Pressure Sensor Foam with Dispersed Conductive Material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Pressure sensing devices face issues with sensitivity degradation due to detachment of conductive fillers and reduced elastic restoring force when repeatedly used, particularly when an adhesive is used in the conductive solution, affecting their performance and durability.
Innovation Solution
A pressure sensor design featuring a foam intermediate layer with a porous region dispersed in a non-porous region and a conductive material dispersed within, providing a higher conductivity rate than the foam, which minimizes filler detachment and maintains high elastic restoring force, using materials like polyurethane, polyolefin, and conductive materials such as Au, Ag, or CNTs, and a manufacturing process that mixes and foam-molds the foam and conductive material to ensure even distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive filler is attached to the surface of elastic foam using adhesive, then conduction performance is improved, but elastic restoring force is degraded
Solution Approach 1:
The conductive filler and elastic foam are merged into a single integrated structure where conductive filler particles are embedded within the foam matrix during the foam formation process. This eliminates the need for separate adhesive layers while maintaining both conduction performance and elastic restoring force, as the filler becomes structurally integrated with the foam rather than being superficially attached.
Solution Approach 2:
The invention uses a composite material structure where conductive filler particles are dispersed throughout the elastic foam matrix. This composite approach allows the foam to maintain its inherent elastic properties while the distributed conductive filler provides conduction pathways, achieving both electrical functionality and mechanical performance without compromise.
2Strength
If adhesive is used in conductive solution to attach conductive filler, then attachment strength is improved, but manufacturing complexity increases
Solution Approach 1:
The adhesive component is extracted from the conductive solution formulation. Instead of using a complex adhesive-based conductive solution, the invention employs a simplified conductive filler that can be directly incorporated into the foam matrix during foam formation, eliminating the need for separate adhesive application steps and reducing manufacturing complexity.
Solution Approach 2:
The conductive filler and elastic foam are merged into a single integrated structure where conductive filler particles are embedded within the foam matrix during the foam formation process. This eliminates the need for separate adhesive layers while maintaining both conduction performance and elastic restoring force, as the filler becomes structurally integrated with the foam rather than being superficially attached.
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 precise pressure detection and distribution analysis with enhanced durability and simplified manufacturing, maintaining consistent resistance values even after repeated use, while ensuring high insulation performance and reduced pollution from detached conductive materials.
Implementation Method 1
a conductive material dispersed in the foam and having a conductivity rate that is higher than that of the foam
Implementation Method 2
The intermediate layer has elasticity
Implementation Method 3
A resistance of the intermediate layer may be changed according to change in at least one of a thickness and a volume of the intermediate layer
Data Source
AI summary
A pressure sensor comprises: a first electrode layer; a second electrode layer; and an intermediate layer disposed between the first electrode layer and the second electrode layer, wherein the intermediate layer changes in resistance, depending on a change in at least one of a thickness or a volume thereof. In addition, the intermediate layer comprises: a foam having porous regions dispersed in a non-porous region thereof; and a conductive material being dispersed in the foam and being more conductive than the foam.