Tessellated Sensor Sheet With Release Liner
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Solution Overview
Problem
There is a need for inexpensive, easily manufactured, and easily handled functional material sensors that can be applied in confined spaces without contaminating or damaging the small sensor elements, which are typically less than 100 mm^2 in size.
Innovation Solution
A sheet with a tessellated zipper pattern of elements coated with a pressure-sensitive adhesive and a continuous strip of functional material, allowing for safe handling and application by grasping the base portion without direct contact with the functional material, using a backing layer, adhesive, and release liner for protection and ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct contact with functional material is avoided to prevent contamination, then sensor purity is improved, but handling difficulty increases
Solution Approach 1:
A release liner serves as an intermediary barrier between the handler and the functional material. The release liner can be peeled away to reveal the functional material only when needed, allowing handling without direct contact and preventing contamination while maintaining ease of operation
Solution Approach 2:
The sensor assembly is segmented into distinct layers: a base layer, a functional material layer, and a release liner layer. This segmentation allows the release liner to be separated and discarded after use, while the functional material remains protected on the base layer
2Loss of substance
If small sensor elements are used to reduce material cost, then functional material usage is reduced, but handling difficulty increases
Solution Approach 1:
Multiple small sensor elements are merged onto a single release liner in an array configuration. This allows handlers to work with the entire array as one unit rather than individual tiny elements, significantly improving handling ease while still using minimal functional material per sensor
3Loss of substance
If functional material is applied in small spots to reduce cost, then material expense is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The functional material is pre-applied to the base layer in controlled patterns before the release liner is attached. This preliminary action allows precise material placement to be achieved during the manufacturing process rather than requiring precision during application, reducing both cost and precision requirements during field 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
Enables efficient and cost-effective application of small functional material sensors in confined spaces, minimizing contamination risk and ensuring reliable detection of conditions such as temperature, pressure, or analyte presence.
Implementation Method 1
coated with a pressure-sensitive adhesive
Data Source
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AI summary
A sheet of sensors and a method of manufacturing such sheet of sensors. The sheet is configured with (A) a tessellated zipper pattern 20 of identically shaped elements 30 defining (i) a right longitudinal column 21r consisting of a base portion 31 of a right set of elements 30r, (ii) a left longitudinal column 21s consisting of a base portion 31 of a left set of elements 30s, and (iii) an intermediate longitudinal column 21i consisting of alternating tab portions 32 of the right 30r and left 30s elements, and (B) a continuous longitudinal strip of functional material 70 positioned only within the intermediate column 21i.