Multi-contact type weight mat sensor and detection system thereof

Abstract

To provide a multi-contact type weight detection system including a multi-contact type weight mat sensor and an external apparatus, the mat sensor having a function of distinguishing and detecting the same load and rigidity / softness, and the external device detecting conduction between electrodes, the weight mat sensor setting the output of a load by a structure with 10-contact outputs so as to detect only a person seated on a vehicle seat.SOLUTION: A structure is configured by using panel electrodes 13, 14 for bearing the entire weight of a load, and thin switch electrodes (16, 17, 18) deformed and brought into contact by the load. An elastic outer-edge spacer 18 closely attached on the upper part and lower part the electrodes surrounds the entire periphery of the outer edge gap and the six locations of the panel electrodes 13, 14, and air holes (23) are provided in all air layers inside an elastic frame spacer (19) disposed between the electrodes. The structure has a configuration including a 10-contact output function so that identification and detection of only a human load and detection setting of other loads are enabled.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a multi-contact weight mat sensor, and more particularly to a multi-contact weight detection system that includes a multi-contact weight mat sensor constructed with a structure that does not detect any load other than a specified load due to the multi-contact configuration, and an external device that detects the flow of electricity, for use in seats in automobiles, wheelchairs, etc.

[0002] Patent Document 1 describes a technology for an ultra-sensitive weight mat sensor that consists of a single conductive pillar located in the center of the bottom of an insulator, elastic insulating vertical spacers located around the conductor, and a panel electrode placed on the spacer facing the single conductive pillar, which only comes into contact with the single conductive pillar when a load of a predetermined magnitude or greater is applied to the panel electrode.

[0003] However, while the ultra-high sensitivity weight sensor described in Patent Document 1 is an excellent structure for detecting lightweight objects weighing a few grams, the weight-type sensor (ON / OFF) requires relatively high manufacturing costs due to the man-hours required for commercialization and the cost of parts, etc., and is not suitable as a structure for detecting and distinguishing between objects with different detection areas for the same load or the texture (hard, soft) of the loaded object. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 5808051 Summary of the Invention [Problem to be solved by the invention]

[0005] The object of the present invention has been made in consideration of the above circumstances, and is to provide a multi-contact weight mat sensor and a multi-contact weight detection system suitable for a wide range of uses for measuring loads, by enabling the contact output to be set depending on the structure configuration, such as the thickness and detection area of ​​the panel electrode and switch electrode resin plate, the size of the electrode area, and the width, thickness, density, compressive residual strain, etc. of the elastic spacer, thereby enabling detection to be set depending on the structure configuration, such as distinguishing between loads of different sizes but the same load, or detecting soft loads but not generally detecting hard loads. [Means for solving the problem]

[0006] The first aspect of the present invention to solve the above problems is a multi-contact weight mat sensor characterized by comprising: panel electrodes in which a conductor is coated on the surface of six squares (various shapes) of a resin plate made of an elastic material; copper foil tape or copper conductive paste for attaching output lead wires to panel electrode S1 and panel electrode E1; a multi-contact switch electrode in which a conductor is coated on the surface of five rectangular resin plates (various shapes) facing panel electrode SE; a band-shaped elastic outer edge spacer attached around the entire periphery of the gap between the panel electrodes and the switch electrodes; and band-shaped elastic frame spacers similarly arranged around the periphery of all six panel electrodes; an air vent provided in the air layer within the panel electrode, and the air in the air layer between the laminated layers has a fluidity function that is not sealed by the air vent at the output line opening, and the structure of the weight mat sensor has a 10-contact detection function using panel electrodes and switch electrodes.

[0007] In a second aspect of the present invention to solve the above problems, the electrode surfaces of the panel electrode and switch electrode resin plates are formed on resin plates made of a material such as polycarbonate, which has impact resistance, antistatic properties, dimensional stability, and elasticity. This conductor is covered with conductive printing, conductive coating, copper foil tape, aluminum foil tape, or the like. The thickness of the electrode plate is 0.1 to 4 mm depending on the application of the load, and the detection area (sensor dimensions) can be expanded or contracted, making it a multi-contact weight mat sensor characterized by the construction of a structure suited to the application.

