Segmented-Electrode Dielectric Sensor for Resin Flow Direction
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Solution Overview
Problem
Existing resin flow monitoring technologies, such as fiber optic and capacitive sensors, are costly, fragile, and require multiple sensors to monitor resin flow direction, increasing complexity and maintenance costs in the liquid composite molding process.
Innovation Solution
A dielectric sensor with a top and bottom electrode design, featuring distinct regions and dual signal channels, allows for single-sensor monitoring of resin flow direction using capacitance signal changes, reducing the need for multiple sensors and simplifying the monitoring system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to monitor resin flow direction, then monitoring capability is improved, but system complexity and cost increase
Solution Approach 1:
The top electrode is segmented into multiple regions (first region, second region, third region, fourth region) with different numbers of second electrical conductors. This segmentation creates directional sensitivity within a single sensor, allowing it to distinguish resin flow direction from multiple directions without requiring multiple separate sensors.
Solution Approach 2:
Multiple sensing functions are merged into a single dielectric sensor. The sensor integrates both magnitude detection and directional detection capabilities by combining the bottom electrode with multiple top electrode regions, replacing what would traditionally require multiple separate sensors.
2Measurement precision
If fiber optic sensors are used for resin flow monitoring, then monitoring accuracy is improved, but cost and fragility increase
Solution Approach 1:
The patent uses a simple dielectric sensor structure with basic electrical conductors and insulating layers, replacing expensive and fragile fiber optic sensors. The sensor uses conventional materials and manufacturing methods, making it more robust and cost-effective while maintaining monitoring functionality.
3Ease of manufacture
If traditional capacitive sensors are used, then cost is reduced, but directional monitoring capability is lost
Solution Approach 1:
Different regions of the top electrode have different configurations of second electrical conductors. The first region has a different number of conductors than the second region, and the third region has a different number than the fourth region. This local variation in electrode structure provides directional information while maintaining the simple and cost-effective capacitive sensor design.
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 dielectric sensor effectively monitors resin flow direction, reducing costs and complexity while improving production efficiency and product quality by detecting abnormalities like uneven filling and voids, ensuring stable and consistent resin flow.
Implementation Method 1
monitoring a capacitance signal change characteristic of the dielectric sensor to reflect the resin flow direction
Implementation Method 2
a dielectric sensor capable of identifying a resin flow direction... a composite layer between the top electrode and the bottom electrode
Data Source
AI summary
The disclosure provides a dielectric sensor capable of identifying a resin flow direction and a preparation method and an application thereof are provided. The dielectric sensor includes a bottom electrode being a first electrical conductor in a shape of a continuous pattern and a top electrode located within an outer contour of the continuous pattern and divided into an upper, a lower, a left and a right regions, provided with second electrical conductors arranged at intervals in the same region. A first wire connects the second electrical conductors in the left and right regions to form a first signal channel, and a second wire connects the second electrical conductors in the upper and lower regions to form a second signal channel.