Flexible Sensor Chain Strain Relief Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current systems fail to provide a non-invasive, ultra-lightweight, low-power, minimally wired method for real-time and stored lower limb kinematics data with sufficient accuracy and redundancy for various applications, particularly in measuring physiological and kinesthetic data for individual soldiers.
Innovation Solution
A flexible sensor chain system is developed, where electrical devices and wires are integrated into a flexible material, arranged in patterns for strain relief, and connected via connectors to facilitate data upload/download, enabling accurate kinematic data collection while withstanding stretching and compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are rigidly connected to sensors for data transmission, then electrical connectivity is ensured, but strain and damage occur during stretching and compression of flexible material
Solution Approach 1:
The wires are arranged in S-shaped or Z-shaped bent patterns instead of straight connections. These curved configurations allow the wires to flex and absorb strain during stretching and compression of the flexible material, preventing wire damage while maintaining electrical connectivity between sensors and processors
Solution Approach 2:
The wire configuration is designed to be dynamic and adaptable to the deformation of flexible material. The S-shaped and Z-shaped patterns enable the wires to dynamically adjust their geometry during stretching and compression cycles, maintaining connectivity without rigid constraints that would cause damage
2Weight of moving object
If sensors are made lightweight and flexible for wearability, then comfort and non-invasiveness are improved, but measurement accuracy and robustness deteriorate
Solution Approach 1:
The sensor chain uses flexible printed circuit boards and thin-film sensor elements that can be integrated into flexible material. These thin-film components maintain measurement accuracy while being lightweight and conformable to body surfaces, enabling non-invasive kinematic data collection
Solution Approach 2:
The sensor chain integrates multiple materials including flexible substrates, conductive traces, and sensor elements into a composite structure. This composite design provides both the mechanical flexibility needed for wearability and the electrical performance required for accurate measurement
3Reliability
If multiple wires are used for redundant data transmission, then measurement reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
Multiple wire functions are merged into integrated flexible printed circuit board traces. The redundant data transmission paths are combined into a single flexible circuit layer, reducing the number of discrete wire components while maintaining measurement reliability through redundant signal paths
Data Source
AI summary
A chain segment having wires that connect various electrical devices and connectors together. The wires are arranged in a pattern to facilitate strain relief. The wires, electrical devices, and connectors are encased in an injection molded material, and they are preferably coupled with a flexible material such as a fabric that can be stitched into a garment. The chain segment facilitates collection of movement data when stitched into an article of clothing. A method of manufacturing the chain segment that is modular to enable different configurations and different lengths of chains.