[0008] The third aspect of the present invention to solve the above problems is a multi-contact weight mat sensor characterized in that the resin plate of the panel electrode is 1 mm thick, and the six panel electrodes are configured as squares measuring 60 mm long x 60 mm wide. The switch electrode plate is 0.1 mm thick, and forms five switch electrodes in total, four measuring 15 mm long x 50 mm wide and one measuring 15 mm long x 70 mm wide. The contacting electrodes are squares measuring 15 mm long x 15 mm wide, and the detection area can be expanded or contracted in accordance with the load, and the size and shape of the electrode area can be varied.

[0009] A fourth aspect of the present invention for solving the above problems is that the elastic spacer has a density of 400 kg / m 2 The weight-type sensor is made of high-performance urethane foam with a small compression residual strain of 2%, and is fitted with an elastic outer edge spacer 1mm long and 5mm wide in the gap around the entire outer edge between the panel electrode and the switch electrode, and panel electrodes S and E. Elastic frame spacers are placed around the outer periphery of all six electrodes, and the air in the air layer within the panel electrode and the air between the elastic spacers is not sealed by the air vent in the output line opening, giving it a fluidity function.The multi-contact weight mat sensor is characterized by having a structure that configures detection for each contact output of a load suitable for multiple uses.

[0010] The fifth aspect of the present invention to solve the above problems is a structure in which elastic spacers are arranged around the entire periphery of the outer edge gaps between a plurality of panel electrodes and a plurality of switch electrodes and around the entire periphery of the six inner panel electrodes. In other words, even with the same load, the sensor will detect loads larger than its detection area and not detect loads smaller than its detection area. Furthermore, the load applied to the entire 0.1 mm thick switch electrode plate and the load received by the elastic spacer arranged around the outer periphery of the panel electrode are such that hard loads such as cardboard boxes and pallets applied to the detection area are not detected due to the load being applied perpendicularly and evenly to the entire surface, preventing deformation of the switch electrode portion on the panel electrode and the remaining thickness of the elastic spacer. On the other hand, for softer loads such as people, the electrode portion of the switch electrode plate deforms under the load, forming a multi-contact weight mat sensor that makes contact.

[0011] The sixth aspect of the present invention to solve the above problems is a multi-contact weight mat sensor that has the characteristic of being a structure for detecting non-deformable loads such as cardboard boxes and pallets that would otherwise go undetected, in which a cushioning protective agent (bubble cushioning material) consisting of a plurality of 2mm thick granular air bubbles arranged between polyethylene sheets is placed on the multi-contact weight mat sensor with the granular air bubbles facing downwards, and the structure comes into contact when the weight of a load such as a cardboard box is applied.

[0012] The seventh aspect of the present invention, which solves the above problems, is a multi-contact weight mat sensor that is adaptable to a wide range of uses, and in which the contact configuration of the switch electrode facing the panel electrode is based on a 10-contact output configuration, and is configured with a structure of multiple contacts that is suitable for the load applied to the sensor and the size of the detection area, and which can utilize external equipment to detect the flow of electricity between the panel electrode and the switch electrode. [Effects of the Invention]

