Adjustable Pressure Array Sensor Module for Flexible Manufacturing

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Solution Overview

Problem

The existing screen printing process for manufacturing pressure array sensor modules is time-consuming and costly, as each design change requires re-designing screens and repeating the printing process multiple times, making it difficult to customize or adjust the density of sensing elements efficiently.

Innovation Solution

A pressure array sensor module with an array electrode board and pressure sensing elements, where the electrode patterns are adjustable, allowing for independent placement and connection of sensing elements without re-manufacturing screens, and a monitoring system with a control module and voltage detecting unit to detect changes in resistance for collision or self-detection loops.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the screen printing process is used to manufacture pressure array sensor modules, then the electrode layer, pressure sensing layer and adhesive layer can be printed on a substrate, but when the density of sensing elements needs to be customized or adjusted, all screens need to be re-designed and the screen printing process need to be repeated three times again, which involves considerable time and cost

Engineering Contradiction:

Improvecustomization of sensing element densityVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent divides the electrode board into a fixed electrode board with pre-formed electrode patterns and movable pressure sensing elements that can be independently positioned. This segmentation allows the sensing elements to be repositioned or replaced without re-manufacturing the entire electrode board, enabling customization of sensing element density without time-consuming screen re-design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces movable or relocatable pressure sensing elements that can be dynamically repositioned on the fixed electrode board. This dynamic capability allows the sensing element density to be adjusted by changing their positions rather than re-manufacturing screens, significantly reducing the time and cost associated with customization

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

Engineering Contradiction:

Improvecustomization of sensing element densityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent separates the fixed electrode board from the movable pressure sensing elements, allowing only the sensing elements to be repositioned or replaced for customization. This reduces manufacturing cost compared to re-designing and re-manufacturing all three screens (electrode, pressure sensing, and adhesive layers) in the traditional screen printing process

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The movable pressure sensing elements enable dynamic adjustment of sensing element density without requiring expensive screen re-design and re-manufacturing. This dynamic repositioning capability significantly reduces the cost of customization while maintaining manufacturing flexibility

Inventive Principle:

Principle #15Dynamics

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

This approach reduces manufacturing time and cost by allowing for flexible adjustment of sensing element density and placement, while enabling efficient detection of pressure changes and surface collisions or contacts through the monitoring system.

Implementation Method 1

Pressure sensor is mainly used to detect a pressure which generates a stress on an element. The pressure array sensing technology can be used to detect the change in the distribution and geometric gradient of pressure when an element receives a pressure.

Methodology Applied

Scientific EffectPiezoresistive effect: Piezoresistive Effect

Data Source

PatentUS9651434B2Pressure array sensor module and manufacturing method thereof and monitoring system and monitoring method using the same

Publication Date: 2017.05.16 IND TECH RES INST

AI summary

A pressure array sensor module including an array electrode board, a plurality of pressure sensing elements, at least one first conductive structure and at least one second conductive structure is provided. The array electrode board includes a substrate and an array electrode. The array electrode, disposed on the substrate, has a first electrode pattern and a second electrode pattern. Each pressure sensing element, disposed on a sensing position of the array electrode board, includes a top electrode layer, a bottom electrode layer and at least one pressure sensing layer disposed between the top and bottom electrode layers. The top electrode layer has a first lead. The bottom electrode layer has a second lead. The first conductive structure is electrically connected between each first lead and a corresponding first electrode pattern. The second conductive structure is electrically connected between each second lead and a corresponding second electrode pattern.