Flexible Pressure Mapping Device with Porous Layered Structure
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Solution Overview
Problem
Flexible pressure mapping devices used for monitoring pressure, such as insoles, face challenges with durability and reliability due to high mechanical stress from repeated bending, necessitating an improvement in design to maintain mechanical integrity while reducing costs.
Innovation Solution
A flexible pressure mapping device is designed with a layered structure comprising a flexible upper and lower sheet, a middle insulating sheet, and a network of force sensors, featuring specific electrode and conductive lead arrangements, along with overcoat sheets to enhance mechanical resistance and flexibility, and integrated with control and transmit electronics for data communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flexible pressure mapping device is made with continuous sheets and no openings, then mechanical strength and structural integrity are improved, but flexibility and ability to follow body movements deteriorate
Solution Approach 1:
The patent applies the porous materials principle by introducing a controlled array of openings (windows) in the flexible sheets. These openings create a porous-like structure that allows the device to bend and flex more easily while maintaining structural integrity through the remaining material framework. The openings reduce material continuity constraints, enabling the device to adapt to body movements without compromising overall strength.
Solution Approach 2:
The patent employs composite materials by combining multiple layers (upper flexible sheet, lower flexible sheet, middle insulating sheet) with different material properties. Each layer serves specific functions: the flexible sheets provide mechanical strength and flexibility, while the middle insulating sheet provides electrical insulation. This composite structure allows the device to simultaneously achieve flexibility for movement adaptation and sufficient strength for mechanical durability.
2Ease of manufacture
If a flexible pressure mapping device is made with simplified structure and fewer components, then manufacturing cost is reduced, but reliability and durability under mechanical stress deteriorate
Solution Approach 1:
The patent applies segmentation by dividing the device into distinct functional modules: upper flexible sheet with electrodes, middle insulating sheet, lower flexible sheet with electrodes, and overcoat layers. Each segment is optimized for its specific function and can be manufactured separately using cost-effective techniques, then assembled into a reliable complete device. This modular approach balances manufacturing simplicity with structural reliability.
Solution Approach 2:
The patent implements local quality by providing enhanced protection (overcoat sheets) only in specific high-stress areas where durability is most critical, rather than uniformly protecting the entire device. The middle insulating sheet is strategically placed only between electrode regions where electrical isolation is needed. This localized approach reduces overall material usage and cost while maintaining reliability where it matters most.
3Reliability
If a flexible pressure mapping device includes multiple protective layers and complex structure, then durability and mechanical resistance are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent employs flexible shells and thin films by using thin flexible sheets with integrated electrode patterns and printed conductive traces. These thin-film structures provide the necessary mechanical protection and electrical functionality without adding significant bulk or complexity. The flexible nature of these thin films allows them to conform to body surfaces while maintaining durability through repeated bending cycles.
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 increases the durability and flexibility of the pressure mapping device, allowing it to withstand mechanical stress while maintaining mechanical integrity, thus improving reliability and reducing costs, enabling effective pressure monitoring applications.
Implementation Method 1
a plurality of force sensors comprising at least one upper electrode on the upper sheet and at least one lower electrode on the lower sheet, said at least one upper electrode facing said at least one lower electrode and being separated from said lower electrode at least by the middle sheet
Data Source
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AI summary
A flexible pressure mapping device (1) comprising flexible upper sheet and lower sheet facing one another with a flexible middle sheet between the upper sheet and the lower sheet, force sensors (10) with upper electrodes on the upper sheet and lower electrodes on the lower sheet separated by the middle sheet, control and transmit electronics (14) electrically connected to electrodes by conductive leads (11). The upper sheet comprises upper openings (70) and the lower sheet at least partially overlaps at least one of said upper openings (70)