[0013] According to the present invention, in a multi-contact weight sensor, a panel electrode and a switch electrode are formed, and elastic spacers are placed in close contact around the entire gap around the outer edge and on all six outer peripheries of the panel electrodes, and air vents are provided in all air layers.This structure makes it possible to provide a multi-contact weight sensor and detection system that has a structure that can detect loads of the same weight by detecting their detection area, can detect loads of different hard or soft types, and can detect hard loads depending on the configuration, and has a wide range of detectability that can detect loads from small to large. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a plan view showing the arrangement of panel electrodes of a multi-contact weight mat sensor according to an embodiment of the present invention and the state in which each component is configured. [Figure 2] 1 is a plan view showing the arrangement of switch electrodes facing panel electrodes of a multi-contact weight mat sensor according to an embodiment of the present invention; [Figure 3] 1 is a cross-sectional view of a contact portion of a switch electrode between a panel electrode and an elastic spacer in a multi-contact weight mat sensor according to an embodiment of the present invention. [Figure 4] 1 is a cross-sectional view showing the contact portions of the panel electrode and the switch electrode of a multi-contact weight mat sensor according to an embodiment of the present invention. [Figure 5] 1 is a cross-sectional view of a contact portion between a panel electrode and a switch electrode that contacts the panel electrode of a multi-contact weight mat sensor according to an embodiment of the present invention. [Figure 6] 1 is a cross-sectional view showing the contact portion between the panel electrode and the switch electrode of a multi-contact weight mat sensor according to an embodiment of the present invention when no load is applied. [Figure 7] 1 is a cross-sectional view showing the contact state of a panel electrode and a switch electrode at one contact point of a multi-contact weight mat sensor according to an embodiment of the present invention when a load is applied. [Figure 8] 1 is a cross-sectional view showing a non-contact state between a panel electrode and a switch electrode of one contact portion of a multi-contact weight mat sensor according to an embodiment of the present invention when a load is applied. [Figure 9] This is a cross-sectional view showing the contact state when a multi-contact weight mat sensor, which is one embodiment of the present invention, is placed on a wooden table and a load is applied to a cardboard box with bubble cushioning material on top. [Figure 10] This is a cross-sectional view showing the contact state during detection when a multi-contact weight mat sensor, which is one embodiment of the present invention, is placed on a wooden table and a 10 kg load is applied on top of bubble cushioning material via an aluminum resin composite material. DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention will be described with reference to the accompanying drawings, but the present invention is not limited to these examples and various modifications are possible without departing from the spirit of the present invention.

[0016] Figure 1 shows a plan view of a multi-contact weight mat sensor 10, an on-off weight sensor. In other words, this embodiment is a multi-contact weight mat sensor that has 10 contact outputs and can be configured to detect loads depending on the structural configuration. The outer periphery is covered with an outer cover 11. Inside are panel electrodes 13 (13S1, 13S2, 13S3), 14 (14E1, 14E2, 14E3), switch electrodes 15 (15S1, 15S2), 16 (16E1, 16E2), and 17 (17SE), each formed of an insulator 12. Elastic edge spacers 18 (see Figure 3) are installed in the gaps around the entire periphery of these electrodes, and elastic frame spacers 19 (see Figure 3) are placed around the periphery of six positions inside the panel electrodes 13S and 14E. In addition, an air vent 23 is provided in the air layer within each panel electrode 13, and panel electrode 13S1 and panel electrode 14E1 are covered with copper foil tape 21 or copper conductive paste (not shown) for lead wire extraction. Lead wires 20S and 20E are extracted from lead wire connection portion 22 through air vent 23 in lead wire opening 24, and these lead wires 20S and 20E are connected to external equipment 25.

[0017] 1, panel electrodes 13, 14 (supporting the entire load), elastic outer edge spacer 18, elastic frame spacer 19 (identifying the load), air vents 23, 24 (removing air pressure), and switch electrodes 15, 16, 17 (identifying contact functions, etc.) according to one embodiment of the present invention each have a function related to the detection of a loaded object based on their respective characteristics. With these functions, the detection function, which is evenly shaped in two rows on the left and right and occupies 72% of the sensor detection area, forms the structure of multi-contact weight mat sensor 10, which uniformly receives the entire weight of a loaded object.

[0018] A specific example of the above-mentioned multi-contact weight mat sensor 10 is as follows: That is, the resin plate of the panel electrodes 13 and 14 covered with the outer cover 11 in Fig. 1 is a 1 mm thick polycarbonate plate measuring 150 mm long and 200 mm wide, with a highly adhesive conductive coating and aluminum foil tape to form a 60 x 60 mm square electrode surface, which constitutes three locations each of panel electrodes 13S (13S1, 13S2, 13S3) and panel electrodes 14E (14E1, 14E2, 14E3), for a total of six locations (see Fig. 4), and copper foil tape 21 or copper conductive paste (not shown) is arranged to connect output lead wires 20 (20S, 20E) to panel electrodes 13S1 and 14E1 in panel electrode 13. In addition, in this embodiment, polycarbonate plates, vinyl chloride plates, acrylic plates, aluminum composite plates, etc., which are durable, impact-resistant, flexible, etc., are used as the material for the resin plates of the electrode part, which plays an important role in detection.

