be embroidered on at least one fitting flap 33, with at least a portion of the reinforcing stitches 36 passing through the first electrode layer 10 and the second electrode layer 20. This strengthens the relative positional relationship between the first electrode layer 10 and the second electrode layer 20.

[0062] Taking a single fitting flap 33 as an example, the reinforcing suture 36 can be positioned between the first side 331 and any portion of the first electrode line 12 on the fitting flap 33; alternatively, the reinforcing suture 36 can be positioned between the first side 331 and any portion of the second electrode line 22 on the fitting flap 33; alternatively, the reinforcing suture 36 can be positioned between the second side 332 and any portion of the first electrode line 12 on the fitting flap 33; or alternatively, the reinforcing suture 36 can be positioned between the second side 332 and any portion of the second electrode line 22 on the fitting flap 33. It should be understood that the specific placement of the reinforcing suture 36 can be flexibly adjusted according to actual application requirements and sensor design requirements. The material of the reinforcing suture 36 can also be selected based on the sensor's working environment and performance requirements, for example, using wear-resistant and corrosion-resistant materials to ensure its reliability during long-term use.

[0063] The inventors also discovered that applying the flexible pressure sensor 100 to smart seats such as aircraft seats, vehicle seats, massage seats, medical chairs, and electric wheelchairs presents several challenges: First, the usage scenarios for these devices are diverse and complex, ranging from medical monitoring to smart homes, from human health tracking to optimizing vehicle seating experience. This necessitates that the sensor be flexibly designed according to the actual scenario to more accurately perceive pressure distribution and achieve intelligent functionality. Second, the occupant support surfaces of these devices are often complex curved surfaces or dynamically changing flexible interfaces, such as human skin, soft tissue, and the curved shape of the seat, and require… The flexible pressure sensor 100 is frequently subjected to long-term complex stress scenarios such as passenger movement, prolonged sitting and standing, and stress on the moving parts 210. It needs to not only fit closely to these complex interfaces, but also be stable and reliable to ensure the accuracy and reliability of the measurement. Thirdly, since the substrate layer of the flexible pressure sensor 100 is made of flexible material and the electrode wires are linear and relatively soft, under long-term complex stress scenarios such as passenger movement, prolonged sitting and standing, and stress on the moving parts 210, the cross sensing part 25 and its array may shift or twist, and even cause unexpected short circuits between the wiring of the two electrode layers, which may damage the normal function and stability of the equipment.

[0064] To address the aforementioned problems, in some embodiments, this application provides a flexible pressure sensor 100, which can be applied to a seat. The flexible pressure sensor 100 has multiple sensing areas formed within the occupant support surface of the seat. Please refer to [link to relevant documentation]. Figures 8 to 10 The flexible pressure sensor 100 may include a first electrode layer 10, a second electrode layer 20, and an insulating layer 40. The insulating layer 40 is disposed between the first electrode layer 10 and the second electrode layer 20, and has multiple penetration spaces 41 corresponding to multiple sensing areas. It should be understood that the sensing areas may include at least one of a head sensing area, a shoulder sensing area, a waist sensing area, a back sensing area, an arm sensing area, a hip sensing area, and a leg sensing area. The first electrode layer 10 may include a first substrate layer 11 and multiple first electrode lines 12. The first substrate layer 11 is made of a flexible material, and the multiple first electrode lines 12 are arranged at intervals along a first direction on the first substrate layer 11. The second electrode layer 20 may include a second substrate layer 21 and multiple second electrode lines 22. The second substrate layer 21 is made of a flexible material, and the multiple second electrode lines 22 are arranged at intervals along a second direction on the second substrate layer 21. The first direction and the second direction are arranged at an angle.

[0065] Specifically, multiple cross-induction sections 25 are formed between multiple first electrode lines 12 and multiple second electrode lines 22 through multiple penetration spaces 41. The multiple first electrode lines 12 and multiple second electrode lines 22 are electrically connected through multiple cross-induction sections 25, and the resistance value of the cross-induction section 25 can change with the change of force. It should be understood that by disposing the insulating layer 40 between the first electrode layer 10 and the second electrode layer 20, and using it to isolate at least a portion of the first electrode line 12 and at least a portion of the second electrode line 22, the electrode lines around the aforementioned cross-sensing part 25 and its array will not be twisted or drifted in the tangential direction due to long-term sitting, standing, friction, etc. by the occupant. Furthermore, as a relatively hard material, the insulating layer 40 can provide force support for the cross-sensing part 25 and its array in the normal direction of the occupant support surface. In addition, by utilizing the multiple penetration spaces 41 corresponding to the multiple sensing areas, and further combining with the design of the first aspect, the position of the cross-sensing part 25 and its array is defined in both the tangential and normal directions, making the sensing array stable, reliable, sensitive, and accurate.

