Foldable Pressure Sensor with Bidirectional Resistors
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Solution Overview
Problem
Existing pressure sensors face challenges in ensuring uniformity and consistency of resistor values, are sensitive to external environmental disturbances, and are affected by temperature changes, leading to inaccurate pressure measurements and high production costs.
Innovation Solution
A pressure sensor design featuring a substrate with a hollow groove and foldable portion, where at least two resistors are molded on opposite surfaces and electrically connected to form a pressure measuring circuit, allowing for accurate detection of deflection deformations and minimizing temperature interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple resistors are separately manufactured and assembled in existing pressure sensors, then the pressure sensor can be constructed with necessary circuit components, but the uniformity and consistency of resistance values cannot be ensured and production costs increase
Solution Approach 1:
The patent merges multiple resistors into a single integrated structure where conductive layers are formed simultaneously on both sides of a flexible substrate. The first and second conductive layers are patterned and connected through vias to form complete resistor circuits, eliminating the need for separate assembly of multiple discrete resistors while ensuring uniform resistance values through simultaneous fabrication.
Solution Approach 2:
The patent utilizes the third dimension by forming conductive layers on both sides of a flexible substrate and connecting them through vertical vias. This bidirectional layering approach allows resistors to be formed in multiple dimensions simultaneously, achieving complex circuit functionality while maintaining manufacturing uniformity through a single integrated process.
2Manufacturing precision
If complex assembly methods are used to ensure resistor uniformity in existing pressure sensors, then resistance consistency can be improved, but the assembly requirements become extremely high and production costs increase
Solution Approach 1:
The patent performs preliminary actions by pre-forming conductive layers, patterns, and via connections during the initial substrate fabrication process. The first and second conductive layers are deposited and patterned before final assembly, ensuring that resistor values are predetermined and consistent without requiring complex post-assembly adjustments or high-precision assembly operations.
3Reliability
If pressure sensors are designed with separate resistor components, then the circuit can be constructed, but the sensors become sensitive to external environmental disturbances and temperature variations
Solution Approach 1:
The patent combines multiple resistor components into a single integrated structure formed simultaneously on both sides of the substrate. This merged structure reduces the number of interfaces and connections that could be affected by environmental disturbances, while the symmetric bidirectional design provides inherent compensation for temperature and stress variations.
Solution Approach 2:
The patent changes the physical configuration by forming conductive layers in a bidirectional manner on both sides of the substrate, creating a symmetric structure. This parameter change in the spatial arrangement provides environmental stability through geometric compensation, where temperature and stress effects on one side are counterbalanced by the opposite side.
4Measurement precision
If existing pressure sensor designs are used, then pressure detection can be achieved, but the sensors take up excessive space in the structure
Solution Approach 1:
The patent transitions from a planar single-sided design to a bidirectional three-dimensional structure, forming conductive layers on both sides of the substrate. This dimensional change allows the pressure sensing circuit to be folded or configured in a compact manner, reducing the planar footprint while maintaining the necessary circuit functionality and pressure detection accuracy.
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 solution ensures uniform resistance values, enhances resistance to environmental interference, and reduces manufacturing complexity and costs, while maintaining high sensitivity and precision in pressure detection.
Implementation Method 1
at least one of the resistors is a strain sensing resistor for detecting a deflection deformation of the substrate
Data Source
AI summary
In the pressure sensor of the present application, at least two resistors are simultaneously formed on the foldable portion and the fixed portion to ensure the uniformity and consistency of the resistance values of all the resistors, and at least one is a strain sensing resistor R1, the foldable portion is folded to the fixed portion, and the resistors are electrically connected to form a pressure measuring circuit. Connecting the pressure sensor to the desired panel can accurately detect the curved deformation of the panel. The resistors in a pressure measuring circuit are adjacently distributed, and the resistance value of the resistor changes with temperature at the same time, so that the influence of the temperature change on the pressure measuring circuit is very small, and the interference against the external environment is good.