[0019] The elastic outer edge spacers 18 and elastic frame spacers 19 surround the entire periphery of panel electrodes 13 and 14. The elastic outer edge spacers 18, measuring 1 mm high and 5 mm wide, are located around the entire periphery of the gap between panel electrodes 13 and 14 and switch electrodes 15, 16, and 17. The elastic frame spacers 19, also measuring 1 mm high and 5 mm wide, are located around the entire periphery of panel electrodes 13S and 14E, for a total of six locations. These spacers are also attached with adhesive tape between the top and bottom of the panel electrodes and switch electrodes. Air vents 23 are provided in the air spaces within the six panel electrodes, and lead wire openings 24 and air vents 25 are provided in the air spaces between the elastic spacers attached between the panel electrodes and switch electrodes. This provides a fluid structure that prevents the air in the air space from being sealed. Eliminating the load pressure on the air is one of the key components of accurate contact output. The elastic outer edge spacers 18 and elastic frame spacers 19 are made of materials such as urethane foam with a uniform cell structure, silicone elastomer, natural rubber, acrylic rubber, and urethane rubber.

[0020] Figure 2 is a cross-sectional view of multi-contact weight mat sensor 10, and a plan view showing the arrangement of switch electrodes 15, 16, and 17 facing panel electrodes 13 and 14. Specifically, five electrodes are formed using a 0.1 mm thick, 150 mm x 200 mm polycarbonate resin plate with a highly adhesive conductive coating and aluminum foil tape: four switch electrodes 15S and 15E (two on each side, 15 mm x 50 mm), and one switch electrode 17SE (70 mm x 15 mm). The area of ​​the electrode contacts is 15 mm x 15 mm, but the size should be selected depending on the load, and it is desirable to install them in the center of panel electrodes 13 and 14. When the load weight on the elastic frame spacer 19 and switch electrodes 15, 16, 17 that are in close contact between the electrodes is a hard load that does not deform the load surface, the entire elastic frame spacer 19 and switch electrodes 15, 16, 17 receive a horizontal load, resulting in no contact (non-detection). However, when a soft load (such as a person) is applied, the central parts of the switch electrodes 15, 16, 17 located inside the elastic frame spacer frame 19 deform due to the load pressure, forming a structure that becomes contact (detection).

[0021] The structure of the panel electrodes 13, 14 that bear the entire load evenly, the contraction rate of the elastic spacer according to the weight of the total load, and the switch electrode, etc., in which the electrode plate only deforms when the load is soft, allows the thickness of the resin plate, detection area (sensor area), electrode area, etc., to be adjusted according to the load amount, making it possible to form a structure suited to the use of frequently used loads, and this is a product that is expected to see increased demand in the market.

[0022] Figure 3 is a cross-sectional view taken along the line A1-A1 in Figure 1. This figure shows panel electrode 13 (13S1, 13S2, 13S3) made of insulator 12 covered with outer cover 11, elastic outer edge spacer 18 tightly attached to the outer edge gap between opposing switch electrode 16 (16E1, 16E2, 16E3) and panel electrode 17 (17SE), and elastic frame spacer 19 tightly attached to the outer periphery of panel electrode 13S, as well as lead wires 20S-E connected to external device 25 (see Figure 1).

[0023] FIG. 4 shows the electrode portions where panel electrodes 13 (13S1, 13S2, 13S3) and switch electrodes 16 (16E1, 16E2, 16E3) and panel electrodes 14 (14E1, 14E2, 14E) and switch electrodes 15 (15S1, 15S2) come into contact with each other. FIG. 5 is a cross-sectional view taken along line A2-A2 in FIG. 1. This figure shows the electrode portions where panel electrodes 13S3 and 14E3 come into contact with switch electrode 17SE.

[0024] Fig. 6 is a cross-sectional view showing the state of the electrode parts and elastic spacer of panel electrode 13 and switch electrode 16 when no load is applied, Fig. 7 is a cross-sectional view of the electrode parts showing the state in which panel electrode 13S and switch electrode 16E are in contact when the entire detection area is loaded with a soft load such as a person, and Fig. 8 is a cross-sectional view of the electrode parts showing the non-contact state between panel electrode 13S and switch electrode 16E when the weight of a hard load is applied.