[0066] In some embodiments, each penetration space 41 may correspond to one or more cross-sensing sections 25. Multiple first electrode lines 12 and multiple second electrode lines 22 may form one or more intersection points in each cross-sensing section 25. If multiple intersection points are formed, the distance between adjacent intersection points within each cross-sensing section 25 is 0.2 cm to 3 cm. Typically, but not limitingly, the distance between adjacent intersection points within each cross-sensing section 25 can be 0.2 cm, 0.5 cm, 1.0 cm, 1.5 cm, 2.0 cm, 2.5 cm, 3.0 cm, or any range of two values. If multiple intersection points are formed, the multiple intersection points within the same cross-sensing section 25 can form an array, such as a 4x4 array, a 5x5 array, etc. The array design of the intersection points can improve the resolution of pressure distribution detection, reduce missed detection areas, and facilitate subsequent algorithms to use the current / resistance values ​​of multiple intersection points for noise reduction and smoothing calculations, avoiding data distortion caused by local stress concentration.

[0067] It should be further understood that, through the overlapping and crossing arrangement of the first electrode line 12 and the second electrode line 22, and the specific shape of the insulating layer 40, the insulating layer 40 can define the penetration space 41 according to the specified measurement location and sensing dot matrix design. The penetration space 41 defines the layout of multiple cross sensing parts 25 formed between the first electrode line 12 and the second electrode line 22 in the tangential direction of the occupant support surface, thereby accurately forming a large area and high density of cross sensing parts 25 and their array. This enables flexible and targeted measurement designs for different forms of flexible interfaces of electronic devices such as skin, soft tissue, smart seats, and smart beds, improving the measurement and control performance of the flexible pressure sensor 100 and the smart seat. Furthermore, since the first electrode line 12 and the second electrode line 22 are themselves linear and relatively flexible, they can better conformally fit with complex curved surfaces and flexible interfaces when forming an array. The insulating layer 40 can shield a portion of the first electrode line 12 and a portion of the second electrode line 22, avoiding problems such as contact drift and false short circuits caused by conformal fitting and long-term movement during riding. This reduces missed detections and false detections. In addition, the relatively rigid insulating layer 40 can also form a certain fit with the occupant support surface, thereby providing stable and reliable morphological support for the flexible pressure sensor 100 and improving the stability of the cross sensing part 25 and its array. In some embodiments, a resistive layer 35 is disposed between the first electrode layer 10 and the second electrode layer 20, and the resistance value of the resistive layer 35 can change with the force applied. The first electrode layer 10 and the second electrode layer 20 are electrically connected through the resistive layer 35, thereby forming a cross-inductance portion 25 whose resistance value can change with the force applied. Specifically, the resistive layer 35 can be disposed between the first electrode layer 10 and the insulating layer 40, and the insulating layer 40 can be adhered to the second electrode layer 20 by hot melt adhesive 42. Alternatively, the resistive layer 35 can be disposed between the second electrode layer 20 and the insulating layer 40, and the insulating layer 40 can be adhered to the first electrode layer 10 by hot melt adhesive 42. It should be understood that when the insulating layer 40 is made of plastic, the insulating layer 40 can be adhered to the electrode layer by hot melt adhesive 42. This adhesion method not only ensures the stability of the structure and ensures that there is no positional drift between the insulating layer 40 and the electrode layer, but also facilitates assembly and adjustment during the production process, avoids generating a large amount of debris and structural cracks in the plastic, and facilitates mass production. The introduction of the resistive layer 35 enables the resistance value of the cross sensing part 25 to change with the force, thereby improving the sensor's response speed and sensitivity to pressure changes. Combined with the aforementioned buffer port 30 and fitting flap 33 structure, it further enhances the sensor's adaptability and reliability in complex mechanical environments, enabling it to monitor pressure distribution more accurately while protecting the sensor from damage caused by excessive stress.

