Multilayer Tactile Sensor with Conductive Yarn Fastening
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Solution Overview
Problem
Existing multilayer tactile sensors lose flexibility and pliability when assembled into a single, rigid unit, limiting their application in non-planar geometries and requiring complex housing or lamination for fixation.
Innovation Solution
A multilayer tactile sensor design featuring electrodes made of electrically conductive yarn with a fastening seam that extends along the longitudinal direction, allowing for individual layer alignment and fixation without significant loss of flexibility, enabling the sensor to be bent, twisted, or applied to uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the sensor layers are assembled into a single rigid unit using housing or lamination, then the structural stability and fixation are improved, but the flexibility and pliability of the sensor are significantly reduced
Solution Approach 1:
The sensor is divided into separate layers (first layer with first electrode, second layer with second electrode, and intermediate pressure-sensitive layer) that can be individually processed and assembled. The conductive yarns in each layer maintain electrical connectivity while allowing the layers to be fixed relative to each other through sewing, preserving flexibility while achieving structural stability.
Solution Approach 2:
The patent uses flexible conductive yarns embedded in textile layers instead of rigid conductive traces. The layers are connected through sewing with flexible thread, creating a soft, pliable structure that can conform to curved surfaces while maintaining electrical connectivity and structural integrity.
2Strength
If housing or lamination is used to fix the layers together, then the fixation strength is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The conductive yarns serve dual functions: they provide electrical conductivity and simultaneously act as the fastening element when sewn into the intermediate layer. This eliminates the need for separate fixation components, reducing manufacturing complexity while maintaining strong mechanical bonding between layers.
Solution Approach 2:
The electrical conductive function and the mechanical fastening function are merged into a single component (the conductive yarn). The same yarn that conducts electricity also serves as the sewing thread to attach layers together, simplifying the overall structure and manufacturing process.
3Area of stationary object
If continuous sheets with electrodes are used, then the sensor coverage area is improved, but the flexibility is reduced due to the need for rigid fixation
Solution Approach 1:
The patent employs flexible textile layers with embedded conductive yarns instead of rigid continuous sheets. The sewing connection method maintains flexibility across large areas, allowing the sensor to cover extensive surfaces while remaining pliable enough to conform to curved geometries like robot exteriors.
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 sensor maintains high flexibility and pliability, supports complex geometries, and can be easily manufactured, making it suitable for applications like robot skins and pinch protection, while being cost-effective and robust.
Implementation Method 1
the intermediate layer can also be made of a material that changes its electrical resistance under pressure
Implementation Method 2
the intermediate layer may comprise compressible elements for this purpose, so that, when pressure is directed transversely to the surface of the pressure mat, the two electrodes are pressed together and the electrodes get into direct contact
Data Source
AI summary
Multilayer tactile sensor with a first layer that comprises a first electrode, a second layer that comprises a second electrode and an intermediate layer of pressure-sensitive material that is disposed between the first and second layers and that spaces apart the first electrode from the second electrode. The sensor further comprises a fastening means for fixing the first and second electrodes relative to each other. At least the first electrode is made of electrically conductive yarn and extends along a defined longitudinal direction. The fastening means comprises at least a first seam that extends in the longitudinal direction and that comprises at least one thread that is fed repeatedly multiple times through the pressure-sensitive material in order to fix the first electrode in a defined position.