Discontinuous Conductive Pressure Sensor for Flexible Wearables

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Solution Overview

Problem

Conventional pressure sensors require complex manufacturing processes and limited material selection due to their reliance on piezo-resistive materials, restricting their diversity and applicability, especially in flexible and wearable applications that need high mechanical flexibility and stability.

Innovation Solution

A pressure sensor design featuring a first layer with conductive regions and a second layer, where the electrical conductivity of the conductive regions is the same as or greater than the second layer, utilizing materials like gold, silver, or graphitic materials, and a discontinuous pattern to enhance sensitivity and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If piezo-resistive materials are used to achieve pressure-dependent resistance, then pressure sensing function is achieved, but manufacturing process becomes complicated and material selection is limited

Engineering Contradiction:

Improvepressure sensing functionVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces piezo-resistive materials with a mechanical structure consisting of a flexible substrate with protrusions that contact a conductive layer. Pressure sensing is achieved through mechanical contact and separation of conductive elements rather than through resistance changes in piezo-resistive materials, simplifying manufacturing and expanding material choices.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the sensing mechanism from electrical resistance changes in piezo-resistive materials to mechanical position changes of conductive protrusions. By varying the contact state between protrusions and the conductive layer, the sensor achieves pressure-dependent electrical connection without requiring complex piezo-resistive materials.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If piezo-resistive materials are used to achieve pressure-dependent resistance, then pressure sensing function is achieved, but material selection is limited

Engineering Contradiction:

Improvepressure sensing functionVSAvoidmaterial selection diversity

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a universal pressure sensing platform that can work with various flexible substrate materials (polymers, elastomers) and conductive materials (metals, conductive polymers, carbon-based materials). This multi-material compatibility enables the sensor to be adapted for different applications including wearable devices and flexible electronics.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If a continuous conductive layer is used, then electrical conductivity is high, but sensitivity to pressure changes is reduced

Engineering Contradiction:

Improveelectrical conductivityVSAvoidpressure detection sensitivity

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent segments the conductive layer into discrete conductive protrusions on the flexible substrate. This segmentation creates multiple independent contact points that can respond to pressure changes, enhancing sensitivity while maintaining overall conductivity through the network of protrusions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates local variations in conductivity by positioning conductive protrusions at specific locations on the flexible substrate. The protrusions have high conductivity where they contact the conductive layer, while the rest of the substrate maintains flexibility. This local quality enhancement improves pressure detection sensitivity without compromising overall electrical performance.

Inventive Principle:

Principle #3Local quality

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 allows for high-performance pressure sensing with increased sensitivity and mechanical flexibility, enabling accurate detection of pressure intensity and position using a simple manufacturing process and diverse material selection, suitable for wearable and robotic applications.

Implementation Method 1

a first layer comprising at least one conductive region having first electrical conductivity; a second layer contacting the first layer to be disposed thereon and having second electrical conductivity

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS10503306B2Pressure sensor comprising layer of discontinuous conductive patterns, device comprising the same, and apparatus and method for detecting pressure

Publication Date: 2019.12.10 KOREA INST OF SCI & TECH

AI summary

Provided is a pressure sensor including: a first layer having first conductivity and at least one conductive region; a second layer contacting the first layer to be disposed thereon and having second conductivity; and a plurality of terminals that are electrically connected with the second layer and spaced apart from the at least one conductive region, wherein the at least one conductive region has electrical conductivity that is greater than or equal to that of the second layer.