[0068] In some embodiments, the resistive layer 35 may include a conductive fabric woven with conductive fibers, or a conductive colloid doped with a conductive substance, such as PI, TPU, foam, or PP, and the conductive substance may include at least one of carbon black, carbon nanotubes, or graphene, thereby producing a resistance value that changes with the applied force. The insulating layer 40 may include at least one of PET, PI, TPU, silicone rubber, EVA, and PU, and may also include a composite film containing any of the above materials, thereby possessing insulating properties and facilitating mass production assembly processes of the flexible pressure sensor 100 such as embroidery, bonding, and cutting. Specifically, the insulating layer 40 can be adhered to the first electrode layer 10 by hot melt adhesive 42, adhered to the second electrode layer 20 by hot melt adhesive 42, or embroidered onto the first electrode layer 10 or the second electrode layer 20. It should be further understood that the resistive layer 35 can be embroidered on the electrode layer or bonded to the insulating layer 40 by hot melt adhesive 42, thereby ensuring structural stability and improving the functional reliability of the flexible pressure sensor 100.

[0069] In some embodiments, when the insulating layer 40 comprises at least one of nonwoven fabric and nonwoven composite fabric, the insulating layer 40 is disposed on the first electrode layer 10 by embroidery, or the insulating layer 40 is disposed on the second electrode layer 20 by embroidery. It should be understood that by embroidery, designated positions of the insulating layer 40, the first electrode layer 10, and the second electrode layer 20, such as the outer contour and the hole contour, can be uniformly embroidered and fixed, ensuring the stability of their relative positions and the functional reliability of the flexible pressure sensor 100.

[0070] The inventors discovered that while using multiple electrode lines simplifies the embroidery process, the electrical connections between these lines require additional reinforcement through welding and other processes, which increases the cost and reduces yield and product reliability.

[0071] To address the aforementioned issues, multiple first electrode lines 12 can be integrally formed, and multiple second electrode lines 22 can also be integrally formed. For example, at least a portion of the multiple first electrode lines 12 can be arranged in a serpentine pattern corresponding to the sensing area, and electrically connected to the multiple second electrode lines 22 within the sensing area, forming multiple intersecting sensing portions 25. It should be understood that by using a smaller number of electrode lines arranged in a serpentine pattern (such as S-shape, W-shape, etc.), it is possible to locally form an arrangement of multiple electrode lines, which reduces cost losses and improves the mechanical reliability of the product circuit pattern and the bonding stability between the circuit pattern and the substrate layer.

[0072] In some embodiments, at least a portion of the plurality of second electrode lines 22 are arranged in a serpentine pattern corresponding to the sensing area, and are electrically connected to the plurality of first electrode lines 12 within the sensing area, forming a plurality of cross sensing portions 25. It should be understood that when the first electrode lines 12 are arranged in a serpentine pattern, the second electrode lines 22 can be multiple independent second electrode lines 22, or they can be arranged in a serpentine pattern, depending on the pressure distribution resolution requirements of the application scenario or the limitation on the number of interfaces on the control board.

[0073] In some embodiments, the first electrode wire 12 may include at least one of stainless steel, silver nanowires, conductive polymer fibers, tin-plated copper, and carbon fibers, wherein the carbon fibers may include graphene fibers or carbon nanotube fibers. The second electrode wire 22 may also include at least one of stainless steel, silver nanowires, conductive polymer fibers, tin-plated copper, and carbon fibers, wherein the carbon fibers may include graphene fibers or carbon nanotube fibers. This design provides excellent conductivity, flexibility, and mechanical stability. Using materials such as stainless steel, carbon fibers, and graphene fibers ensures that the electrode wires maintain stable electrical performance in complex mechanical environments, while possessing good flexibility to adapt to the bending and deformation requirements of the sensor. This material selection, combined with the resistive layer 35 and the buffer port 30 structure, further enhances the overall performance of the flexible pressure sensor 100, enabling it to exhibit higher sensitivity and reliability in dynamic pressure monitoring, while extending the sensor's lifespan.

