Flexible Pressure Sensor for Headwear Fit Analysis
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Solution Overview
Problem
Existing pressure sensors struggle to accurately measure head and facial wearing pressure due to their inflexibility and inability to conform to large curved surfaces, leading to inaccurate pressure distribution readings.
Innovation Solution
A device comprising a human head model with a hard bottom shell and flexible skin layer, equipped with a flexible pressure sensor featuring interlaced conductive threads that form pressure detection points, allowing direct contact with the wearable device for precise pressure measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If regular-shaped pressure sensors are used, then manufacturing is simplified, but they cannot meet customization requirements with high degrees of freedom for curved facial surfaces
Solution Approach 1:
The pressure sensor is divided into multiple independent sensing points arranged in an array, where each sensing point can be independently positioned and shaped. This segmentation allows the overall sensor to be customized for complex curved surfaces while each individual sensing point maintains a simple structure for ease of manufacture.
Solution Approach 2:
The pressure sensor transitions from a single-plane regular shape to a three-dimensional conformal structure that can wrap around curved facial surfaces. By adding the dimension of spatial flexibility and using multiple sensing points at different positions and orientations, the sensor achieves high adaptability to various surface geometries.
2Measurement precision
If PET film printed carbon-based silver paste circuits are used, then manufacturing is easier, but they cannot meet the softness, accuracy, and fit requirements for large curved facial surfaces
Solution Approach 1:
The pressure sensor uses a flexible substrate with thin-film conductive traces instead of rigid PET film with printed paste. This flexible thin-film structure can conform to large curved facial surfaces while maintaining measurement precision. The flexibility allows the sensor to adapt to the curvature of the face without compromising the accuracy of pressure detection at each sensing point.
Solution Approach 2:
The sensor employs composite material construction combining flexible substrate materials with conductive trace materials, creating a structure that simultaneously achieves softness for curved surface conformity and precision for accurate pressure measurement. The composite structure integrates the beneficial properties of different materials to resolve the contradiction between ease of manufacture and measurement precision.
3Measurement precision
If indirect measurement is used, then the sensor structure is simpler, but pressure dispersion occurs causing reduced measurement accuracy
Solution Approach 1:
The pressure sensor directly extracts and measures pressure at multiple discrete sensing points across the surface, eliminating the need for indirect measurement through intermediate elements. By taking out the measurement function and placing it directly at the contact interface with multiple sensing points, the system achieves accurate pressure distribution boundary detection without pressure dispersion.
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 accurate and flexible pressure measurement by ensuring direct contact with the wearable device, reducing pressure dispersion and enhancing measurement accuracy, while maintaining a good fit with the human head model.
Implementation Method 1
The squeezing force in the contact area will cause the pressure detection point formed by the flexible pressure sensor (i.e., the horizontal and vertical intersection of the conductive thread) to output a changing electrical signal
Data Source
AI summary
The present application relates to the technical field of wearable devices, and specifically discloses a device and system for measuring head and facial wearing pressure, including a human head model and a flexible pressure sensor. The human head model includes a hard bottom shell and a flexible skin layer provided outside the hard bottom shell. The flexible pressure sensor is provided outside the detection area of the flexible skin layer. The flexible pressure sensor includes an insulating pad and a plurality of conductive threads, the plurality of conductive threads are interlacingly woven on the insulating pad, and two conductive threads at horizontal and vertical intersections are separated by the insulating pad to serve as pressure detection points.