Thermo-formable Sensor Device for 3D Touch and Pressure Sensing
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Solution Overview
Problem
Existing touch sensing technologies are limited by their reliance on rigid, flat formats and require numerous traces and sensors, which are prone to contamination and increase production costs, and lack the ability to provide 3D touch interactions and soft tactile feedback.
Innovation Solution
A sensor device with non-metallic, thermo-formable electrodes that can be molded into any 3D shape, using capacitive interactions between separate electrode portions to provide 3D touch and pressure sensing, reducing the need for metal traces and allowing for soft tactile feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional rigid touch sensing technologies are used, then touch location sensing can be achieved, but the device is limited to flat formats and requires numerous traces and sensors increasing complexity
Solution Approach 1:
The patent combines multiple sensing functions (touch location, pressure sensing, 3D shape detection) into a single flexible sensor device. The conductive material with 3D textured surface integrates what would traditionally require separate components, reducing the quantity of traces and sensors while enabling both flat and 3D formats.
Solution Approach 2:
The sensor device uses a flexible substrate that can be deformed into various 3D shapes while maintaining sensing functionality. The conductive material's electrical properties change dynamically in response to both touch location and applied pressure, enabling multiple sensing modes without additional components.
2Strength
If moulded hard encapsulation materials are used, then structural protection is provided, but soft pressure tactile feedback cannot be delivered
Solution Approach 1:
The patent employs composite material construction with a flexible substrate containing conductive material embedded within or coated on the surface. This composite structure provides both the structural integrity needed for protection and the softness required to deliver pressure tactile feedback to the user.
Solution Approach 2:
Instead of rigid encapsulation, the patent uses a flexible substrate that can deform under pressure to provide tactile feedback. The flexible nature of the substrate allows it to conform to pressure applied by the user while maintaining structural coherence and protection for internal components.
3Ease of operation
If gaps are provided between control features and housing, then control feature accessibility is improved, but contamination entry is facilitated
Solution Approach 1:
The patent extracts the control features from traditional mechanical buttons with gaps and reimagines them as surface-level 3D textured patterns on the flexible substrate. This eliminates the need for deep gaps between controls and housing while maintaining accessibility, as the 3D features can be actuated directly on the surface without creating contamination pathways.
4Measurement precision
If numerous traces and sensors are used, then sensing precision can be improved, but production costs increase
Solution Approach 1:
The patent segments the sensing function into two components: the 3D textured surface geometry and the conductive material properties. By optimizing the 3D texture patterns and conductive material distribution, the device achieves high sensing precision for both touch location and pressure without requiring a dense array of discrete sensors and traces, thereby reducing manufacturing complexity and cost.
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 3D touch and pressure sensing with reduced components, enhancing user interaction and reducing manufacturing complexity and contamination risks while maintaining reliability.
Implementation Method 1
a capacitive touch switch, a person needs merely to touch the sensor, which changes the capacitance within the sensor and triggers the switch
Implementation Method 2
These may operate based on piezoresistive, piezoelectric, capacitive and elastoresistive sensing
Implementation Method 3
These may operate based on piezoresistive, piezoelectric, capacitive and elastoresistive sensing
Data Source
Figure 1~2
Figure 3(a)~4(a)
Figure 4(b)~5
AI summary
A sensor device (100) comprises a plurality of electrode portions (10a, 10b, 10c) configured to provide one or more electrical signals and a non-conductive material (20) provided on or over the plurality of electrode portions. The one or more electrical signals are provided in response to a change in capacitance between (i) at least one of the plurality of electrode portions and a conductive object (40) being near to or in contact with the non-conductive material, and/or (ii) at least one of the plurality of electrode portions and at least one other of the plurality of electrode portions. A system comprising the sensor device and method of manufacturing the sensor device are also provided.