[0074] For the manufacturing process of smart seats, many seats are produced separately from the backrest and seat before assembly to ensure a good fit between the seat cover and the seat frame. Since the flexible pressure sensor 100 is often located between the seat cover and the seat frame (and the foam 220 installed on it), it can also be designed as a separate unit to facilitate mass production of smart seats. For example, the flexible pressure sensor 100 may include a first sensor and a first host computer. The first sensor includes at least one of a shoulder sensing area, a waist sensing area, a back sensing area, and an arm sensing area, and is electrically connected to the first host computer. The flexible sensor may also include a second sensor and a second host computer. The second sensor includes at least one of a hip sensing area and a leg sensing area. It should be understood that the first host computer and the second host computer can be the same host computer. The flexible pressure sensor 100 can be designed with metal terminals, conductive foam, and other connectors on the electrode layer, and in conjunction with the wiring design of the electrode lines, the electrode lines are connected to the interface of the host computer, such as the electronic control board, through the connectors to achieve electrical signal transmission.

[0075] When applying the flexible pressure sensor 100 to applications such as robotic dexterity hands, the inventors discovered that the electrical connection of the cross-sensing portion 25 between the first electrode layer 10 and the second electrode layer 20 of the flexible pressure sensor 100 is sometimes unstable. Especially when the number of electrode line intersections in the cross-sensing portion 25 is very limited, not only will the intersection position itself drift in the tangential direction of the substrate layer after long-term use, but the electrical connection of the intersection itself will also be intermittent.

[0076] To address the aforementioned problems, and through extensive design and testing experiments, this application proposes a flexible pressure sensor 100. Please refer to [link to relevant documentation]. Figure 9 , Figure 10 and Figure 11 The flexible pressure sensor 100 includes a first electrode layer 10 and a second electrode layer 20. The first electrode layer 10 includes a first electrode wire 12 and a flexible first substrate layer 11. The first electrode wire 12 extends along a first direction and is embroidered on the first substrate layer 11. The second electrode layer 20 includes a second electrode wire 22 and a flexible second substrate layer 21. The second electrode wire 22 extends along a second direction and is disposed on the second substrate layer 21. The first and second directions are arranged at an angle. By embroidering the first electrode wire 12 onto the first substrate layer 11, the position of the first electrode wire 12 can be fixed by addressing numerous points in the circuit pattern of the first electrode wire 12. Furthermore, the two steps of fixing the first electrode wire 12 and implementing the routing of the first electrode wire 12 are integrated into a single embroidery step, significantly reducing process costs and improving the stability and reliability of the product. It should be understood that the sensing area can be understood as a region or regions on the flexible pressure sensor 100, which may correspond to the user's shoulder, back, waist, etc. Each sensing area may correspond to multiple penetration spaces 41, or each sensing area may correspond to multiple cross sensing parts 25.

[0077] However, the inventors also discovered that the embroidery process in the embroidery process can also cause the material of the base layer to interfere with the electrical connection between the first electrode line 12 and the second electrode line 22. For example, the first electrode line 12 needs to be threaded on and off the first base layer 11. When the first base layer 11 is made of fabric, at least a portion of the surface thread of the first base layer 11 will be placed between the first electrode line 12 and the second electrode line 22.

[0078] To resolve the above issues, please refer to [link / reference]. Figure 11 and Figure 12 The insertion density of the electrode wires within the sensing area can be adjusted to reduce the occlusion of the electrode wires by the surface wires, allowing the electrode wires to be exposed to a greater extent in the direction from the substrate layer to the other electrode layer. It should be understood that the insertion density can be the number of insertion points per unit length of electrode wire. For example, at least a portion of the first electrode wire 12 can be embroidered along a first direction through multiple insertion points onto the first substrate layer 11 and passing through the sensing area, with the insertion density of at least a portion of the first electrode wire 12 within the sensing area being less than the insertion density of at least a portion of the first electrode wire 12 outside the sensing area. Similarly, at least a portion of the second electrode wire 22 can be embroidered along a second direction through multiple insertion points onto the second substrate layer 21 and passing through the sensing area, with the insertion density of at least a portion of the second electrode wire 22 within the sensing area being less than the insertion density of at least a portion of the second electrode wire 22 outside the sensing area.

[0079] In some embodiments, the plurality of insertion points located within the sensing area include a plurality of first insertion points 131 and a plurality of second insertion points 132. The first electrode wire 12 passes through the first electrode layer 20 and through the first substrate layer 11 via the first insertion points 131 toward the second electrode layer 20, and passes through the first substrate layer 11 via the second insertion points 132 away from the second electrode layer 20. It is understood that, since the needle direction of the embroidery process can be adjusted according to actual needs in actual products, the first insertion points 131 and the second insertion points 132 can be understood as a relative concept. The plurality of first insertion points 131 and the plurality of second insertion points 132 arranged at adjacent intervals help to understand the structural design where part of the electrode wire is on one side of the substrate layer and part is on the other side of the substrate layer.

