Flexible Thin-Film Blunt Force Sensor Array for Non-Planar Surfaces
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Solution Overview
Problem
Conventional force sensors are too large for space-constrained testing environments, such as helmet testing, and their presence can alter the measurements being taken, particularly in blunt trauma testing where precise force detection on non-planar surfaces like the skull is required.
Innovation Solution
A flexible thin-film substrate-based blunt force sensor array with multiple force sensors and a strain gauge, connected via traces on the substrate, allowing for precise force and strain measurement on non-planar surfaces, and a method for subdermal implantation to improve measurement accuracy and reduce placement errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional force sensors are used, then measurement capability is provided, but sensor size is too large for space-constrained environments and alters measurements
Solution Approach 1:
The sensor system is divided into multiple discrete force sensing elements (first force sensor, second force sensor, third force sensor) distributed across the impact surface. Each sensor is small in size, but collectively they provide comprehensive force measurement coverage, resolving the contradiction between small individual sensor size and comprehensive measurement capability
Solution Approach 2:
Multiple force sensors and strain gauges are integrated onto a single flexible substrate that conforms to the impact surface. This merging of multiple sensing elements into one flexible assembly provides complete force measurement coverage while maintaining small individual sensor sizes, eliminating measurement alteration effects
2Measurement precision
If sensors are placed in space-constrained environments, then measurement capability is achieved, but placement precision deteriorates due to difficulty in accurate positioning
Solution Approach 1:
The flexible substrate serves multiple functions: it provides a common mounting platform for all force sensors and strain gauges, enables conformation to curved surfaces, and facilitates simultaneous placement of multiple sensors. This universal platform approach eliminates individual placement errors and ensures precise relative positioning of all sensing elements
Solution Approach 2:
A flexible substrate is used to mount the force sensors and strain gauges, allowing the entire sensor array to conform to the curved impact surface. This flexible mounting approach simplifies placement by treating all sensors as a single adaptable unit, thereby improving placement precision while maintaining measurement accuracy on non-planar surfaces
3Measurement precision
If multiple sensors are used to improve measurement accuracy, then measurement precision improves, but device complexity increases
Solution Approach 1:
Multiple force sensors and strain gauges are merged onto a single flexible substrate with integrated wiring and signal conditioning. This merging approach provides comprehensive force and strain measurement capability while presenting a single, manageable device interface, thereby improving measurement precision without proportionally increasing operational complexity
Solution Approach 2:
The flexible substrate and associated electronics provide multiple sensing functions (force measurement at multiple points, strain measurement) through a single integrated platform. This multi-functionality allows comprehensive measurement capability while simplifying the overall device structure and reducing the complexity of handling multiple separate sensor systems
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 flexible sensor array can accurately detect forces and strains on non-planar surfaces without significantly affecting the measurements, enhancing test repeatability and providing detailed force propagation analysis, including potential health effects from blunt trauma.
Implementation Method 1
a strain gauge secured on the flexible thin-film substrate proximate to the center measurement point
Data Source
AI summary
A blunt force sensor array for application to a non-planar surface includes a flexible thin-film substrate, a plurality of force sensors secured to the flexible thin-film substrate proximate to a center measurement point, a strain gauge secured on the flexible thin-film substrate proximate to the center measurement point, and a sensor interface configured to connect to external measurement and control circuitry. The sensor interface may be electrically connected to each of the force sensors and the strain gauge via traces disposed on the flexible thin-film substrate. The flexibility and shape of the flexible thin-film substrate may permit the blunt force sensor array to be applied to the non-planar surface to detect forces and strains experienced by the non-planar surface in response to a blunt force event on the non-planar surface.