Soft Sensor with Liquid Metal Between Elastic Layers
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Solution Overview
Problem
The existing manufacturing processes for soft sensors used in hand-wearable devices are complex and do not easily accommodate the need for improved performance and elasticity, particularly in measuring hand movements for virtual reality applications.
Innovation Solution
A soft sensor design featuring an elastic sheet with multiple layers, including a first and second elastic layer, and a sensor unit formed by printing conductive liquid metal between these layers, allowing for flexible and accurate measurement of hand movements by varying resistance based on finger joint angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing processes are used for soft sensors, then manufacturing complexity is high, but manufacturing ease deteriorates
Solution Approach 1:
The soft sensor is divided into multiple elastic layers (first elastic layer, second elastic layer, third elastic layer) with the sensor unit positioned between specific layers. This segmentation allows each layer to be manufactured and processed independently, simplifying the overall manufacturing process while maintaining sensor functionality.
Solution Approach 2:
A base substrate is introduced as an intermediary element during the manufacturing process. The first elastic layer is formed on the base substrate, which facilitates the printing of conductive liquid metal and subsequent layer formation. The base substrate is later removed, having served its purpose as a manufacturing aid without appearing in the final product.
2Reliability
If conductive liquid metal is printed between elastic layers, then sensor performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes the unique properties of conductive liquid metal, which can be printed in a liquid state and then solidifies to form conductive patterns. This parameter change from liquid to solid state allows for precise patterning while accommodating slight variations in printing precision, as the liquid metal can flow to fill gaps and conform to the elastic layer surface.
Solution Approach 2:
The soft sensor employs composite materials including multiple elastic layers with different materials (first elastic material, second elastic material) and conductive liquid metal. This composite structure enhances sensor performance by combining the flexibility and elasticity of different elastic materials with the high conductivity of the liquid metal, while the layered structure provides mechanical support that tolerates manufacturing variations.
3Adaptability or versatility
If multiple elastic layers with different materials are used, then sensor adaptability is improved, but device complexity increases
Solution Approach 1:
Different elastic layers are made from different elastic materials tailored to specific functional requirements. The first elastic layer contacts the user's hand and requires high flexibility, while intermediate layers may require different mechanical properties for structural support. This local differentiation of material properties optimizes sensor performance for specific functions without requiring complete redesign of the entire structure.
Solution Approach 2:
The multi-layer elastic structure serves multiple functions simultaneously: the first elastic layer provides user comfort and skin contact, intermediate layers provide structural support and sensor positioning, and the overall structure enables various sensing functions (bending, stretching, adduction/abduction measurement). This multi-functionality reduces the need for separate components, thereby managing complexity while enhancing adaptability.
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 simplifies the manufacturing process while enhancing the sensor's performance and elasticity, enabling precise measurement of hand movements, including bending, stretching, and adduction/abduction, making it suitable for virtual reality applications.
Implementation Method 1
a sensor unit formed by printing a predetermined conductive liquid metal between the first elastic layer and the second elastic layer
Implementation Method 2
an elastic sheet including a first elastic layer and a second elastic layer facing each other
Data Source
AI summary
A soft sensor includes an elastic sheet, which includes a first elastic layer and a second elastic layer facing each other, and a sensor unit formed by printing a predetermined conductive liquid metal between the first elastic layer and the second elastic layer. A hand-wearable device may include at least one soft sensor, wherein the hand-wearable device has a shape corresponding to at least a portion of a shape of a hand, and the soft sensor is located at a position corresponding to at least some joints of the hand.