[0080] In some embodiments, the design can also be based on the length of the line segment. For example, a segment of the first electrode wire 12 that passes through the first penetration point 131 and then exits through the adjacent second penetration point 132 can be designated as a first segment 141, with at least a portion of the first segment 141 being closer to the second electrode layer 20 than the first substrate layer 11. A segment of the first electrode wire 12 that passes through the second penetration point 132 and then enters through the adjacent first penetration point 131 can be designated as a second segment 142, with at least a portion of the second segment 142 being farther away from the second electrode layer 20 than the first substrate layer 11. In this configuration, at least one first segment 141 is longer than the length of an adjacent second segment 142.

[0081] In some embodiments, at least one first segment 141 is longer than twice the length of an adjacent second segment 142. It should be understood that since there may be multiple first segments 141 within the sensing area, only a portion of the first segments 141 intended for electrical connection with electrode lines on another electrode layer can be extended as needed, while others can remain equal to or similar in length to the second segment 142. This balances the stability of the electrode line arrangement within the sensing area with the reliability of the electrical connection, preventing excessively sparse penetration points within the sensing area that could affect structural reliability. Specifically, multiple first segments 141 of equal or similar length to the adjacent second segment 142 can be spaced apart between first segments 141 that are longer than twice the length of an adjacent second segment 142. This prevents two excessively long first segments 141 from being too close together, which could cause the second segments 142 between them to be easily pulled, or even to become entangled and damage the substrate layer under complex stress conditions.

[0082] In some embodiments, please refer to Figure 13 and Figure 14 This allows at least a portion of the first electrode line 12 to be serpentinely embroidered on the first substrate layer 11, forming a plurality of first segments 141 arranged in parallel within the sensing area, with the plurality of first segments 141 arranged in parallel along a first direction.

[0083] In some embodiments, at least a portion of the second electrode wire 22 is embroidered on the second substrate layer 21 through a plurality of penetration points along the second direction and passes through the sensing area. The plurality of penetration points also include a plurality of third penetration points 231 and a plurality of fourth penetration points 232. At least a portion of the plurality of third penetration points 231 and at least a portion of the plurality of fourth penetration points 232 are arranged adjacent to each other along the second direction. The second electrode line 22 passes through the second substrate layer 21 towards the first electrode layer 10 via the third penetration point 231, and passes through the second substrate layer 21 away from the first electrode layer 10 via the fourth penetration point 232.

[0084] In some embodiments, the second electrode line 22 may include a plurality of third segments 241 and a plurality of fourth segments 242. A segment of the second electrode line 22 that passes through a third penetration point 231 and then exits through an adjacent fourth penetration point 232 is a third segment 241. At least a portion of the third segment 241 is disposed closer to the first electrode layer 10 than the second substrate layer 21. A segment of the second electrode line 22 that passes through a fourth penetration point 232 and then passes through an adjacent third penetration point 231 is a fourth segment 242. At least a portion of the fourth segment 242 is disposed further away from the first electrode layer 10 than the second substrate layer 21. In this embodiment, at least a portion of the length of the third segment 241 is longer than the length of the adjacent fourth segment 242.

[0085] In some embodiments, by correspondingly configuring the first segment 141 and the third segment 241, electrical connection can be strengthened simultaneously from both electrode layers. At least a portion of the second electrode line 22 is serpentinely embroidered on the second substrate layer 21, and a plurality of third segments 241 are formed in parallel within the sensing area, the plurality of third segments 241 being arranged in parallel along the second direction; or, at least a portion of the third segments 241 and at least a portion of the first segment 141 are correspondingly configured.

[0086] In some embodiments, the flexible pressure sensor 100 has multiple fixed through holes outside the sensing area, and the shapes of the multiple fixed through holes include circular, elliptical, or polygonal; or, the edge of the flexible pressure sensor 100 has multiple fixed through slots. This design allows for the assembly of the fixed through slots and fixed through holes with pre-set fasteners on the seat frame or foam 220 body using automated equipment or manual methods during mass production. This assembly is achieved through insertion and sliding, greatly improving mass production efficiency and product yield. Furthermore, it ensures the stability of the cross-sensing portion 25 and its array shape when the flexible pressure sensor 100 is used with complex contact surfaces 230 such as seats, preventing displacement, missed detections, and false detections.

