Mesh-Like Flexible Substrate for Wearable Sensor Alignment
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Solution Overview
Problem
Flexible substrates with sensor elements mounted on them face errors due to expansion and contraction, affecting sensing accuracy in curved surfaces or on the human body.
Innovation Solution
The electronic device comprises a first substrate with a mesh-like insulating base, wiring layer, and sensor electrodes, and a second substrate with a mesh-like insulating base, common electrode, and sensor sheet, bonded together with an adhesive layer to maintain contact and prevent misalignment during expansion and contraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible substrate with sensor elements is mounted on a curved surface or attached to the human body, then the device can be applied to curved surfaces and wearable applications, but sensing errors occur due to expansion and contraction of the substrate
Solution Approach 1:
The substrate is divided into multiple independent sensor elements arranged in a matrix, with each element capable of independent deformation. The insulating base is segmented into island-shaped portions and band portions that can expand and contract independently, allowing the overall substrate to be mounted on curved surfaces while maintaining sensing accuracy at each local sensor element position
Solution Approach 2:
Different regions of the substrate are designed with different properties: the insulating base has island-shaped portions for sensor mounting and band portions for flexibility. The sensor elements maintain consistent contact pressure with their respective target surfaces locally, while the overall substrate adapts to global curved geometries through the compliant band portions
2Shape
If the flexible substrate expands or contracts to adapt to curved surfaces, then the substrate can conform to the target surface, but misalignment occurs between sensor elements and their target positions
Solution Approach 1:
The substrate design allows dynamic adaptation: the band portions of the insulating base can dynamically expand and contract to accommodate different curved surface geometries. This dynamic flexibility enables the substrate to maintain proper alignment between sensor elements and their target positions across various deformation states, rather than being fixed in a single configuration
3Adaptability or versatility
If sensor elements are mounted on a flexible substrate that expands and contracts, then the substrate can adapt to curved surfaces, but wear increases at the contact interface
Solution Approach 1:
The contact interface is segmented into multiple discrete sensor elements rather than a continuous mounting. Each sensor element makes localized contact with the target surface, distributing the mechanical stress and wear across many points. The insulating base is also segmented into island and band portions, allowing flexible deformation while maintaining stable contact at each sensor element position
Data Source
AI summary
According to one embodiment, an electronic device includes a first substrate and a second substrate. The first substrate includes a first insulating base, a wiring layer and a sensor electrode. The first insulating base is made into a mesh-like form. The wiring layer is disposed over a first band portion of the first insulating base. The sensor electrode is disposed over a first island-shaped portion of the first insulating base. The second substrate includes a second insulating base, a common electrode and a sensor sheet. The second insulating base is made into a mesh-like form. The common electrode is made into a mesh-like form. The sensor sheet overlaps a second island-shaped portion of the second insulating base in plan view and is disposed below the common electrode.