Fabric-Based Flexible Pressure Sensor Array for 3D Surface Conformity
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Solution Overview
Problem
Traditional flexible pressure sensors on plastic foils are unreliable when applied to soft surfaces due to cracking from twisting or flexing, and struggle to conform to three-dimensional objects with curved surfaces.
Innovation Solution
A flexible pressure sensor array made from a fabric substrate with piezoresistive material, where the fabric is divided into filling and non-filling portions, and electrodes are stitched or attached to create pressure-sensing columns with top and bottom surfaces, allowing for electrical separation and adherence to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If printed pressure sensors are made on plastic foils to achieve flexibility, then the sensors become flexible, but the electrodes and pressure sensitive material crack when twisted or flexed
Solution Approach 1:
The patent replaces rigid plastic foil substrates with flexible fabric substrates that can bend and twist without cracking. The fabric substrate acts as a flexible shell that maintains structural integrity while allowing the sensor array to conform to curved surfaces and withstand mechanical deformation.
Solution Approach 2:
The patent uses composite construction by integrating conductive yarns with fabric substrate, and combining piezoresistive material with flexible housing. This composite approach combines the flexibility of fabric with the conductivity of metal yarns and the sensing capability of piezoresistive material, creating a reliable flexible sensor system.
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 a reliable, flexible pressure sensor array that can conform to 3D surfaces, maintaining flexibility and accuracy in pressure mapping, with improved durability and cost-effectiveness in fabrication.
Implementation Method 1
a piezoresistive material
Data Source
AI summary
The present disclosure provides a flexible pressure sensor array and method for fabricating the same. The pressure sensor array comprises a pressure-sensing substrate, top electrodes and bottom electrodes. The pressure-sensing substrate comprises a piezoresistive material, a fabric and pressure-sensing columns. The top electrodes and the bottom electrodes are attached to the pressure-sensing columns. The pressure sensor array is ultra-flexible and conforms to 3-dimensional surface for pressure monitoring.