Deformation Detection Sensor Using Hot-Pressed Thermoplastic Resin
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Solution Overview
Problem
The increasing demand for downsized electronic components in portable devices poses a challenge as they require more components to be mounted, necessitating a deformation detection sensor that can function as both a transmission line and perform additional functions while maintaining flexibility and avoiding heat application to sensitive piezoelectric films.
Innovation Solution
A deformation detection sensor is created using a conductive member and thermoplastic resin layers laminated by hot pressing, with a piezoelectric film attached afterwards to form a piezoelectric element, allowing the sensor to integrate transmission line and deformation detection capabilities without exposing the piezoelectric film to high heat during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the piezoelectric film is attached to the thermoplastic resin layers before hot pressing, then the manufacturing process is simplified, but the piezoelectric film is exposed to high heat which damages its integrity and performance
Solution Approach 1:
The conductive member is formed on the thermoplastic resin layer before lamination, and the piezoelectric film is attached after lamination but before final hot pressing. This sequencing of operations ensures that the piezoelectric film is not exposed to high heat during the hot pressing process, while still allowing the thermoplastic resin layers to be properly bonded. The preliminary formation of the conductive member and subsequent attachment of the piezoelectric film creates a manufacturing sequence that protects the piezoelectric film from heat damage while maintaining process efficiency.
2Volume of moving object
If multiple electronic components are mounted to achieve downsizing, then the device size is reduced, but the number of components increases making the structure more complex
Solution Approach 1:
The deformation detection sensor combines multiple functions into a single integrated component: it serves as both a transmission line for signal transmission and as a deformation detection element with piezoelectric properties. The thermoplastic resin layers provide both mechanical support and electrical insulation, while the conductive member and piezoelectric film work together to detect deformation and transmit signals. This merging of transmission line and deformation detection functions into one sensor assembly reduces the overall number of components needed in the device while maintaining compact size.
Solution Approach 2:
The deformation detection sensor is designed as a multi-functional component that simultaneously performs signal transmission through the thermoplastic resin layers and deformation detection through the piezoelectric film. This universal design allows a single component to replace what would traditionally require separate transmission line and sensor elements, thereby reducing device complexity while achieving downsizing.
3Ease of manufacture
If the thermoplastic resin layers are not integrally formed by hot pressing, then the manufacturing process is simpler, but the structural stability and flexibility of the sensor is compromised
Solution Approach 1:
The thermoplastic resin layers are heated to a specific temperature range during hot pressing to achieve proper lamination and bonding. This controlled temperature parameter change allows the resin layers to melt slightly and bond together, forming a structurally stable integrated body while maintaining flexibility. The hot pressing process applies both heat and pressure simultaneously, creating strong interlayer bonding without compromising the flexible nature of the thermoplastic resin, thus achieving both structural stability and manufacturability.
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 solution enables a sensor that functions as both a transmission line and performs additional functions, maintaining flexibility and stability, while ensuring the piezoelectric film is not subjected to high heat, thus preserving its integrity and performance.
Implementation Method 1
the plurality of thermoplastic resin layers are laminated and integrally formed by hot pressing into a laminated body
Implementation Method 2
a piezoelectric film is attached to the laminated body to form a piezoelectric element
Data Source
AI summary
A method for manufacturing a deformation detection sensor that includes: preparing a plurality of thermoplastic resin layers, at least one of which has a main surface on which a conductive member is formed; laminating the plurality of thermoplastic resin layers; after lamination, integrally forming the plurality of thermoplastic resin layers by hot pressing to obtain a laminated body configured so that a transmission line is formed from a first portion of the conductive member and the laminated body; and attaching a piezoelectric film to the laminated body so that a piezoelectric element is formed from a second portion of the conductive member, the laminated body, and the piezoelectric film.