Flexible Sensor With Segmented Substrates For Strain Detection

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Solution Overview

Problem

Existing flexible sensors face challenges in accurately measuring strain and deformation due to potential damage to the main substrate during manufacturing and limited precision in resistance value measurement when bent, particularly in applications requiring high sensitivity and accuracy for 2-dimensional strain detection.

Innovation Solution

A flexible sensor design featuring a main substrate with a support substrate having electric insulation, a transistor, and a variable resistance part on a flexible support substrate, where the resistance value changes with strain, allowing for accurate measurement of strain through a matrix configuration and improved durability during manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a flexible sensor is manufactured with a conventional structure, then the manufacturing process is simple, but the main substrate is damaged during manufacturing and measurement precision deteriorates when bent

Engineering Contradiction:

Improvesubstrate integrity during manufacturingVSAvoidsensor structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The sensor is divided into two independent substrates: a main substrate for mounting electronic components and a support substrate for providing mechanical strength and flexibility. This segmentation allows each substrate to be optimized independently, preventing damage during manufacturing while maintaining structural integrity during use.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support substrate acts as an intermediary between the main substrate and the external environment. It provides mechanical support and protection to the main substrate during manufacturing processes, preventing damage while allowing the sensor to maintain flexibility for accurate strain measurement when bent.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If the sensor structure is simplified, then manufacturing is easier, but measurement precision deteriorates when the sensor is bent

Engineering Contradiction:

Improvestrain detection accuracyVSAvoidsensor assembly process

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

By separating the sensing function (on the support substrate) from the electronic component mounting function (on the main substrate), the sensor can be manufactured using standard PCB techniques while maintaining the flexibility needed for accurate strain measurement during bending.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support substrate is designed as a flexible thin film structure that allows the sensor to bend without damaging components. This flexible support structure enables accurate measurement of strain and deformation while maintaining ease of manufacture through conventional flexible PCB techniques.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If a single substrate is used, then the device is simpler, but durability during manufacturing is reduced

Engineering Contradiction:

Improvesubstrate durabilityVSAvoidsubstrate configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The dual-substrate configuration divides the functional requirements between two specialized substrates, allowing each to be optimized for its specific purpose while improving overall durability during manufacturing and use.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support substrate serves as a protective intermediary that shields the main substrate from mechanical damage during manufacturing processes. This intermediary structure enhances reliability by preventing substrate damage while the modular design keeps the overall device manageable in complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enhances the accuracy and durability of strain measurement by minimizing damage to the main substrate during manufacturing and enabling precise detection of 2-dimensional strain with high sensitivity, suitable for applications like human motion detection.

Implementation Method 1

a variable resistance part over a first surface which is an upper surface of the support substrate, in which a resistance value of the variable resistance part changes according to strain of the variable resistance part

Methodology Applied

Scientific EffectStrain resistance change: Piezoresistive Effect

Data Source

PatentUS20240377180A1Flexible sensor and method for manufacturing flexible sensor

Publication Date: 2024.11.14 NIKON CORP

AI summary

A flexible sensor includes a main substrate having flexibility, a transistor over the main substrate, a support substrate over the transistor, wherein the support substrate has flexibility and at least an outer surface of the support substrate comprises a material having electric insulation, and a variable resistance part over a first surface which is an upper surface of the support substrate, in which a resistance value of the variable resistance part changes according to strain of the variable resistance part.