System and method of in-place functionalization of 3D regions and arrays thereof, in VLAP cushions, as integrated VLAP pressure sensing cushions
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Solution Overview
Problem
Existing cushioning support apparatuses often require pressure detection functionality without compromising their primary cushioning function, and discrete pressure sensing cushions are desired for precise pressure profiling and distribution analysis.
Innovation Solution
Integration of flexible, in-place functionalized sensors on compressible nonwoven materials, such as VLAP nonwoven material, using conductive polymers to form columnar pressure varying electrical conductance (PVEC) devices within the cushion, allowing for pressure distribution monitoring and analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If discrete pressure sensing cushions are distributed throughout the cushioning support apparatus, then measurement precision of pressure profiles is improved, but device complexity increases
Solution Approach 1:
The patent combines pressure sensing functionality with the cushioning material itself by integrating conductive polymer particles into the sponge matrix. This merging eliminates the need for separate discrete pressure sensing cushions while achieving precise pressure profile measurements across the entire surface, thereby improving measurement precision without proportionally increasing device complexity
Solution Approach 2:
The conductive polymer-infused sponge material serves multiple functions simultaneously: it provides cushioning support while also functioning as a pressure sensing element. This multi-functionality allows the same material to replace both the structural cushioning component and the pressure detection component, reducing overall device complexity while maintaining measurement precision
2Ease of manufacture
If sponge-type materials are used for pressure detection, then ease of manufacture is improved, but adaptability to non-cushioning applications deteriorates
Solution Approach 1:
The conductive polymer-infused material serves dual purposes as both cushioning support and pressure sensing element, making it adaptable to various applications including seats, mattresses, and medical devices. This universality allows the same manufactured component to fulfill multiple functional requirements across different application contexts
Solution Approach 2:
The patent uses composite materials combining conventional sponge or nonwoven substrates with conductive polymer particles. This composite approach maintains the cushioning properties of the base material while adding pressure sensing capabilities, thereby improving adaptability to diverse applications without sacrificing ease of manufacture
3Ease of manufacture
If conductive polymer is applied as surface coating only, then ease of manufacture is improved, but measurement precision of pressure distribution deteriorates
Solution Approach 1:
The patent utilizes the porous structure of sponge or nonwoven materials to embed conductive polymer particles throughout the three-dimensional volume of the material. This volumetric distribution within pores allows precise measurement of pressure at multiple depths and locations, significantly improving pressure distribution measurement precision compared to surface-only coating while remaining manufacturable through simple immersion or infiltration processes
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 precise pressure distribution monitoring and analysis, enhancing comfort and posture sensing in applications like smart mattresses and seating surfaces by maintaining flexibility and breathability while detecting pressure points effectively.
Implementation Method 1
forming within a three-dimensional (3D) target region of the CNM cushion a columnar distribution of non-solidified conductive polymer... converting the columnar distribution of non-solidified conductive polymer into a columnar compressible pressure varying electrical conductance structure
Data Source
AI summary
Methods include functionalizing, into a compressible pressure varying electrical conductance device, a portion of a compressible nonwoven material (CNM) cushion. A process includes forming within a three-dimensional (3D) target region of the CNM cushion a columnar distribution of non-solidified conductive polymer, and converting the columnar distribution of non-solidified conductive polymer into a columnar compressible pressure varying electrical conductance structure. The columnar distribution of non-solidified conductive polymer extends along a column axis. Forming the columnar distribution includes injecting into at least a portion of the 3D target region a liquid carrying conductive polymer in suspension. The columnar compressible pressure varying electrical conductance structure includes mutually separated masses of solidified conductive polymer respectively supported by mutually separated flexible fibers of the compressible nonwoven material. Optionally, forming the columnar distribution of non-solidified conductive polymer includes a first injection followed by partial drying, and a second injection.