Flexible Pressure Sensor Structure Without Spacer Assembly

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Solution Overview

Problem

Existing pressure sensitive sensors face increased production costs and difficulty in bending due to complex manufacturing processes and the use of spacers, which limits their flexibility in adhering to curved shapes.

Innovation Solution

A pressure sensitive sensor design featuring a first conductive member, a second conductive member, and an insulating member with elasticity, allowing for manufacturing without spacers through extrusion molding, and enabling relative movement between components to absorb expansion and contraction differences during bending.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a spacer is used to form the hollow structure in the pressure sensitive sensor, then the hollow helical structure can be realized, but the production costs increase due to additional processes and materials

Engineering Contradiction:

Improvehollow helical structureVSAvoidproduction cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The invention removes the spacer component from the manufacturing process entirely. The hollow structure is formed directly through extrusion molding of the conductive member, eliminating the need to insert and subsequently remove spacers. This extraction of the problematic component resolves the contradiction by achieving the hollow shape without the associated cost penalties.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the mechanical spacer-based formation method with a molding process. Instead of using physical spacers to define the hollow space during assembly, the extrusion molding process directly creates the hollow helical structure in one step, substituting a complex mechanical assembly process with a more efficient forming operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Shape

If a spacer is used to form the hollow structure, then the hollow structure can be created, but the number of manufacturing processes increases

Engineering Contradiction:

Improvehollow structureVSAvoidnumber of processes

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The invention merges the hollow structure formation with the extrusion molding process itself. The hollow helical shape is created as an integral part of the conductive member during the single extrusion operation, rather than requiring separate steps for spacer insertion, structure formation, and spacer removal. This consolidation of operations directly reduces the total number of manufacturing processes.

Inventive Principle:

Principle #5Merging (Combining)

3Shape

If the pressure sensitive sensor has a complex internal structure with spacers, then the hollow structure is formed, but the allowable bending performance decreases

Engineering Contradiction:

Improvehollow structureVSAvoidbending performance

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The invention employs a flexible helical structure formed directly in the conductive member through extrusion molding. This helical configuration inherently provides flexibility and bendability, allowing the sensor to conform to curved surfaces. The continuous helical form acts as a flexible shell that can deform without compromising the hollow structure, thereby improving bending performance while maintaining the desired shape.

Inventive Principle:

Principle #30Flexible shells and thin films

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

This design inhibits manufacturing cost increases and ensures easy bending performance by allowing for flexible arrangement on curved surfaces without the need for spacers.

Implementation Method 1

an insulating member having an insulating property and elasticity, the insulating member holding the first conductive member to separate the first conductive member from the second conductive member, the insulating member being movable relative to at least one of the first conductive member and the second conductive member

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12372421B2Pressure sensitive sensor with conducting members and an insulating member

Publication Date: 2025.07.29 PROTERIAL LTD

AI summary

A pressure sensitive sensor includes: a first conductive member formed into a long shape, the first conductive member having conductivity and elasticity; a second conductive member internally including a long space to arrange the first conductive member, the second conductive member having conductivity and elasticity; and an insulating member having an insulating property and elasticity, the insulating member holding the first conductive member to separate the first conductive member from the second conductive member, the insulating member being movable relative to one or both of the first conductive member and the second conductive member.