Flexible Sensor Array for Irregular Surface Detection
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Solution Overview
Problem
Existing technologies face challenges in accurately detecting temperature, pressure, and moisture across irregularly-shaped or dynamically changing surfaces using electronic sensor arrays, as they often require precise placement and are not flexible enough to conform to curved or flexing surfaces.
Innovation Solution
A flexible electronic sensor array apparatus is developed, comprising a continuous flexible sheet with multiple layers of conductive pattern layers and sensors spaced along axes, including thermistor, pressure, and humidity sensors, which can be formed into a two-dimensional array to detect properties across irregular surfaces by using conductive vias and metal pattern layers connected through flexible sheet layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional electronic sensor arrays are used on irregular surfaces, then measurement precision may be maintained, but device complexity and difficulty of operation increase due to precise placement requirements
Solution Approach 1:
The patent employs flexible circuit board layers that can conform to irregular surfaces, eliminating the need for precise manual placement of individual sensors. The flexible substrate allows the entire sensor array to be adapted to curved or non-planar geometries while maintaining electrical connections and measurement accuracy.
2Stability of the object's composition
If rigid sensor arrays are used on curved surfaces, then structural stability is maintained, but adaptability to irregular surfaces deteriorates
Solution Approach 1:
The sensor array is divided into multiple flexible circuit board layers stacked along the thickness direction. Each layer can independently flex and conform to the underlying irregular surface while maintaining its structural integrity and electrical connectivity, thus achieving both stability and adaptability.
Solution Approach 2:
The use of flexible circuit board layers as the substrate for mounting sensors enables the entire array to bend and conform to curved surfaces. The flexible nature of the substrate allows adaptation to irregular geometries while maintaining the structural organization and stability of the sensor array.
3Adaptability or versatility
If multiple sensor layers are stacked to form flexible sheet, then adaptability to irregular surfaces improves, but device complexity increases
Solution Approach 1:
Multiple flexible circuit board layers are combined and stacked to form an integrated flexible sensor array. The layers are electrically connected through conductive vias and patterned traces, creating a unified structure that maintains flexibility while providing multi-layer sensing capabilities and reducing overall device complexity through integration.
4Area of stationary object
If sensors are spaced in two-dimensional array across flexible sheet, then coverage area increases, but manufacturing precision requirements increase
Solution Approach 1:
The flexible circuit board substrate allows the sensor array to be manufactured with standard precision techniques and then conform to the target surface geometry. The flexibility of the substrate compensates for minor positioning variations, enabling large-area coverage without requiring extremely high manufacturing precision for each sensor location.
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 temperature, pressure, and humidity across irregular surfaces, conforming to curved or flexing surfaces due to its flexible design, allowing for precise location-based property association and effective sensing of dynamic changes.
Implementation Method 1
water absorption by the flexible sheet layer positioned between the respective plate portions changes a dielectric constant between the respective plate portions responsive to changes in a local humidity
Implementation Method 2
at least some of sensors of the plurality of electronic sensors are flexible thermistor temperature sensors
Implementation Method 3
the metal pattern layers forming a voltage divider circuit that is electrically responsive to physical flexing of the membrane portion
Data Source
AI summary
A flexible electronic sensor array apparatus comprising: a continuous flexible sheet having a length defining a first axis, a width defining a second axis and a thickness comprising a third axis; wherein the flexible sheet comprises multiple flexible sheet layers formed of one or more flexible materials stacked along the third axis; a plurality of electronic sensors disposed within the flexible sheet, each respective sensor comprising at least two conductive pattern layers, the two conductive pattern layers of the respective sensor spaced apart from one another along the third axis by one of the flexible sheet layers interposed between the conductive pattern layers; and wherein each respective sensor of the plurality of sensors is disposed at a different respective position along the first axis or the second axis of the flexible sheet from the remaining sensors, thereby forming an array of sensors spaced along the first and second axes.