Segmented Foot Sensor Array for Contoured Motorized Boards

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Solution Overview

Problem

Existing motorized boards suffer from worn sensor arrays that buckle or produce false signals when applied to contoured surfaces, leading to malfunctions and safety hazards due to the lack of a design that can conform to uneven surfaces without stressing or buckling.

Innovation Solution

A laminate structure sensor array system with interconnected sensor fields and narrow lead fields that can adhere to contoured surfaces, preventing buckling and false signals by concentrating stress on the lead fields, allowing independent movement and flexible slots to accommodate uneven surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If sensor arrays are applied to contoured surfaces, then the sensor arrays can conform to the foot contact surfaces, but the sensor arrays buckle or become stressed causing false signals

Engineering Contradiction:

Improveconformability to contoured surfacesVSAvoidsensor signal accuracy

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The sensor array is divided into multiple independent sensor fields that are only interconnected by narrow lead fields. This segmentation allows each sensor field to move independently without stressing the sensors, while maintaining electrical connectivity through the flexible lead fields.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor array uses a flexible laminate structure with slots that allow the material to bend and conform to contoured surfaces. The narrow lead fields act as flexible connections that can accommodate surface irregularities without transmitting stress to the sensor elements.

Inventive Principle:

Principle #30Flexible shells and thin films

2Stability of the object's composition

If sensor arrays are made rigid to prevent buckling, then structural stability is improved, but the sensor arrays cannot conform to uneven surfaces

Engineering Contradiction:

Improvestructural stabilityVSAvoidconformability to contoured surfaces

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The rigid laminate structure is segmented into multiple sensor fields connected by narrow lead fields and slots. This segmentation allows the overall structure to remain stable while local regions can flex independently to accommodate contoured surfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor array transitions from a completely rigid structure to a dynamically flexible structure where narrow lead fields and slots allow controlled movement and deformation to match the contours of the foot contact surface while maintaining structural integrity.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If sensor arrays are designed for flat surfaces, then manufacturing is simplified, but the sensor arrays buckle or break when applied to contoured surfaces

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidresistance to buckling and breaking

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The sensor array is manufactured as a segmented laminate with pre-defined narrow lead fields and slots. This segmentation is built into the manufacturing process, allowing the structure to inherently accommodate contoured surfaces without requiring complex post-manufacturing adjustments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The manufacturing process incorporates variable flexibility parameters through the narrow lead fields and slots, allowing the sensor array to adapt its structural properties to match the underlying contoured surface while maintaining sensor functionality.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If sensor arrays are made flexible to conform to surfaces, then adaptability to contoured surfaces is improved, but the sensor arrays send false contact signals

Engineering Contradiction:

Improveconformability to contoured surfacesVSAvoidcontact detection accuracy

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The sensor array is segmented into independent sensor fields connected only by narrow lead fields. This segmentation isolates each sensor field so that flexing in one area does not stress or activate sensors in other areas, preventing false contact signals while maintaining conformability.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20260008337A1Sensor Array System for a Motorized Board

Publication Date: 2026.01.08 HILTON GREGORY L

AI summary

A system and method of replacing a worn foot sensor array on a motorized board. A new sensor array is provided that is made from a laminate structure. The laminate structure has multiple sensor fields, wherein the multiple sensor fields are disposed symmetrically about a midline. Slots can be formed or cut into the laminate structure, wherein the sensor fields are only interconnected by narrow lead wires. This enables the various sensor fields to move independently and rest against contoured surfaces without buckling, bending, or otherwise stressing the sensors on the sensor fields.