[0087] The inventors discovered in their experiments that electrode wires, including stainless steel wire, carbon fiber, and silver-plated copper wire, often provide stable and reliable conductivity and signal transmission in environments with high stress, such as chairs and medical beds. However, these electrode wires often consist of wire harness structures. If embroidery techniques such as flat stitching are used, the metal plating on the surface of the wire harness can easily be scratched by the base material. Furthermore, the special structure and material of the wire harness itself can produce metal burrs, severely affecting the stability and reliability of the electrical connection.

[0088] To resolve the above issues, please refer to [link / reference]. Figures 15 to 17 This application proposes an electrode layer. Please refer to the relevant embodiments and terminology of the first electrode layer 10 for a detailed description of the electrode layer. For example, this electrode layer may correspond to the first electrode layer 10, and the electrode wire may correspond to the first electrode wire 12. The electrode layer may include a substrate layer, electrode wires, and fixing wires 50. The substrate layer is a flexible substrate layer, and the electrode wires extend along a first direction and are disposed on the substrate layer.

[0089] In some embodiments, at least a portion of the fixing wire 50 extends along a third direction and is disposed on the substrate layer, the third direction being at an angle to the first direction. Furthermore, at least a portion of the fixing wire 50 extends out of the substrate layer on one side of the electrode wire and extends into the substrate layer on the other side of the electrode wire, thus binding the electrode wire to the substrate layer. It should be understood that when the electrode wire is disposed on the substrate layer using a bonding process, embroidery process, or rope embroidery process, the design of the fixing wire 50 can also prevent the electrode wire from shifting or twisting under stress conditions on complex dynamic curved surfaces, ensuring the stability and reliability of the flexible pressure sensor 100.

[0090] In some embodiments, the electrode wires corresponding to the sensing area can form a first segment 141 and a second segment 142. The first segment 141 is used to cross and overlap with electrode wires on another electrode layer and be electrically connected. The second segment 142 is used to cooperate with a fixing wire 50 to fix the first segment 141. At least a portion of the fixing wire 50 extends out of the substrate layer on one side of the second segment 142 and into the substrate layer on the other side of the second segment 142, thus confining at least a portion of the second segment 142 to the substrate layer. It should be understood that the fixing wire 50 can bind at least a portion of the second segment 142, and can also extend to the first segment 141 and bind at least a portion of the first segment 141.

[0091] In some embodiments, at least a portion of the fixing wire 50 is formed with a serpentine structure, which meanders along a first direction and around the second segment 142, binding at least a portion of the second segment 142 to the substrate layer. It should be understood that the serpentine structure design effectively enhances the fixing wire 50's ability to secure the electrode wire while maintaining the flexibility of the substrate layer. The serpentine structure, through its meandering shape, increases the contact area and friction between the fixing wire 50 and the electrode wire, thereby more firmly fixing the second segment 142 of the electrode wire to the substrate layer. This design not only improves the stability of the electrode wire but also allows the substrate layer to bend and deform to a certain extent without significantly affecting the fixing effect of the electrode wire.

[0092] In some embodiments, at least a portion of the serpentine structure may meander along a first direction and around the first segment 141, and at least a portion of the first segment 141 may be bound to the substrate layer. It should be understood that the fixing wire 50 of the serpentine structure can also absorb and disperse stress to a certain extent, reducing the direct stress on the electrode wires caused by bending or stretching of the substrate layer, thereby extending the service life of the electrode wires and improving the overall reliability of the sensor. This design, combined with the aforementioned selection of electrode wire materials, further optimizes the performance of the flexible pressure sensor 100, enabling it to better adapt to the application requirements of complex curved surfaces and dynamic soft interfaces.

[0093] In some embodiments, the serpentine structure may include at least one of silver fiber, copper fiber, and silver-plated nylon wire, or the electrode wire may include at least one of stainless steel wire, carbon fiber, and silver-plated copper wire. It should be understood that selecting materials such as silver fiber, copper fiber, and silver-plated nylon wire for the fixing wire 50 of the serpentine structure, and selecting materials such as stainless steel wire, carbon fiber, and silver-plated copper wire for the electrode wire, can fully utilize the high conductivity, flexibility, and mechanical stability of these materials. This combination of materials not only improves the stability and durability of the electrode wire and fixing wire 50 under complex mechanical environments, but also further enhances the sensitivity and response speed of the flexible pressure sensor 100.

