Polymer Strain Sensor with Conductive Additives
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Solution Overview
Problem
Existing sensors embedded in elastic articles, such as conveyor belts and tires, fail to effectively detect changes in strain and excitation frequencies, making it difficult to predict overload or failure during operation.
Innovation Solution
Incorporating electrically conductive additives into polymeric materials, such as vulcanized rubber compounds and thermoplastic elastomers, to create strain sensors that measure static and dynamic strains, allowing for the tracking of changes over time and enabling the detection of mechanical load and aging status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electrically conductive additives are incorporated into polymeric materials to enable strain detection, then measurement precision is improved, but manufacturing precision deteriorates due to challenges in uniformly distributing additives throughout the polymer matrix
Solution Approach 1:
The patent uses composite materials by combining polymeric matrix with electrically conductive additives (such as carbon black, metal particles, or conductive polymers) to create a material that possesses both structural properties and electrical sensitivity. This composite approach enables the material to function as both the structural component and the sensing element, resolving the contradiction by integrating measurement capability into the base material itself.
Solution Approach 2:
The patent applies parameter changes by modifying the electrical properties of the polymeric material through the addition of conductive additives. By changing the electrical conductivity parameter of the base material, the patent enables strain detection capability while maintaining the mechanical properties of the polymer. The conductivity changes in response to strain, allowing precise measurement without compromising manufacturing.
2Measurement precision
If the polymer material is made highly conductive for better signal detection, then measurement precision is improved, but the standard properties of the polymer material deteriorate
Solution Approach 1:
The patent applies local quality by creating regions of varying conductive additive concentration within the polymer matrix. Rather than uniformly distributing additives throughout the entire material, the patent concentrates conductive additives in specific regions or at specific orientations where they are most effective for strain detection. This localized approach enables good signal detection while preserving the standard polymer properties in other regions.
Solution Approach 2:
The patent carefully controls the concentration and distribution parameters of conductive additives to achieve optimal electrical conductivity for signal detection while maintaining the mechanical and chemical stability of the polymer. By precisely adjusting these parameters, the patent resolves the contradiction between enhanced measurement capability and preservation of material stability.
3Reliability
If electrically conductive additives are added to detect static and dynamic strains, then reliability is improved through failure prediction, but device complexity increases due to additional components and processing steps
Solution Approach 1:
The patent merges the structural function and sensing function into a single integrated component. The polymeric material with conductive additives serves simultaneously as the structural element and the strain sensor, eliminating the need for separate sensing components. This merging approach improves reliability through continuous monitoring while avoiding the complexity of multi-component sensor systems.
Solution Approach 2:
The patent applies self-service by enabling the polymer material itself to perform the sensing function through its inherent electrical properties. The conductive additives embedded in the polymer allow the material to self-monitor its own strain and stress conditions, providing failure prediction capability without requiring external sensing devices. This self-service approach simplifies the overall system while enhancing reliability.
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 sensitive detection of mechanical load and aging status, allowing for real-time monitoring of strain and predicting potential failures, while maintaining the standard properties of polymer materials.
Implementation Method 1
The polymeric material is provided with electrically conductive additives and acts as a strain sensor by measuring the static and dynamic strains of the article in relation to the forces acting
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a sensor as a built-in component of an object, especially an elastic object, said sensor comprising a polymer material containing electroconductive additives according to the invention and thereby acting as an expansion sensor (2), in that it measures the static and dynamic expansions of the object in relation to the acting forces and also monitors the changes of the polymer material generated by the static and dynamic expansions of the object over time. The invention also relates to a sensor arrangement (1) acting especially in combination with the following components: an expansion sensor (2), a fixed resistor (3), an analog/digital converter (4), a micro-controller comprising a memory (5), a radio interface (6), a controlled current/voltage source (7), an energy supply (8), a coupling coil (9), and a receiving unit (10).