Conformable Conductive Sheets for Industrial Roll Sensors
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Solution Overview
Problem
Existing papermaking rolls face challenges with sensor durability under high dynamic loads and aggressive chemical environments, particularly due to the unsupported sections of conductive material in pressure sensors which can lead to catastrophic failure.
Innovation Solution
A papermaking roll design featuring piezoelectric sensors with a substrate and electrodes where the conductive material is attached to the side surface, forming a gap that reduces the risk of unsupported sections, and a processor to process signals from these sensors, ensuring reliable pressure and temperature monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pressure sensors with unsupported conductive material sections are used in papermaking rolls, then the sensors can detect pressure and provide position information, but the unsupported sections are susceptible to catastrophic failure under high dynamic loads and aggressive chemical environments
Solution Approach 1:
The conductive material is extended from a planar configuration into the third dimension by forming it into a three-dimensional lattice structure. This lattice structure provides multiple support paths and distributes mechanical stresses throughout the volume, eliminating unsupported sections while maintaining electrical connectivity. The dimensional transformation from 2D to 3D architecture fundamentally resolves the susceptibility to catastrophic failure.
Solution Approach 2:
The conductive material is configured as a flexible lattice structure that can deform elastically under dynamic loads while maintaining its structural integrity. The lattice geometry provides inherent flexibility and compliance, allowing the sensor to withstand high dynamic loads and aggressive chemical environments without catastrophic failure, while the conductive properties are maintained through the lattice framework.
2Adaptability or versatility
If the entire metallic roll is replaced to improve performance characteristics, then the roll can meet different performance demands, but the replacement cost is quite expensive
Solution Approach 1:
The roll is segmented into a permanent metallic core and a replaceable polymeric cover with embedded sensors. The core provides structural integrity and mechanical strength, while the cover can be replaced to change performance characteristics such as surface hardness, chemical resistance, or friction properties. This segmentation allows selective replacement of only the cover and sensor assembly rather than the entire roll, significantly reducing replacement costs.
Solution Approach 2:
The metallic core serves as a universal platform that can support multiple different polymeric cover configurations for different papermaking applications. The same core can be reused with different covers optimized for pressing, drying, or other functions, making the system multi-functional and economically efficient.
3Measurement precision
If pressure sensors are embedded in the polymeric cover to monitor pressure profile, then the quality of paper produced can be improved, but the sensors are exposed to demanding environments with high dynamic loads and aggressive chemicals
Solution Approach 1:
The pressure sensors are nested within the polymeric cover, which itself is nested on the metallic core. The polymeric cover acts as a protective shell that shields the embedded sensors from direct exposure to aggressive chemicals and extreme mechanical loads. The sensors operate in a more benign environment within the cover while still measuring the pressure profile accurately through the cover material.
Solution Approach 2:
The polymeric cover serves as an intermediary between the pressure sensors and the harsh external environment. It transmits pressure information to the sensors while protecting them from chemical degradation and mechanical damage. The cover material is selected to be compatible with both the sensors and the papermaking environment, mediating the interaction between the sensing system and the process conditions.
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 design enhances sensor durability and accuracy by preventing catastrophic failure, allowing for precise pressure profiling and improved paper quality under demanding conditions.
Implementation Method 1
a substantially cylindrical core having an outer surface and an internal lumen; a polymeric cover circumferentially overlying the core outer surface; and a sensing system comprising: a plurality of piezoelectric sensors at least partially embedded in the cover
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
An industrial roll includes: a substantially cylindrical core having an outer surface and an internal lumen; a polymeric cover circumferentially overlying the core outer surface; and a sensing system. The sensing system includes: a plurality of sensors at least partially embedded in the cover, the sensors configured to sense an operating parameter of the roll and provide signals related to the operating parameter; and a processor operatively associated with the sensors that processes signals provided by the sensors. Each of the plurality of sensors includes: a first electrode overlying the top surface of a substrate and a second electrode underlying the bottom surface of the substrate, wherein the first electrode overlies the top surface of the substrate and the second electrode underlies only a portion of the bottom surface of the substrate, thereby forming a gap adjacent the bottom surface and a side surface of the substrate; a first sheet of conductive material attached to the first electrode and the side surface of the substrate and extended in a first direction away from the bottom surface of the substrate; and a second sheet of conductive material attached to the second electrode and extended in a second direction away from the bottom surface of the substrate, the second surface being opposite the first direction.