Spiral Electrode Tactile Sensing Array for Complex Surfaces
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Solution Overview
Problem
Conventional tactile sensing arrays have limited extensibility and elasticity, are costly to manufacture, and are prone to damage and short circuits when applied to complicated surfaces due to their material and structural limitations.
Innovation Solution
A tactile sensing array featuring spirally wound first and second electrodes with elastic wires and conducting wires, clad with a soft material, and a manufacturing method that includes injecting a cladding layer solution, arranging electrodes, applying conductor drops, and performing vacuum and heating processes to create a flexible and durable sensing array.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If doped conductors and soft plastic materials are used in conventional tactile sensing arrays, then the manufacturing cost increases, but the extensibility and elasticity are improved
Solution Approach 1:
The patent changes the material parameters from conventional soft plastic doped with conductors to liquid silicone rubber, which inherently provides both the required extensibility/elasticity and lower manufacturing cost. The spiral electrode structure also changes the geometric parameters to accommodate deformation while maintaining conductivity.
Solution Approach 2:
The patent uses composite materials by combining liquid silicone rubber with spiral wire electrodes, creating a tactile sensing array that leverages the elasticity of the rubber and the conductivity of the wire structure. This composite approach achieves both high adaptability and cost-effectiveness.
2Adaptability or versatility
If the tactile sensing array is applied to complicated cambered surfaces, then the applicability scope is improved, but the risk of damage and short circuit due to deformation increases
Solution Approach 1:
The patent employs spiral wire electrodes instead of straight conductors. The spiral configuration allows the electrodes to naturally accommodate curved and cambered surfaces without experiencing excessive tensile stress that would cause damage or discontinuous contact. This curved geometry inherently matches the topology of complicated surfaces.
Solution Approach 2:
The patent changes the conductor geometry from straight to spiral, which fundamentally alters how the electrode responds to deformation. The spiral structure maintains continuous electrical contact even when stretched or bent, preventing short circuits and maintaining reliability on complicated surfaces.
3Ease of manufacture
If straight conductors are used in conventional tactile sensing arrays, then the manufacturing process is simplified, but the resistance increases and short circuits occur due to discontinuous contact during deformation
Solution Approach 1:
The spiral configuration of the wire electrodes provides a curved path that maintains continuous contact with the conductive elastomer throughout deformation. This geometric change ensures that the electrical connection remains stable and resistance-free even when the sensor is stretched or bent during 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 solution achieves high extensibility, high elasticity, and low manufacturing cost, preventing damage from deformation and ensuring accurate application on complex surfaces by maintaining continuous conductivity and stability.
Implementation Method 1
each first electrode including a first elastic wire, and a first conducting wire spirally wound around the first elastic wire
Implementation Method 2
prevents damages caused by high deformation when the tactile sensing array is used and covered onto a complicated surface
Data Source
AI summary
In a tactile sensing array and its manufacturing method, the tactile sensing array includes first and second electrodes at different layers, conductors provided for cladding intersection positions of the first and second electrodes, and a cladding layer for cladding the first and second electrodes and conductors. Each of the first and second electrodes is a spiral conducting wire wound onto an elastic wire. During manufacture, a cladding layer solution is injected into a mold; first electrodes are installed in rows and apart, and each first electrode includes conductor solution drops; second electrodes are installed at the conductor solution drops; a cladding layer solution is injected again; and vacuum, heating and demolding process are performed. The invention has the effects of high extensibility, high elasticity and low manufacturing cost and prevents damages caused by high deformation when the tactile sensing array is used and covered onto a complicated surface.