Pressure-Sensitive Sensor Using Thermoplastic Elastomer and Acid-Modified Polyurethane
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Solution Overview
Problem
Pressure-sensitive sensors with rubber compositions require post-molding crosslinking, increasing manufacturing steps and costs, and may suffer from insufficient adhesion between the hollow insulation and outer layer, leading to poor waterproofing and dimensional errors.
Innovation Solution
A pressure-sensitive sensor design using a styrene-based thermoplastic elastomer for the hollow insulation and a thermoplastic polyurethane outer layer modified with an acid-modified polymer, eliminating the need for crosslinking and enhancing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If rubber composition is used for hollow insulation and conductive covers, then flexibility and resilience are improved, but manufacturing complexity increases due to required post-molding crosslinking
Solution Approach 1:
The patent changes the material parameter from rubber composition requiring crosslinking to thermoplastic elastomer that does not require crosslinking. This parameter change maintains the flexibility and resilience needed for the hollow insulation and conductive covers while eliminating the complex post-molding crosslinking process, thereby reducing manufacturing complexity
Solution Approach 2:
The patent uses composite material formulation by incorporating specific additives and modifiers into the thermoplastic elastomer composition to achieve the desired flexibility, resilience, and adhesion properties without requiring crosslinking, thus maintaining operational performance while simplifying manufacturing
2Strength
If thermoplastic urethane is used for outer layer, then mechanical characteristics are improved, but adhesion to hollow insulation deteriorates
Solution Approach 1:
The patent formulates a composite outer layer material consisting of thermoplastic polyurethane as the base resin with added adhesion promoters and modifiers. This composite formulation maintains the excellent mechanical characteristics of thermoplastic urethane while significantly improving adhesion to the thermoplastic elastomer hollow insulation, preventing resin infiltration and ensuring reliable bonding
Solution Approach 2:
The patent modifies the chemical and physical parameters of the outer layer material by incorporating specific additives and adjusting the composition ratio of thermoplastic polyurethane and modifiers. This parameter optimization enables the outer layer to simultaneously achieve high mechanical strength and strong adhesion to the hollow insulation without requiring crosslinking
3Reliability
If crosslinking process is performed separately from molding, then material properties are improved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges the molding process with the crosslinking process by using thermoplastic elastomer that achieves the desired elastic properties through thermoplastic processing alone, without requiring a separate post-molding crosslinking step. This merging of processes eliminates the additional time and cost associated with separate crosslinking operations while maintaining the necessary material properties
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 provides excellent adhesion between the hollow insulation and outer layer, reducing manufacturing steps and costs, while maintaining high-temperature operability and reliability.
Implementation Method 1
a long hollow insulation that is elastically deformable and comprises a hollow portion extending continuously in a longitudinal direction
Implementation Method 2
an insulating composition (C) comprising a thermoplastic polyurethane (c1) and an acid-modified polymer (c2) that is modified with an unsaturated carboxylic acid or a derivative thereof
Data Source
AI summary
A pressure-sensitive sensor includes a long hollow insulation that is elastically deformable and includes a hollow portion extending continuously in a longitudinal direction, a plurality of electrode wires that are provided along the inner peripheral surface of the hollow portion throughout the longitudinal length and are arranged facing each other with a distance therebetween so as to come into contact with each other when bent with elastic deformation of the hollow insulation, each electrode wire being formed by providing a conductive cover around a conductor, and an outer layer formed to cover an outer surface of the hollow insulation. The hollow insulation includes an insulating composition (A) including a styrene-based thermoplastic elastomer (a1). The outer layer including an insulating composition (C) including a thermoplastic polyurethane (c1) and an acid-modified polymer (c2) that is modified with an unsaturated carboxylic acid or a derivative thereof.