[0094] In some embodiments, the fixing thread 50 can be embroidered on a base layer. The base layer includes at least one of spunlace fabric, knitted fabric, and nonwoven fabric. The base layer may also be laminated with at least one of TPU composite fabric, PU coated fabric, elastic fabric, and spunbond nonwoven fabric. Alternatively, the fixing thread 50 may be made of a different material than the electrode thread, or the fixing thread 50 may be made of a different material than the base layer. It should be understood that... In some embodiments, the fixing wire 50 may include a first wire 51 and a second wire 52. The electrode wire includes a stainless steel wire. The first wire 51 includes a face wire, and the second wire 52 includes a silver fiber conductive wire. The second wire 52 is embroidered on the first substrate layer 11. The second wire 52 meanders along a first direction and around the first segment 141. The second wire 52 binds at least a portion of the first segment 141 to the substrate layer and is electrically connected to the first segment 141. It should be understood that the face wire refers to a wire that can be applied to the substrate layer, such as fabric thread. The first wire 51 being a face wire can effectively simplify the embroidery process. The second wire 52 being a silver fiber conductive wire with strong conductivity forms a certain number of electrical connections between electrode wires, second wire 52, and electrode wires, avoiding interference from the weakly conductive face wires with the electrical connections between the electrode wires, and improving the accuracy and reliability of the flexible pressure sensor 100.

[0095] In some embodiments, please refer to Figure 9 and Figure 10 The electrode layer can be applied to a flexible pressure sensor 100, which can be any of the flexible pressure sensor 100 provided in any embodiment of this application, and includes the electrode layer provided in any embodiment of this application. Specifically, the flexible pressure sensor 100 may include a first electrode layer 10 and a second electrode layer 20. The first electrode layer 10 can be the electrode layer provided, and the second electrode layer 20 may include a second substrate layer 21 and a second electrode line 22. The second electrode line 22 extends along a second direction and is disposed on the second substrate layer 21, with the first direction and the second direction forming an angle.

[0096] In some embodiments, the flexible pressure sensor 100 may have a sensing area, with a first electrode layer 10 having a plurality of first electrode lines 12 extending along a first direction arranged at intervals within the sensing area, and a second electrode layer 20 having a plurality of second electrode lines 22 extending along a second direction arranged at intervals within the sensing area. This design allows for the formation of a 4x4, 5x5, or other cross-sensing point array within the sensing area. In some embodiments, the flexible pressure sensor 100 has a sensing area, and a first electrode layer 10 has five first electrode lines 12 arranged at intervals along a first direction within the sensing area, and a second electrode layer 20 has five second electrode lines 22 arranged at intervals along a second direction within the sensing area. It should be understood that a 5*5 array of intersecting sensing points, compared to arrays with more intersecting sensing points (such as 6*6, 7*7, etc.), can effectively reduce the complexity and manufacturing cost of the sensor while maintaining higher spatial resolution, thereby reducing the computational load of signal processing and improving the overall efficiency of the system. Furthermore, it can avoid excessive electrode lines accumulating in a small sensing area, preventing short-circuit interference between electrode lines under complex stress conditions. While arrays with fewer intersecting sensing points have a simpler structure, their spatial resolution is relatively low, making it difficult to meet the requirements of high-precision pressure distribution monitoring and related noise reduction algorithms.

[0097] Please see Figure 4 , Figure 5 and Figure 18 This application also provides an electric device 200, which may include at least one of a massage chair, car seat, massage bed, massager, and robot, and includes a flexible pressure sensor 100 as described in any embodiment of this application. When the flexible pressure sensor 100 is applied to a moving part 210 such as a robot dexterous hand or a flexible adsorption component, its contact flap 33 can cooperate with the moving part 210, thereby better measuring the force on the original contact surface 230 in the tangential direction.

[0098] The electric device 200 can also include smart wearable devices, smart cushions, smart insoles, etc. This flexible pressure sensor can be applied to pressure acquisition at the end of robots, medical rehabilitation equipment, mattresses, armrests, steering wheels, and other pressure-sensitive applications.

[0099] This application also provides a smart seat, which may include the flexible pressure sensor 100 as described in any embodiment of this application. The smart seat may include transportation seats such as aircraft seats and vehicle seats, or it may include massage seats, medical seats, wheelchairs, etc.

