Conductive Composite Contact Sensors for Dynamic Surface Load Mapping
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Solution Overview
Problem
Contact sensors struggle to accurately measure dynamic contact data between complex surfaces, as film-based sensors introduce foreign materials that alter contact characteristics and fail to provide real-time data, especially in medical and industrial applications where complex curvatures are involved.
Innovation Solution
The development of contact sensors using an electrically conductive composite material comprising a polymer and a conductive filler, which can be thermoformed to replicate the shape of the surfaces, allowing for accurate measurement of contact data without altering the contact dynamics, and can be integrated into the surface to provide real-time data on load, stress, and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If film-based contact sensors are used to measure contact between surfaces, then contact data can be gathered, but the foreign material between surfaces alters contact characteristics and overestimates contact areas
Solution Approach 1:
The invention extracts the sensing function from a separate film material and integrates it directly into the surface of one of the mating components. The contact sensor is formed as an integral part of the first member, eliminating the need for a separate film that would interfere with the contact. This is achieved by incorporating conductive material into the surface of the first member, allowing contact area and pressure measurement without introducing foreign material between the surfaces.
Solution Approach 2:
The invention merges the structural component with the sensing function. The first member serves both as a structural element and as the contact sensor. The conductive material is integrated into the surface of the first member, combining the mechanical function of the component with the measurement function, thereby eliminating the need for separate sensing film.
2Measurement precision
If film-based contact sensors are used, then static contact characteristics can be examined, but real-time dynamic contact characteristics cannot be measured
Solution Approach 1:
The invention replaces the passive mechanical film-based sensing system with an active electrical sensing system. Conductive materials and electrical circuits are used to detect contact dynamically in real-time. The conductive material in the first member forms electrical connections that can be monitored to determine contact area and pressure distribution dynamically, enabling real-time measurement of contact characteristics.
3Adaptability or versatility
If complex curvature surfaces are examined with film sensors, then contact data can be obtained, but it is difficult to conform the films to fit the surfaces without degrading sensor performance
Solution Approach 1:
The sensing capability is built into the component during manufacturing, before the component is put into service. The conductive material is incorporated into the surface of the first member during its fabrication process, so the sensor is pre-configured to match the specific geometry of the component. This eliminates the need to conform a separate film to the surface later, preserving both the surface geometry and sensor performance.
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
These sensors provide precise and dynamic contact information, reducing wear and improving the longevity of materials and implants by accurately replicating the surface characteristics and providing real-time data on contact conditions, thus enhancing the performance and lifespan of machined parts and medical implants.
Implementation Method 1
an electrically conductive composite material comprising a polymer and a conductive filler... The sensor can be formed entirely of the composite material... configured to measure current flow therethrough the sensing point during application of a load
Implementation Method 2
the contact sensors can be thermoformed into a desired substantially inflexible three-dimensional shape... a surface of the contact sensors of the invention can be formed to be substantially inflexible so as to replicate a surface
Data Source
AI summary
Disclosed herein are novel contact sensors. The contact sensors disclosed herein include a conductive composite material formed of a polymer and a conductive filler. In one particular aspect, the composite materials can include less than about 10 wt % conductive filler. Thus, the composite material of the contact sensors can have physical characteristics essentially identical to the polymer, while being electrically conductive with the electrical resistance proportional to the load on the sensor. The sensors can provide real time dynamic contact information for joint members under conditions expected during use.