[0025] Figure 9 shows another embodiment in which the multi-contact weight mat sensor 10 is adapted to handle non-deformable loads that are not detected, as shown in Figure 8. In this embodiment, the contact electrode part is shown with a 10 kg cardboard box load placed on a structure in which bubble cushioning material 28 is placed on the mat sensor 10.

[0026] That is, this is a cross-sectional view of the contact electrode portion with a weight of 10 kg placed on the air bubble cushioning material 28 shown in FIG. 10, with an aluminum resin composite panel (not shown).

[0027] (Verification experiment) Conventional weight-type mat sensors have a single-contact output and can detect a wide range of weights by using a threshold value to identify the weight of individual loads, but are not suitable for identifying loads of the same weight or detecting loads based on their hardness or softness. The purpose of this invention was to create a structure that would detect the presence or absence of a person in the driver's seat of a vehicle, but would not detect any loads other than people.However, from the perspective that it would also be possible to detect and identify various loads according to their purpose and use in the process of constructing the structure, a multi-contact weight mat sensor of the present invention was created and performance verification experiments were conducted.

[0028] The panel electrode was made of a 1mm thick polycarbonate resin plate, 60mm long x 60mm wide, coated with conductors in six places, and had output lead wires attached. The opposing switch electrode was made of a 0.1mm thick polycarbonate resin plate, 15mm long x 50mm wide, coated with conductors in four places and 70mm long x 15mm wide, coated with conductors in one place, a total of five places. A band-shaped elastic spacer, 1mm long x 5mm wide, was attached to the entire outer edge of the gap between the two electrodes and the outer periphery of the panel electrode. An air vent was placed in the air layer between the six panel electrodes and the switch electrode. A load test was conducted on a multi-contact weight mat sensor.

[0029] First, a multi-contact weight mat sensor measuring 150mm long x 200mm wide x 3mm thick was placed on several different seats (seats using cushioning materials such as urethane), and a person sat on it with a 65g load several dozen times at regular intervals, and all of the seats were detected correctly. Naturally, person loads outside the entire detection area were not detected. Similarly, a seat mat made of low-resilience elastic foam measuring 365mm long x 430mm wide x 30mm thick was placed on the multi-contact weight mat sensor, and it was confirmed that a 65kg person load and cardboard boxes weighing 20kg and 40kg were detected everywhere on the seat mat area.

[0030] When a PVC board measuring 180mm long x 290mm wide x 1mm thick and an aluminum resin composite board measuring 150mm long x 250mm wide x 5mm thick were placed on the multi-contact weight mat sensor on the same seat, a 65g human load was not detected. Similarly, loads of 20kg and 40kg cardboard boxes measuring 250mm long x 350mm wide x 150mm wide x 5mm thick were not detected. Furthermore, when a multi-contact weight mat sensor was placed on a wooden table, a 65kg human load was detected, but a 20kg and 40kg cardboard box load was not detected.

[0031] Under the above conditions, it was confirmed that the load applied to the resin plate (aluminum resin composite plate, PVC plate) sandwiched between the multi-contact weight mat sensor and a 2mm thick foam impact material (air packing, etc.) and urethane foam material was 13kg for the PVC plate and 12.5kg for the aluminum resin composite plate.

[0032] In the above verification experiments, it became clear that the multi-contact weight mat sensor has a wide measurement capability capable of measuring and distinguishing between small and large loads by configuring a highly durable structure with functions for identifying identical weights, detecting loads based on their rigidity, and configuring the sensor detection area and electrode area, by attaching an elastic spacer to the entire outer periphery of the gap between the two electrodes, which form the panel electrode on which the output lead wire is located and the switch electrode, and by creating a fluid function that prevents the air layer between the electrodes from being sealed by arranging air vents. [Explanation of symbols]

