Conductive Elastomer Sensor for Vulcanization Pressure Mapping
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Solution Overview
Problem
Current technologies for detecting pressure distribution during vulcanization processes are inadequate due to material limitations that cannot withstand high temperatures and pressures, and they require complex cabling and evaluation, making them unsuitable for applications like vulcanization and unable to record two-dimensional pressure distributions effectively.
Innovation Solution
A flexible sensor arrangement using electrically conductive elastomer material with conductive carbon black or carbon nanotubes, which can withstand high pressures and temperatures, and employs a resistance measurement principle to detect pressure distribution, reducing cabling costs and allowing for adaptation to uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pressure sensor materials are used to detect pressure distribution during vulcanization, then measurement capability is provided, but the materials cannot withstand the high temperature and pressure conditions of vulcanization processes
Solution Approach 1:
The patent changes the material parameters by using elastomer compounds with specific glass transition temperatures (Tg) below the vulcanization temperature, and by incorporating conductive fillers in specific concentrations to achieve both thermal stability and electrical conductivity. This allows the sensor material to withstand vulcanization conditions while maintaining measurement capability
Solution Approach 2:
The patent employs composite materials consisting of elastomer base materials combined with conductive fillers (carbon black, carbon nanotubes, or metal particles). This composite structure provides both the thermal/pressure resistance of the elastomer and the electrical conductivity needed for measurement, enabling reliable operation during vulcanization
2Measurement precision
If complex cabling and wiring are used for electrode connections in pressure measurement, then measurement accuracy is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the evaluation function from the physical sensor structure by using a single conductive elastomer layer that provides both sensing and signal transmission functions. The complex evaluation is performed digitally after measurement, separating the simple physical sensing from the complex data processing
Solution Approach 2:
The conductive elastomer layer serves multiple functions simultaneously: it acts as the pressure-sensitive element, provides electrical conductivity for signal transmission, and enables both capacitive and resistive measurement modes. This multi-functionality eliminates the need for separate wiring for different measurement functions
3Stability of the object's composition
If rigid sensor structures are used for pressure detection, then structural stability is maintained, but the sensor cannot adapt to uneven surfaces and tool contours
Solution Approach 1:
The patent uses thin film structures made of elastomeric materials that are inherently flexible and capable of conforming to uneven surfaces and tool contours. The thin film maintains structural integrity through its material properties while adapting to complex geometries, enabling pressure measurement on curved and irregular surfaces
4Measurement precision
If elastomeric materials with high electrical conductivity are used for pressure sensing, then sensitivity to pressure changes is improved, but electromagnetic compatibility issues and noise interference increase
Solution Approach 1:
The patent optimizes the electrical conductivity parameter by carefully controlling the type and concentration of conductive fillers in the elastomer. This creates a balanced state where the material is sufficiently conductive for sensitive pressure detection but not so conductive as to generate excessive electromagnetic interference or noise
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 solution provides a cost-effective and flexible means to accurately record pressure distributions in high-pressure and high-temperature environments, such as vulcanization processes, with improved sensitivity and reduced electromagnetic compatibility issues, enabling precise monitoring and optimization of vulcanization processes.
Implementation Method 1
The flexible sensor arrangement has an electrically conductive layer (4) made of an elastomer material with electrical conductivity. The electrical conductivity of the elastomer material changes under the influence of pressure applied in a direction perpendicular to the plane of the elastomer material.
Implementation Method 2
The elastomer material has a glass transition temperature (Tg) below the vulcanization temperature and has been modified with at least one conductivity additive, in particular with conductive carbon black or carbon nanotubes.
Data Source
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AI summary
The invention relates to a flexible sensor assembly (1) for sensing a pressure distribution, comprising a plurality of first contacting elements (31-35) and at least one second contacting element (51-55), preferably a plurality of second contacting elements (51-55), which are spaced apart from each other in the direction of a pressure application (Z) by an electrically conductive layer (4). The flexible sensor assembly (1) is characterized in that the electrically conductive layer (4) has at least one elastomer material.