Selectively Adhered Resistive Force Sensor Air Gap Control
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Solution Overview
Problem
Resistive touch sensors face challenges with air gaps between the conductive layer and sensor electrodes, leading to reduced sensitivity, false touch detection, and manufacturing complexities due to the need for strict adhesion and stiffness to maintain contact, which affects the accuracy and reliability of touch detection.
Innovation Solution
The use of selectively adhered force sensors with adhesion areas within the sensor active area to constrain the flexible membrane, reducing air gaps and enhancing sensor sensitivity by allowing closer proximity of the conductive layer to the sensor electrodes, eliminating the need for a ring spacer adhesive and improving modularity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ring spacer adhesive is used to maintain a strict air gap, then the sensor can prevent false touch detection, but the manufacturing complexity increases and the device size must be reduced
Solution Approach 1:
The patent divides the continuous ring spacer adhesive into discrete adhesive dots distributed across the sensor surface. This segmentation simplifies manufacturing by eliminating the need for precise ring adhesive application while maintaining the air gap function at multiple discrete points, reducing false touch detection without complex manufacturing processes
Solution Approach 2:
The patent applies adhesive properties locally at specific dot positions rather than uniformly across the entire perimeter. Each adhesive dot creates a localized air gap where needed, allowing the membrane to be constrained at multiple points without requiring a continuous adhesive ring, thus simplifying manufacturing while maintaining reliability
2Device complexity
If glass beads or adhesive dots are used for larger devices, then the manufacturing is simplified, but the air gap control becomes less precise
Solution Approach 1:
The patent optimizes the parameters of adhesive dots including their size (50-500 micrometers), spacing (1-10 millimeters), and distribution pattern to achieve both manufacturing simplicity and adequate air gap control. By carefully selecting these parameters, the system maintains sufficient separation without requiring precise control of every individual gap, balancing manufacturing ease with functional performance
3Device complexity
If the flexible membrane is allowed to rest on sensor electrodes, then the manufacturing is simplified, but the sensor sensitivity decreases due to reduced contact area
Solution Approach 1:
Instead of allowing the membrane to rest on electrodes and hoping for sufficient contact, the patent inverts the approach by using adhesive dots to actively create and maintain the desired air gap. This ensures the membrane is positioned optimally for sensitivity while keeping the overall structure simple, achieving both manufacturing ease and measurement precision
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 increases sensor sensitivity, reduces false touch detection, simplifies manufacturing, and enhances durability by stabilizing the membrane under stress, while minimizing the incidence of false positives and improving user experience.
Implementation Method 1
a first flexible membrane can be selectively adhered to a sensor surface within an active area of the sensor
Implementation Method 2
the conductive layer (typically a conductive polymer composite) contacts a sensor electrode and creates a new electrical path
Implementation Method 3
When a force is applied to deflect or depress the flexible membrane
Data Source
AI summary
A system and method for fabricating a selectively-adhered force sensor comprising a flexible membrane constrained at a multitude of points within the sensor active area. The system comprising a processor; and a memory that stores executable instructions that, when executed by the processor, facilitate performance of operations, comprising: facilitating application of a conductive layer to a first surface; and facilitating curing of the conductive layer to the first surface.