Strain Gauge Noise Reduction via Conductive Layer

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Solution Overview

Problem

Conventional strain gauges experience increased noise at the resistor, leading to reduced measurement accuracy.

Innovation Solution

A strain gauge with a flexible resin substrate and a resistor made of chromium or nickel, featuring a conductive layer on the opposite side of the substrate to reduce noise, which is formed using a Cr composite film with a stable crystalline phase and a conductive layer with high electrical conductivity to minimize noise and measurement errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a conventional strain gauge structure is used with a resistor formed on an insulating resin substrate, then the device is simple to manufacture, but noise is superimposed at the resistor leading to reduced measurement accuracy

Engineering Contradiction:

Improvemeasurement accuracyVSAvoidnoise

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

A conductive layer is introduced as an intermediary component between the insulating resin substrate and the external environment. This conductive layer acts as a mediator that dissipates static electricity and reduces noise interference, thereby improving measurement accuracy without complicating the fundamental resistor-on-substrate structure

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The noise reduction function is extracted from the resistor itself and assigned to a separate conductive layer on the substrate. This separation allows the resistor to maintain its measurement function while the conductive layer independently handles noise dissipation, resolving the contradiction between simplicity and noise reduction

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If the substrate is made of insulating resin to provide electrical isolation, then insulation is achieved, but static electricity accumulates causing noise interference

Engineering Contradiction:

Improveelectrical insulationVSAvoidstatic electricity

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The substrate exhibits local quality differentiation: the bulk substrate material maintains insulating properties for electrical isolation, while a surface conductive layer is applied to specifically address static electricity accumulation. This localized functional differentiation resolves the contradiction between insulation and static electricity dissipation

Inventive Principle:

Principle #3Local quality

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 strain gauge effectively reduces noise and enhances measurement accuracy by stabilizing the crystalline phase of the resistor and reducing static electricity interference, particularly in sensitive gauges with a gauge factor of 10 or more.

Implementation Method 1

a conductive layer formed on the other side of the substrate

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

formed using a Cr composite film with a stable crystalline phase

Methodology Applied

Scientific EffectCrystalline phase stabilization: Crystallisation

Data Source

PatentUS20230109237A1Strain gauge

Publication Date: 2023.04.06 MINEBEAMITSUMI INC

AI summary

A strain gauge includes a flexible resin substrate and a resistor formed of material including at least one of chromium or nickel, the resistor being situated on one side of the substrate. The strain gauge includes a conductive layer formed on the other side of the substrate.