3D Lattice Sensor Structure for Tunable Force-Resistance Response
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Solution Overview
Problem
Existing deformable sensors face limitations in adjusting resistance value changes relative to external forces due to restricted material choices, making it difficult to integrate them effectively in devices and ensure appropriate functionality.
Innovation Solution
A sensor design utilizing a three-dimensionally continuous unit lattice structure with both conductive and non-conductive elements, manufactured using a 3D printer, allows for adjustable repulsive force and resistance value changes based on compression, enhancing sensitivity and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If commercially available foamed materials or porous materials are used, then the sensor can be manufactured with simple materials, but it is difficult to adjust the amount of deformation caused by external forces
Solution Approach 1:
The patent changes the structural parameters of the sensor by introducing a lattice pattern with adjustable cell sizes, wall thicknesses, and geometric configurations. This allows the deformation characteristics to be tuned by modifying structural parameters rather than relying on material composition changes, thereby achieving both ease of manufacture and deformability adjustment.
Solution Approach 2:
The sensor body is segmented into a lattice structure composed of repeated unit cells. Each cell can deform independently, and the overall deformation characteristics are controlled by the number, size, and arrangement of these cells. This segmentation enables fine-tuning of deformation properties while maintaining manufacturing simplicity.
2Reliability
If the sensor uses a deformable structure to detect external forces, then the sensor can detect user motions, but the change in resistance value cannot be correctly set relative to the external force
Solution Approach 1:
The patent employs parameter changes by systematically varying the lattice geometry parameters (cell size, wall thickness, node configuration) to achieve desired resistance change characteristics. This allows precise control over the relationship between external force and resistance output without compromising detection reliability.
Solution Approach 2:
The sensor incorporates dynamic adjustment capabilities through variable lattice configurations that can adapt their structural properties. The lattice structure allows for progressive deformation stages, enabling the resistance value to change dynamically in response to different magnitudes of external force, thus achieving correct resistance setting across various operating conditions.
3Ease of manufacture
If the sensor is made with fixed material properties, then the manufacturing process is simple, but the repulsive force against compression cannot be adjusted
Solution Approach 1:
Instead of changing material properties, the patent changes structural parameters of the lattice configuration. By adjusting cell size, wall thickness, and geometric arrangement, the repulsive force characteristics are tuned while keeping the base material simple and easy to manufacture. This decouples material complexity from force adjustment requirements.
Solution Approach 2:
The patent transitions from considering only material properties (one dimension) to incorporating structural geometry (additional dimensions). The lattice structure introduces spatial dimensions for adjustment, allowing repulsive force to be controlled through geometric parameters rather than material composition, thereby maintaining manufacturing simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sensor accurately detects and responds to external forces with high precision, enabling precise resistance value changes and improved user interaction, adaptable to various devices and uses.
Implementation Method 1
the resistance value changing at least when the conductive structure is compressed by an external force
Implementation Method 2
forming the sensor section by stacking using a 3D printer
Data Source
AI summary
A sensor includes: a sensor section including a conductive structure made up of a three-dimensionally continuous unit lattices, each including a plurality of columnar beams; and output connectors that output a resistance value of the sensor section, the resistance value changing at least when the conductive structure is compressed by an external force. A method for manufacturing a sensor includes forming the sensor section by stacking using a 3D printer. The sensor and method for manufacturing the sensor enable the adjustment of the repulsive force against compression to an input member and thus appropriately setting the change in resistance value against external force according to the device, in which the sensor is to be incorporated and the mode of use.