[0032] 10 Multi-contact weight mat sensor 11 Outer cover 12 Insulators 13 13S1, 13S2, 13S3, Panel electrode 14 14E1, 14E2, 14E3, Panel electrode 15 15S1, 15S2, Switch electrode 16 16E1, 16E2 Switch electrodes 17 17SE Switch electrode 18 Elastic outer edge spacer 19 Elastic frame spacer 20 Lead wire 20S, 20E, 21 Copper foil tape, copper conductive paste 22 Lead wire connection 23 Air vent 24 Lead wire opening 25 External equipment 27 Wooden Table 28 Bubble wrap 29 Aluminum composite material / PVC board 30 Danhall Box

Claims

1. A multi-contact weight mat sensor that detects only by weight applied to the entire detection area of ​​the sensor, characterized in that it has a structure with a multi-contact detection function that includes a plurality of panel electrodes made of an elastic material covered with an outer cover and coated with a conductor, a plurality of switch electrodes facing each other, and an elastic spacer attached to the gap between the electrodes.

2. The multi-contact weight mat sensor of claim 1, characterized in that it comprises panel electrodes S and E coated with a conductor at six locations (the four corners and the top and bottom centers) of the resin plate made of elastic material, copper foil tape with output lead wires attached to panel electrode S1 and panel electrode E1, a multi-contact switch electrode coated with a conductor at five locations on the surface of the resin plate facing the panel electrodes, a band-shaped elastic outer edge spacer attached to the gap around the entire outer edge between the electrodes, and a band-shaped elastic frame spacer with an air vent on part of the inside of the panel electrode, which are tightly attached to form a fluidity function that prevents the air in each air layer between the electrodes from being sealed by the air vent at the output line opening, thereby forming a structure with a multi-contact detection function between the two electrodes.

3. The multi-contact weight mat sensor of claims 1 and 2, characterized in that the elastic material used for the panel electrodes and the switch electrodes is any of polycarbonate, acrylic, polypropylene, PET, ABS, melamine, phenol, epoxy, vinyl chloride, urethane, aluminum composite, etc. to form the electrode surface, the conductor on the electrode surface is covered with a material with strong adhesion, and the material of the elastic spacer is a material with a uniform cell structure such as urethane, acrylic, urea, nitrile, silicone elastomer, styrene-based thermoplastic elastomer, fluororubber, natural rubber, etc.

4. A multi-contact weight mat sensor as described in claims 1 to 3, which has a structure corresponding to the load by configuring the thickness, vertical width, density, etc., of the resin plate of the panel electrode and the switch electrode, the electrode area to be detected, the number of contacts, and the elastic spacer using a cushioning material that has little compressive residual strain, excellent sagging, dimensional stability, thickness accuracy, etc., and has a detection value setting function.

5. The multi-contact weight mat sensor according to any one of claims 1 to 4, characterized in that it has a structure including a plurality of switch electrodes facing a plurality of panel electrodes, an elastic spacer, and an air vent, and is configured such that loads of the same weight that are smaller than the sensor's detection area are not detected, and loads larger than the sensor's detection area are detected. In the case of a hard load that does not deform, such as a cardboard box or a pallet, a load is applied evenly to the entire switch electrode plate and the entire elastic spacer, resulting in no deformation of the switch electrode plate and the remaining compression thickness of the elastic spacer, and the sensor is not detected. In the case of a soft load, such as a person, the load is not evenly applied to the switch electrode plate on the panel electrode layer and the elastic spacer surrounding the outer periphery of the panel electrode, so the sensor detects the load by the switch electrode plate, which has a small load capacity, bending when pressure is applied.

6. A multi-contact weight mat sensor as described in any one of claims 1 to 5, characterized in that a structure for detecting the weight of non-deformable loads such as cardboard boxes and pallets, which would otherwise be non-detectable, is constructed by forming bubble cushioning material on the multi-contact weight mat sensor, thereby forming a structure for detecting the weight of non-deformable loads such as cardboard boxes.

7. The contact configuration of the switch electrode facing the panel electrode is based on a 10-contact structure, and the multi-contact weight mat sensor described in any one of claims 1 to 6 is suitable for a wide range of uses by increasing or decreasing the number of contacts to suit the load applied to the sensor and the size of the detection area.

8. A multi-contact weight detection system comprising the multi-contact weight mat sensor according to any one of claims 1 to 7 and an external device that detects the conduction of electricity between the panel electrode and the switch electrode.

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