Deformable Suspension Web With Conductive Ink Sensor
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Solution Overview
Problem
Existing seat detection systems in vehicles are hindered by thickness and stiffness issues due to the use of multiple substrates and semiconductor materials with microprotrusions, leading to unreliable operation and assembly challenges.
Innovation Solution
A deformable suspension sheet with an electric track formed by conductive ink, which varies linear resistance with deformation, is integrated directly into the suspension ply, providing a single, aligned sensor for reliable operation and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple substrates with semiconductor material are used to create a pressure detector, then the detection function is achieved, but the thickness and stiffness increase
Solution Approach 1:
The patent combines the substrate and sensor elements into a single integrated structure. The conductive ink is applied directly onto a single flexible support, eliminating the need for multiple stacked substrates and reducing overall thickness while maintaining the pressure detection function through the variable resistance layer.
Solution Approach 2:
The patent uses a thin flexible support as the base structure, replacing thick rigid substrate assemblies. This flexible film approach enables the sensor to be thin and compliant, solving both the thickness reduction goal and maintaining flexibility for proper seat integration.
2Reliability
If semiconductor material with microprotrusions is used, then pressure sensitivity is achieved, but the stiffness in bending and torsion increases
Solution Approach 1:
The patent employs a thin flexible support structure that inherently provides the necessary compliance for bending and torsion. This flexible film replaces rigid substrate assemblies, allowing the sensor to flex with the seat material while maintaining pressure detection capability through the conductive ink layer's variable resistance.
3Reliability
If electrode structures and semiconductor material are placed on separate substrates, then the detection function works, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges the substrate, electrode structures, and sensing material into a single integrated component. The conductive ink serves multiple functions simultaneously as it is applied directly onto the flexible support, eliminating the need for separate substrate assemblies and reducing overall device complexity.
Solution Approach 2:
The conductive ink layer performs multiple functions: it serves as the electrode structure, the sensing element, and the conductive pathway all in one. This multi-functional approach replaces the need for separate specialized components on different substrates, simplifying both the device structure and assembly process.
4Length of stationary object
If a single support sheet is used with electrode structures and semiconductor material, then thickness is reduced, but operational reliability decreases
Solution Approach 1:
The patent uses a specifically designed flexible support that maintains structural integrity while enabling proper sensor operation. The flexible film provides the necessary mechanical properties for the conductive ink to function reliably as a pressure sensor, ensuring operational reliability despite the reduced thickness and single-substrate construction.
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 configuration enhances passenger comfort, reduces weight and thickness, and ensures accurate detection of seat occupancy, allowing for efficient activation of seat functions like airbag deployment and heated seats, while differentiating between passengers and objects.
Implementation Method 1
configured to present a variable linear resistance in depending on the deformation of the suspension layer
Data Source
Figure 1~2
AI summary
The invention relates to an improved seating element for a seat, particularly a vehicle seat, comprising a deformable suspension web (3) and at least one electrical track (2) configured to exhibit a linear resistance that varies according to the deformation of the suspension web (3), the electrical track (2) being formed directly on the suspension web (3) or within the suspension web (3). The invention also relates to a seat comprising such a seating element.