Pressure Sensor Helical Ribs Eliminate Spacer

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Solution Overview

Problem

The existing pressure-sensitive sensors require a spacer for manufacturing, increasing costs and risking damage during the process, limiting the length and reusability of the finished product due to high frictional resistance.

Innovation Solution

A pressure-sensitive sensor with helical ribs on the tubular member, allowing electrode wires to be helically arranged without a spacer, enabling free length setting and low-cost manufacturing through extrusion with rotating dies or mandrels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a spacer is used in the manufacturing process, then the electrode wires can be positioned correctly, but the manufacturing cost increases and the process complexity increases

Engineering Contradiction:

Improveelectrode wire positioningVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention removes the spacer component entirely from the manufacturing process. Instead of using a spacer to position electrode wires during molding, the patent directly molds the elastic insulation around the electrode wires in a helical arrangement, eliminating the need for spacer making, wire placement, and spacer removal steps.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention combines the electrode wire arrangement and insulation molding into a single integrated process. The electrode wires are fed at a distance from one another and the elastic insulation is molded around them simultaneously, merging the positioning function and insulation function into one step.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If a spacer is used in the manufacturing process, then the electrode wires can be supported during molding, but the frictional resistance causes spacer breakage or wire damage

Engineering Contradiction:

Improvestructural support during moldingVSAvoidrisk of spacer breakage or wire damage

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The spacer is completely removed from the system. The patent feeds electrode wires directly into the molding process with spacing between them, and the elastic insulation material directly supports and holds the wires during molding without requiring a separate spacer component.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention changes the physical state and properties of the elastic insulation material during molding, allowing it to flow around and support the electrode wires. The material transitions from a moldable state during injection to a solidified state that provides structural support, eliminating the need for a separate spacer.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the spacer is pulled out after cutting into short lengths, then the frictional resistance is reduced, but the spacer cannot be reused and material cost increases

Engineering Contradiction:

Improvespacer removal easeVSAvoidspacer material reusability

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The spacer is eliminated entirely from the manufacturing process. The patent achieves easy removal by simply not using a spacer at all, thereby completely avoiding the issues of spacer material waste and reusability problems.

Inventive Principle:

Principle #2Taking out (Extraction)

4Strength

If the spacer is used to hold electrode wires, then the wires are supported during molding, but the length of the finished sensor is limited

Engineering Contradiction:

Improvewire support during moldingVSAvoidfinished sensor length

Core Design Contradiction:

StrengthVSLength of moving object

Solution Approach 1:

The invention enables continuous molding of the elastic insulation around continuously fed electrode wires. Without the need to accommodate spacer length limitations, the process can produce sensors of any required length by simply adjusting the wire feeding and molding parameters.

Inventive Principle:

Principle #20Continuity of useful action

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

Enables mutual contact of electrode wires in any direction, allows for flexible product length, and reduces manufacturing costs by eliminating the need for a spacer and minimizing damage during production.

Implementation Method 1

extruding the tubular elastic insulation while rotating the tubular elastic insulation in a circumferential direction of the tubular member such that the plurality of electrode wires are helically arranged along a longitudinal direction of the tubular member

Methodology Applied

Scientific EffectRotation:

Implementation Method 2

forming the tubular member by extruding the tubular elastic insulation such that the plurality of electrode wires are held on the inner circumferential surface

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS10890495B2Pressure-sensitive sensor including a hollow tubular member of an elastic insulation

Publication Date: 2021.01.12 PROTERIAL LTD

AI summary

A pressure-sensitive sensor includes a hollow tubular member including an elastic insulation, plural electrode wires spaced from one another and held on an inner circumferential surface of the tubular member, and helical ribs formed on at least one of inner and outer circumferential surfaces of the tubular member along a longitudinal direction thereof. The electrode wires are helically arranged along the longitudinal direction. A helical direction of the helical ribs of the tubular member is a same as a helical direction of the helically-arranged electrode wires.