Multi-Type Pressure Sensor With Segmented Circuit Paths
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Solution Overview
Problem
Conventional pressure sensors are limited in their ability to measure pressures below a certain threshold, require additional devices for data editing, and often suffer from non-linearity, low response speed, and temperature-related errors, with piezoelectric sensors unable to measure static pressure and showing frequency-dependent outputs.
Innovation Solution
A pressure sensor design featuring a substrate with a patterned circuit and a conductive material layer having protrusions that deform to establish contact between circuit paths, allowing for selective pressure measurement and electrical connection, enabling measurement of various pressure ranges and types through different pattern configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional resistance pressure sensor is used, then it can measure applied pressure, but it cannot ignore pressure less than a predetermined level or perform selective pressure measurement
Solution Approach 1:
The circuit is divided into multiple path parts (first path part, second path part, third path part) with different gap configurations. Each path part can be selectively connected to the conductive material layer at different pressure levels, enabling the sensor to measure different pressure ranges using the same physical structure without requiring additional editing devices.
Solution Approach 2:
The circuit paths are designed to be dynamically connected or disconnected based on applied pressure. The gaps between path parts allow the circuit configuration to change automatically with pressure variations, enabling selective measurement of different pressure levels without manual intervention or additional control mechanisms.
2Productivity
If a linear pressure sensor is used, then it does not require data editing, but it can measure only a very narrow range of pressure
Solution Approach 1:
The measurement range is segmented into multiple pressure levels, each corresponding to a different circuit path configuration. The first path part measures lower pressure ranges, while the second and third path parts measure higher pressure ranges, allowing the sensor to achieve a wide overall measurement range while maintaining linearity within each segment.
Solution Approach 2:
Different path parts have different gap distances and conductive material layer configurations optimized for specific pressure ranges. This local optimization allows each path part to maintain high measurement precision and linearity for its designated pressure range while the entire system covers a broad spectrum.
3Reliability
If a strain-gauge pressure sensor is used, then it can measure pressure, but it has a low response speed and may have significant error caused by temperature disturbance
Solution Approach 1:
The sensor replaces strain-gauge mechanical measurement with an electrical field-based measurement system. The conductive material layer's electrical connection to different circuit paths directly responds to pressure-induced deformation, eliminating the mechanical strain measurement process and its associated temperature sensitivity and response delays.
4Adaptability or versatility
If a piezoelectric pressure sensor is used, then it can measure dynamic pressure changes, but it cannot measure static pressure and shows different output values for the same pressure depending on dynamic frequency
Solution Approach 1:
The sensor replaces piezoelectric measurement with a resistive measurement system based on electrical conductivity changes. This substitution allows the sensor to measure both static and dynamic pressure with consistent output values, as the electrical resistance change directly reflects the physical deformation without frequency-dependent effects.
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 allows for precise measurement of pressure in multiple ranges and types, including low and high pressures, and offers improved sensitivity and reduced temperature-related errors, enabling ON/OFF switching and selective pressure detection.
Implementation Method 1
a pressure sensor measures pressure based on a change in the flow of electric current caused by a change in resistance depending on the pressure applied in a vertical direction
Implementation Method 2
The conductive material layer, resiliently disposed on the patterned circuit, has protrusions. The conductive material layer deforms to determine a contact area between the protrusions and the substrate
Data Source
AI summary
A pressure sensor includes a substrate, a patterned circuit, and a conductive material layer. The patterned circuit, formed on the substrate, includes a first-path part and a second-path part of which at least a part is formed at a predetermined gap from at least a part of the first-path part. The conductive material layer, resiliently disposed on the patterned circuit, has protrusions. The conductive material layer deforms to determine a contact area between the protrusions and the substrate, and upon deformation of the conductive material layer to contact the first-path part, the gap between the first-path part and the second-path part, and the second-path part, the first-path part electrically connects to the second-path part.