[0100] This application also provides an electronic device that may include the flexible pressure sensor 100 as described in any embodiment of this application. The electronic device may include at least one of a smart seat, a wearable device, and an electric device 200.

[0101] Without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of the different embodiments or examples.

[0102] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A flexible pressure sensor, characterized in that, Applied to electric equipment, the electric equipment having a variable element corresponding to the user's contact surface, including: A first electrode layer, comprising a first substrate layer and a plurality of first electrode lines, wherein the first substrate layer comprises a flexible material, and the plurality of first electrode lines are arranged at intervals along a first direction in the first substrate layer; The second electrode layer includes a second substrate layer and multiple second electrode lines. The second substrate layer is made of a flexible material. The multiple second electrode lines are arranged at intervals along a second direction in the second substrate layer. The first direction and the second direction are arranged at an angle. Multiple cross-induction portions are formed between the multiple first electrode lines and the multiple second electrode lines. The multiple first electrode lines and the multiple second electrode lines are electrically connected through the multiple cross-induction portions. The resistance value of the cross-induction portions can change with the change of force. The first electrode layer and the second electrode layer are provided with buffer openings corresponding to the variable element. When at least a part of the variable element expands or moves toward the user through the buffer openings, the buffer openings expand to form a penetration space.

2. The flexible pressure sensor as described in claim 1, characterized in that, The buffer opening includes a first opening and a second opening, which are set at an angle to each other.

3. The flexible pressure sensor as described in claim 2, characterized in that, The buffer opening also includes a third opening, which is set at an angle to the first opening and at an angle to the second opening.

4. The flexible pressure sensor as described in claim 2, characterized in that, The projection of the variable member on the contact surface is square or near square, the first opening is arranged along one diagonal of the square or near square, the second opening is arranged along the other diagonal of the square or near square, and the first opening and the second opening intersect.

5. The flexible pressure sensor as described in claim 2, characterized in that, The first electrode layer and the second electrode layer extend axially toward the buffer opening to form a fitting flap. The fitting flap includes a first side and a second side. At least a portion of the first opening is disposed corresponding to the first side, and at least a portion of the second opening is disposed corresponding to the second side.

6. The flexible pressure sensor as described in claim 5, characterized in that, The fitting flap includes a first flap and a second flap, with at least a portion of the first opening formed between the first flap and the second flap.

7. The flexible pressure sensor as described in claim 6, characterized in that, The fitting flap further includes a third flap and a fourth flap, and at least a portion of the first opening is formed between the third flap and the fourth flap; Wherein, at least a portion of the second opening is formed between the third lobe and the second lobe; or, At least a portion of the second opening is formed between the fourth lobe and the first lobe.

8. The flexible pressure sensor as described in claim 5, characterized in that, Multiple first electrode lines are embroidered at intervals along a first direction on the first electrode layer of the bonding flap, and multiple second electrode lines are embroidered on the second electrode layer of the bonding flap. The bonding flap further includes a resistive layer, which is disposed between the first electrode layer and the second electrode layer, and electrically connects the first electrode line on the bonding flap and the second electrode line on the bonding flap through the resistive layer to form the plurality of cross-sensing portions.

9. The flexible pressure sensor as described in claim 8, characterized in that, The fitting flap is embroidered with reinforcing stitches, and at least a portion of the reinforcing stitches passes through the first electrode layer and the second electrode layer; Wherein, the reinforcing suture is disposed in the region between the first electrode line on the first side and any part of the fitting flap; or, The reinforcing suture is disposed in the region between the first edge and the second electrode line on any part of the fitting flap; or... The reinforcing suture is disposed in the region between the second side and the first electrode line on any part of the fitting flap; or, The reinforcing suture is disposed in the area between the second side and the second electrode line on any part of the fitting flap.

10. The flexible pressure sensor according to any one of claims 1-9, characterized in that, The variable component includes at least one of an airbag, rollers, massage head, support, and heating head.

11. The flexible pressure sensor according to any one of claims 1-9, characterized in that, At least a portion of the plurality of cross-sensing portions are formed on the periphery of the buffer port; or, The buffer port includes two opposing sides, at least a portion of the plurality of cross-sensing units are disposed on one side of the buffer port, and at least a portion of the plurality of cross-sensing units are disposed on the other side of the buffer port.

12. An electric device, characterized in that, The electric device includes at least one of a massage chair, a car seat, a massage bed, and a massager, and the electric device includes a flexible pressure sensor as described in any one of claims 1-11.

Images