Hand-Wearable Device Liquid Metal Sensor Integration
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Solution Overview
Problem
Existing hand-wearable devices face challenges in manufacturing ease and performance due to complex electrode insertion methods, especially as the thickness of soft sensors decreases, making automation impossible and increasing operation time for multiple channels.
Innovation Solution
A hand-wearable device is designed with an elastic sheet comprising a first and second elastic layer, a sensor unit formed by printing conductive liquid metal between the layers, a wire unit, an electrode substrate, and a connection electrode, all formed using the same conductive liquid metal, such as EGaln, to simplify manufacturing and enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex electrode insertion methods are used to connect wire units to electrode substrates, then connection reliability is improved, but manufacturing complexity increases and automation becomes impossible
Solution Approach 1:
The patent merges the wire unit and electrode substrate into a single integrated structure where the wire unit is directly formed on the electrode substrate. This integration eliminates the need for separate insertion and connection steps, reducing manufacturing complexity while maintaining connection reliability through direct electrical contact.
Solution Approach 2:
The wire unit is preliminarily positioned and connected to the electrode substrate during the sensor fabrication process itself, before final device assembly. This preliminary action allows automated manufacturing systems to establish electrical connections as part of the standard fabrication sequence, eliminating later manual intervention.
2Manufacturing precision
If manual electrode insertion methods are used for multiple channels, then connection precision is improved, but operation time increases significantly
Solution Approach 1:
The patent replaces manual mechanical insertion operations with automated printing or deposition processes that form conductive material patterns directly on the electrode substrate. This substitution enables simultaneous fabrication of multiple channels with consistent precision, dramatically reducing operation time compared to sequential manual insertion.
3Reliability
If conductive paste is used for electrode connections, then electrical conductivity is improved, but additional heating processing steps are required
Solution Approach 1:
The patent changes the material parameter from conductive paste (requiring heating) to conductive liquid metal or metallic ink that maintains adequate conductivity at room temperature. This parameter change eliminates the heating step while preserving electrical conductivity, simplifying the manufacturing process.
Solution Approach 2:
The patent utilizes materials that remain in liquid or semi-liquid state at room temperature, allowing direct deposition without thermal processing. The conductive liquid metal maintains workable fluidity for printing/depiction while providing sufficient conductivity, avoiding the solidification step required for traditional conductive pastes.
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 enables easy manufacturing and improved performance by automating the connection of the wire unit to the electrode substrate, reducing operation time, and maintaining elasticity, while avoiding the need for additional processing steps like heating conductive pastes.
Implementation Method 1
a sensor unit formed by printing a predetermined conductive liquid metal between the first elastic layer and the second elastic layer
Implementation Method 2
a connection electrode formed by printing a predetermined conductive liquid metal between the wire unit and the electrode substrate
Data Source
AI summary
A hand-wearable device includes an elastic sheet including a first elastic layer and a second elastic layer facing each other; a sensor unit formed by printing a predetermined conductive liquid metal between the first elastic layer and the second elastic layer; a wire unit extending from the sensor unit and electrically connected to the sensor unit; an electrode substrate formed on one side of the wire unit and spaced apart from the wire unit by a predetermined distance; and a connection electrode formed by printing a predetermined conductive liquid metal between the wire unit and the electrode substrate.