Two-Layer MFR Sensor Array for Rolling and Folding Durability

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Solution Overview

Problem

Existing mechanical force redistribution (MFR) sensor arrays require multiple supporting layers, which increase cost and are prone to damage from layer misalignment and abrasion during rolling or folding.

Innovation Solution

A mechanical force redistribution sensor array is designed with only two supporting layers, integrating force sensing components and protrusions into a single layer, using piezoresistive materials on protrusions to transmit force without additional layers, allowing for flexible and damage-resistant operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple supporting layers are used in MFR sensor arrays, then structural support and component mounting are improved, but cost increases and the sensor becomes prone to damage from layer misalignment and abrasion during rolling or folding

Engineering Contradiction:

Improvestructural supportVSAvoiddurability during rolling or folding

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent combines multiple supporting layers into a single supporting layer structure. The force sensing components are directly mounted on this single layer, eliminating the need for multiple separate supporting layers. This merging approach maintains structural support functionality while eliminating the problems of layer misalignment and abrasion between layers during rolling or folding operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single supporting layer is designed to perform multiple functions simultaneously: it provides structural support, serves as a mounting substrate for force sensing components, and acts as a protective layer during rolling or folding. This multi-functional design eliminates the need for separate specialized layers for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If multiple supporting layers are used in MFR sensor arrays, then component mounting capability is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecomponent mounting capabilityVSAvoidnumber of supporting layers

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges multiple supporting layers into a single integrated layer structure. Force sensing components are directly mounted on this single layer, simplifying the manufacturing process by eliminating the need to handle, align, and assemble multiple separate supporting layers. This reduces both manufacturing complexity and cost while maintaining component mounting capability.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If additional supporting layers are added to protect force sensing components, then component protection is improved, but cost increases and flexibility decreases

Engineering Contradiction:

Improvecomponent protectionVSAvoidflexibility during rolling or folding

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The single supporting layer is designed to simultaneously provide component protection and maintain flexibility for rolling or folding operations. By integrating the protective function into the single supporting layer rather than adding separate protective layers, the patent maintains flexibility while providing necessary protection for force sensing components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reduces costs to less than $1.00 per square foot, enhances durability by eliminating layer misalignment and abrasion, and maintains sensor functionality during rolling or folding.

Implementation Method 1

using piezoresistive materials on protrusions to transmit force

Methodology Applied

Scientific EffectPiezoresistive effect: Piezoresistive Effect

Data Source

PatentUS12585354B2Mechanical force redistribution sensor array embedded in a single support layer

Publication Date: 2026.03.24 TACTONIC TECHNOLOGIES LLC

AI summary

An MFR sensor array having a first supporting layer. The array has a second supporting layer. The array has a force sensing component disposed between the first and second supporting layers. The array has protrusions combined with the force supporting component, where there are only two supporting layers. When a force is applied to the second supporting layer, the force causes the second supporting layer to contact protrusions so the force is transmitted through the protrusions to the force supporting component and through the force supporting component. An MFR sensor array. A system for sensing. A method for sensing.