Sensor With Controllable Adhesion Using Functional Cuts
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Solution Overview
Problem
Traditional sensors face challenges with uncontrollable adhesion and separation, leading to low reuse rates and difficulties in removing adhesive agents, which affects production efficiency and device functionality.
Innovation Solution
A sensor design featuring a flexible substrate with axisymmetric functional cuts, crack-arrest holes, and a patterned electrode, combined with an adhesive layer, allowing for controllable adhesion and easy separation by adjusting cut widths and patterns, enabling strong adhesion and peelability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional sensors use high viscosity adhesive agents to obtain strong adhesion, then adhesion strength is improved, but separation becomes difficult and adhesive agents remain on device surfaces affecting device use
Solution Approach 1:
The sensor is divided into a sensor substrate and a release paper layer through functional cuts. The release paper acts as a temporary carrier that can be easily separated from the sensor substrate, while the sensor substrate itself maintains strong adhesion to the target surface. This segmentation allows the adhesive properties to be controlled and separated from the sensor core functionality.
Solution Approach 2:
The adhesive function is extracted from the sensor substrate and transferred to the release paper through the functional cuts design. The release paper with adhesive layer can be easily peeled off after serving its purpose of holding the sensor in place during application, leaving no residue on the device surface.
2Ease of operation
If traditional sensors are separated from surfaces, then they can be removed, but they are difficult to be used again and reuse rate is very low
Solution Approach 1:
By segmenting the sensor into a reusable sensor substrate and a disposable release paper component through functional cuts, the sensor substrate can be easily separated and reused on different surfaces while the release paper is discarded after single use.
Solution Approach 2:
The release paper with adhesive layer is designed to be discarded after single use, while the sensor substrate is recovered and can be reused multiple times on different surfaces, significantly improving the reuse rate of the sensor system.
3Adaptability or versatility
If functional cuts are made in the sensor substrate, then adhesion control is improved, but structural integrity may be compromised
Solution Approach 1:
Functional cuts are made only in specific local areas of the sensor substrate where adhesion control is needed, rather than compromising the entire structure. The cuts allow controlled separation at specific locations while maintaining the overall structural integrity of the sensor substrate for sensing functionality.
Solution Approach 2:
The functional cuts are pre-formed in the sensor substrate during manufacturing, creating predetermined separation paths that guide the separation process. This preliminary action ensures that when separation is needed, it occurs cleanly along the pre-defined cuts without compromising the sensor substrate's structural strength during normal use.
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 sensor achieves strong adhesion and easy peelability, with adjustable adhesion forces, improved reusability, and enhanced sensing capabilities for various surfaces, including complex and deformed ones, while reducing manufacturing costs and damage during peeling.
Implementation Method 1
an adhesive layer, allowing for controllable adhesion and easy separation
Implementation Method 2
sticking the release paper on a bottom of the adhesive layer as a protective layer
Data Source
AI summary
A sensor and a preparation method thereof are provided, the sensor includes a sensor substrate, functional cuts, crack-arrest holes, a patterned electrode, wires, an adhesive layer, and release paper. The preparation method includes following steps, preparing the sensor substrate and sticking the adhesive layer on the sensor substrate; then sticking the release paper on the adhesive layer; obtaining the functional cuts by laser cutting or blanking process; pasting a metal mask on a surface of the sensor substrate; depositing a material of the patterned electrode into a gap of the metal mask; removing the metal mask after a solvent of the liquid is volatilized; leading out the wires from patterned electrode pins; obtaining the sensor eventually. The sensor has advantages such as controllable adhesion, small size, light weight, sensitive sensing and simple manufacturing. The sensors are arrayable and suitable for sticking and sensing of large deformation and complex surfaces.