Stretch Sensor Flexible Interconnect Strain Management

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Solution Overview

Problem

Existing stretch sensors face challenges in interconnecting stretchable electrodes with sensing circuits, particularly due to electromagnetic noise and the difficulty of maintaining reliable connections as the sensors stretch away from rigid terminals.

Innovation Solution

A stretch sensor design featuring electrode films separated by dielectric films, with interconnection components that include conductive regions for bonding to terminals, and strain control features like tapers and apertures to manage strain and shield the electrodes, allowing for flexible yet non-stretchable interconnection components to connect stretchable sensor components to sensing circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If stretchable electrodes are directly connected to rigid terminals, then the sensor can be stretched, but the connection becomes unreliable due to strain and electromagnetic noise

Engineering Contradiction:

ImprovestretchabilityVSAvoidconnection reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The interconnection component is segmented into multiple conductive regions (first conductive region, second conductive region, third conductive region) that are spatially separated and functionally distinct. This segmentation allows each region to handle specific tasks: bonding to electrodes, providing shielding, and connecting to terminals, thereby maintaining connection reliability during stretching

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interconnection component acts as an intermediary element between the stretchable sensor component and the rigid sensing circuit terminals. It provides a transition zone that accommodates mechanical deformation while maintaining electrical connectivity, using multiple conductive regions to mediate the connection and reduce strain transmission

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If electrodes are exposed without shielding, then the sensor structure is simpler, but electromagnetic noise interferes with measurement accuracy

Engineering Contradiction:

Improveinterconnection structureVSAvoidcapacitance measurement accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The second conductive region is specifically designed as a shielding layer with local quality different from the bonding and terminal connection regions. This localized shielding structure provides electromagnetic protection precisely where needed without requiring complete redesign of the entire interconnection component

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Multiple functions are merged into the interconnection component: electrical bonding (first conductive region), electromagnetic shielding (second conductive region), and terminal connection (third conductive region). This integration achieves noise protection while maintaining a relatively compact structure

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If the interconnection component is fully stretchable, then the sensor can be stretched freely, but the electrical connection properties become unstable

Engineering Contradiction:

Improvestretch rangeVSAvoidelectrical connection stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The interconnection component incorporates dynamic characteristics through its flexible substrate that allows bending and deformation, while the conductive regions maintain stable electrical properties. The structure adapts to stretching through controlled flexibility rather than uniform stretchability

Inventive Principle:

Principle #15Dynamics

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 design enables reliable measurement of stretch-induced changes in capacitance, effectively addressing the challenges of electromagnetic noise and stretch-induced strain, while maintaining a stable connection to sensing circuits.

Implementation Method 1

the second conductive film is bonded to connect the second electrode film to the second terminal, wherein the second electrode film overlays the first electrode film on the interconnection component to shield the first electrode film

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Implementation Method 2

the sensor component is operable to stretch to change an area of overlap of the electrode films and/or change the separation of the electrode films to change the capacitance

Methodology Applied

Scientific EffectCapacitance variation with geometry: Capacitance

Data Source

PatentUS10539475B2Stretch sensor with an improved flexible interconnect

Publication Date: 2020.01.21 SENSOR HLDG LTD

AI summary

In one embodiment the invention provides an interconnection component operable to interconnect a stretchable sensing component and cable for a sensing circuit. The interconnection component has a flexible circuit board comprising conductive regions to electrically connect to conductive layers of a sensor component overlaying the circuit. The flexible circuit board of one embodiment comprises engagement features to allow the sensor cast over the component to engage the flexible circuit board.