Pressure-Sensitive Sensor Extrusion Without Spacer
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Solution Overview
Problem
The existing method for manufacturing pressure-sensitive sensors requires multiple steps, including creating and removing a spacer, which is time-consuming and costly, especially when producing long sensors.
Innovation Solution
A method using an extruder with a cylindrical die, a mandrel with helical grooves, and an annular outlet to simultaneously extrude elastic insulating and conductive materials, forming a tubular body with helically arranged conductive and insulating ribs without the need for a spacer, reducing manufacturing steps and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the traditional method using a spacer is employed to manufacture pressure-sensitive sensors, then the electrode wires can be properly positioned and the sensor structure can be formed, but the manufacturing process becomes complex and time-consuming due to the additional steps of creating and removing the spacer
Solution Approach 1:
The invention extracts and eliminates the spacer component from the manufacturing process. Instead of using a separate spacer to position electrode wires and then removing it, the patent directly forms the sensor structure with electrode wires positioned on the elastic insulation surface through a simplified extrusion process, removing the unnecessary spacer element entirely
Solution Approach 2:
The invention merges the positioning function previously performed by the spacer into the extrusion molding process itself. The electrode wires are positioned and fixed directly during the extrusion of the elastic insulation material, combining the positioning and structural formation steps into a single integrated process
2Manufacturing precision
If the traditional method with spacer creation and removal is used, then the sensor can be manufactured with proper electrode positioning, but the manufacturing time increases significantly
Solution Approach 1:
The invention performs preliminary positioning of the electrode wires during the extrusion process itself, rather than requiring subsequent positioning steps. The electrode wires are arranged on the elastic insulation surface as the material is being extruded, ensuring proper positioning is achieved in advance before the main sensor assembly begins
Solution Approach 2:
The invention maintains continuous useful action throughout the manufacturing process by eliminating the interruptive spacer removal step. The extrusion and positioning operations proceed continuously without interruption, and the sensor assembly follows immediately without downtime for spacer removal, maintaining productive action throughout
3Manufacturing precision
If spacers are used in the manufacturing process, then electrode wires can be positioned correctly, but the manufacturing cost increases due to additional materials and process steps
Solution Approach 1:
The invention extracts and eliminates the spacer material from the bill of materials. By removing the spacer component entirely, the patent eliminates the cost of spacer materials as well as the costs associated with the additional manufacturing steps required to create and remove the spacer
Solution Approach 2:
The invention replaces the expensive and complex spacer system with a simpler, more economical direct positioning method. The electrode wires are positioned directly during extrusion using minimal additional materials or fixtures that are far less costly than traditional spacers
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
This approach significantly reduces manufacturing time and costs, enabling the production of longer pressure-sensitive sensors without the need for expensive spacers and simplifies the manufacturing process by eliminating the spacer removal step.
Implementation Method 1
performing simultaneous extrusion-molding of an elastic insulating material and an elastic conductive material by supplying the elastic conductive material into not less than two of the grooves from the inside of the mandrel while extruding the elastic insulating material
Data Source
AI summary
A method for manufacturing a pressure-sensitive sensor includes providing an extruder that includes a cylindrical die, a mandrel arranged inside the die and having plural helical grooves on an outer circumferential surface, and an annular outlet sandwiched between the die and the mandrel, and by using the extruder, performing simultaneous extrusion-molding of an elastic insulating material and an elastic conductive material by supplying the elastic conductive material into not less than two of the grooves from the inside of the mandrel while extruding the elastic insulating material, so as to form a pressure-sensitive sensor. The sensor includes a tubular body including an elastic insulation and having a hollow portion along a longitudinal direction, and not less than two conductive ribs including an elastic conductor and helically provided along an inner circumferential surface of the hollow portion of the tubular body so as to protrude inward from the inner circumferential surface.