Matrix Electrode Sensor Using Conductive Carbon Black Coating
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Solution Overview
Problem
Existing pressure-sensitive sensors face challenges in stably measuring pressurizing forces due to point- or line-contact states, which are unstable and result in greater resistance values. Additionally, conventional methods involving conductive noble metal particles are costly, complex, and limited by facility size restrictions.
Innovation Solution
The proposed pressure-sensitive sensor employs a conductive cloth with first- and second-electrode cloths arranged in a matrix structure. Conductive carbon black is used to coat the cloth, providing flexibility and reducing material costs. The sensor's design allows for wide-range pressure distribution measurement without facility size restrictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive noble metal particles are used to plate cloths, then electrical conductivity is improved, but material cost increases significantly and treatment complexity increases
Solution Approach 1:
The patent replaces expensive conductive noble metal particles with inexpensive conductive carbon black particles. The conductive carbon black is applied through a simple coating process using a coating solution containing conductive carbon black and binder resin, eliminating the need for complex plating treatments and expensive materials while achieving sufficient electrical conductivity for pressure sensing.
Solution Approach 2:
The patent substitutes the mechanical/chemical plating process with a coating process. Instead of using electroplating or chemical deposition to apply noble metal particles, the invention uses a coating solution containing conductive carbon black that is applied and dried to form a conductive layer on the cloth, simplifying the manufacturing process.
2Measurement precision
If conventional pressure-sensitive sensors are used, then pressure measurement is possible, but measurement stability deteriorates due to point- or line-contact states
Solution Approach 1:
The patent transitions from point-contact or line-contact measurement modes to a surface-contact measurement mode. By arranging conductive linear members that extend across the cloth surface and forming electrode patterns that contact the cloth surface area, the invention creates a two-dimensional contact interface that provides stable measurement across the entire contact area rather than at isolated points or lines.
3Measurement precision
If conventional pressure-sensitive sensors are used, then pressure measurement is possible, but resistance value increases in point- or line-contact states
Solution Approach 1:
The patent creates a two-dimensional surface contact between the conductive linear members and the cloth, increasing the contact area from points or lines to a continuous surface. This dimensional change reduces resistance by providing multiple parallel conduction paths across the contact area, thereby lowering the overall resistance value compared to point- or line-contact configurations.
4Ease of manufacture
If plating facilities are used to apply conductive particles, then conductive cloth can be manufactured, but facility size restrictions limit production scale
Solution Approach 1:
The patent replaces the plating process with a coating process that can be performed on large-scale cloth materials. The coating solution containing conductive carbon black is applied using conventional coating techniques that are not restricted by facility size, enabling the manufacturing of large-area conductive cloths for full-body pressure sensing applications.
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 sensor achieves stable measurement of pressurizing forces in a surface-contact state, reduces material costs, and enhances productivity. The matrix structure improves accuracy in measuring pressurizing forces, and the use of conductive carbon black reduces resistance values and production costs.
Implementation Method 1
first-conductive particles are composed of conductive carbon black
Implementation Method 2
a dispersion liquid of first-conductive particles is applied to coat a first-base cloth
Implementation Method 3
a pressure-sensitive sensor for measuring biological information
Data Source
AI summary
A pressure-sensitive sensor includes a plurality of first-electrode cloths arranged at a first-interval on a first-surface of a conductive cloth and a plurality of second-electrode cloths arranged at a second-interval on a second-surface of the conductive cloth in a direction intersecting that of the first-electrode cloths. Areas of intersection between the first-electrode cloths and the second-electrode cloths are formed to have a matrix structure, first-conductive particles are applied to coat the conductive cloth, and second-conductive particles having greater electrical conductivity than the first-conductive particles are applied to coat the first-electrode cloths and the second-electrode cloths.