Flexible Sensor Membrane Transfer Printing
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Solution Overview
Problem
Existing sensor membranes for wearable devices lack flexibility, elasticity, precision, and are complex and expensive, failing to provide precise and punctual measurements.
Innovation Solution
A sensor membrane composed of a piezoresistive fabric layer with aligned conductive electrodes, integrated through a transfer printing process using conductive and insulating inks, allowing direct deposition on a substrate, creating a flexible and elastic single-layer structure for precise strain measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional multi-layer sensor membranes are used, then measurement precision is improved, but flexibility and elasticity deteriorate
Solution Approach 1:
The patent combines multiple functional layers (conductive layer, insulating layer, piezoresistive layer) into a single integrated fabric layer, eliminating the need for separate stacked layers while maintaining all sensor functions. This merging approach preserves measurement precision through the piezoresistive effect while achieving the flexibility and elasticity of a single fabric layer.
Solution Approach 2:
The patent creates a composite fabric structure integrating conductive threads, insulating materials, and piezoresistive elements within a single flexible fabric layer. This composite approach enables the membrane to maintain mechanical flexibility while incorporating multiple sensor functions that traditionally required separate rigid layers.
2Measurement precision
If traditional multi-layer sensor membranes are used, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple discrete layers into a single fabric layer, reducing the number of components and assembly steps. This simplifies the overall device structure while maintaining the functional capabilities of conductive elements, insulating layers, and piezoresistive sensing regions through integrated fabric construction.
Solution Approach 2:
The patent implements different functional properties at different locations within the single fabric layer - conductive regions for electrode formation, insulating regions for electrical isolation, and piezoresistive regions for strain sensing. This local differentiation enables precise measurements without requiring complex multi-layer stacking.
3Measurement precision
If traditional multi-layer sensor membranes are used, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple manufacturing processes into a single fabric production step, where conductive, insulating, and piezoresistive elements are integrated during fabric fabrication rather than requiring separate layer deposition and assembly operations. This reduces manufacturing complexity and cost while maintaining precise measurement capabilities.
Solution Approach 2:
The patent employs cost-effective fabric materials and standard textile manufacturing techniques to create the sensor membrane, replacing expensive specialized materials and complex assembly processes with affordable, scalable fabric production methods that maintain sufficient performance for wearable applications.
4Area of stationary object
If sensors are developed over the entire plane, then coverage is improved, but precision at specific points deteriorates
Solution Approach 1:
The patent implements distinct functional zones within the fabric layer - conductive regions for electrode formation, insulating regions for electrical isolation, and piezoresistive regions for localized strain sensing. This spatial differentiation enables precise point measurements while maintaining comprehensive coverage across the entire sensor membrane surface.
Solution Approach 2:
The patent divides the sensor membrane into functionally segmented regions within the single fabric layer, with discrete conductive, insulating, and piezoresistive zones that can be independently optimized for their specific functions while collectively providing full-surface coverage and precise localized measurements.
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 membrane achieves precise, economical, and robust strain measurements, suitable for integration into wearable items like shoe insoles, with improved flexibility and durability.
Implementation Method 1
The piezoresistive elements are known to vary their electrical resistance as a function of their deformation. If an electric current flows through these elements, the resistance reading, given by the variation of the electric variables of the current flowing through them, obtains direct information on the deformation and therefore on the stress or strain faced by these elements.
Data Source
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AI summary
It is provided a process for making a flexible sensor membrane (1) and defined a prevalent development surface (1a) and comprising a layer of piezoresistive material (2) extending predominantly along the prevalent development surface (1a) the process comprising: the deposition of conductive portions (30, 40) in material solidifiable at room temperature, on a transfer paper and the transfer, by means of a transfer process, of the conductive portions (30, 40) directly onto the sensitive layer (2).