Coaxial Pressure Sensor Structure for Bending Without Spacers
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Solution Overview
Problem
Pressure sensitive sensors with hollow helical structures face increased production costs and limited bending performance due to complex manufacturing processes and material requirements.
Innovation Solution
A pressure sensitive sensor design featuring a first conductive member, a second conductive member, and an insulating member with elasticity, allowing for coaxial arrangement and relative movement to absorb expansion and contraction differences, eliminating the need for spacers and enhancing bending performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hollow helical structure with spacers is used to maintain conductor separation, then insulation reliability is improved, but manufacturing complexity and production cost increase
Solution Approach 1:
The patent removes the spacer component from the sensor structure entirely. Instead of using a separate spacer to maintain separation between conductive layers, the design relies on the self-supporting hollow helical structure of the conductive members themselves, which inherently maintain the required geometric relationship without additional components.
Solution Approach 2:
The patent combines the structural support function and the conductive function into a single integrated component. The hollow helical conductive member serves both as the electrical conductor and as the structural element that maintains separation from other conductive layers, eliminating the need for a separate insulating spacer.
2Stability of the object's composition
If spacers are used to form the hollow structure, then structural stability is improved, but material cost and processing cost increase
Solution Approach 1:
The spacer material is completely removed from the design. The hollow structure is formed directly by the conductive member itself through a single extrusion process, eliminating the need for separate spacer materials and the complex multi-step manufacturing process required to assemble conductors around spacers.
Solution Approach 2:
The patent changes the manufacturing approach from a multi-step assembly process involving spacers to a single-step extrusion process. This parameter change in the manufacturing method directly reduces both material costs (by eliminating spacer materials) and processing costs (by reducing the number of manufacturing steps).
3Manufacturing precision
If the sensor has a rigid internal structure with spacers, then manufacturing precision is improved, but bending performance deteriorates
Solution Approach 1:
The patent introduces dynamic flexibility to the sensor structure by using elastic insulating material that allows relative movement between conductive layers. This enables the sensor to adapt to bending deformations while maintaining electrical insulation, combining positioning precision with bending adaptability.
Solution Approach 2:
The patent changes the mechanical properties of the insulating material to be elastic rather than rigid. This parameter change allows the insulating layer to deform with the sensor during bending while maintaining its insulating function, thus improving bending performance without sacrificing conductor positioning precision.
4Reliability
If multiple spacers and complex assembly processes are used, then insulation performance is improved, but production time increases
Solution Approach 1:
The patent segments the manufacturing process into a single integrated extrusion step rather than multiple separate assembly steps. The hollow helical conductive member and insulating material are formed together in one continuous process, dramatically reducing production time while maintaining insulation performance.
Solution Approach 2:
The patent performs the insulation structure formation in advance during the extrusion process itself, rather than adding spacers as a separate post-processing step. The insulating material is incorporated into the structure during its primary formation, eliminating subsequent assembly operations and accelerating production.
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 configuration reduces manufacturing costs and ensures improved bending performance by allowing for easier assembly and deformation management without the use of spacers, while maintaining conductivity and insulating properties.
Implementation Method 1
an insulating member having an insulating property and elasticity, the insulating member holding the first conductive member to separate the first conductive member from the second conductive member
Implementation Method 2
the insulating member is movable relative to at least one of the first conductive member and the second conductive member. Thus, the differences in expansion and contraction between the first conductive member and the second conductive member generated when the pressure sensitive sensor is bent can be easily absorbed by the above-described relative movement
Data Source
AI summary
A pressure sensitive sensor includes: a first conductive member formed into a long shape, the first conductive member having conductivity and elasticity; a second conductive member internally including a long space to arrange the first conductive member, the second conductive member having conductivity and elasticity; and an insulating member having an insulating property and elasticity, the insulating member holding the first conductive member to separate the first conductive member from the second conductive member, the insulating member being movable relative to one or both of the first conductive member and the second conductive member.