Polymeric foam deformation gauge

• US 10,260,968 B2
• Filed: 08/05/2016
• Issued: 04/16/2019
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Nano Composite Products, Inc.
• Original Assignee: Nano Composite Products, Inc.
• Inventors: Merrell, Aaron Jake, Bowden, Anton E., Fullwood, David T., Mazzeo, Brian Anthony
• Primary Examiner(s): Patel, Harshad R
• Application Number:
  US15/229,662
• Publication Number:
  US 20160341610A1
• Time in Patent Office: 984 Days
• Field of Search: None
• CPC Class Codes: G01B 7/16 for measuring the deformation in a solid, e.g. by resistance strain gauge
• CPC Class Codes: G01L 1/04 by measuring elastic deformation of gauges, e.g. of springs
• CPC Class Codes: G01L 1/06 by measuring the permanent deformation of gauges, e.g. of compressed bodies
• CPC Class Codes: G01L 1/16 using properties of piezoelectric devices
• CPC Class Codes: G01L 1/18 using properties of piezo-resistive materials, i.e. materials of which the ohmic resistance varies according to changes in magnitude or direction of force applied to the material
• CPC Class Codes: G01L 1/20 by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids of piezo-resistive materials G01L1/18; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress
• CPC Class Codes: G01L 5/0052 measuring forces due to impact G01L5/0061, G01L5/14 take precedence; impact testing of structures G01M7/08; impact testing of material G01N3/00
• CPC Class Codes: H10N 30/092 Forming composite materials
• CPC Class Codes: H10N 30/852 Composite materials, e.g. having 1-3 or 2-2 type connectivity
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

In one general aspect, an apparatus includes at least two conductive elements disposed in a polymeric foam and at least two voltage detectors. Each voltage detector is coupled to a respective conductive element and configured to detect a charge generated by an impact to the polymeric foam within a sensing radius of the respective conductive element. In another general aspect, an apparatus includes a deformation sensor and a voltage detector. The deformation sensor includes a conductive element disposed in a polymeric foam, a portion of the conductive element extending beyond an outer wall of the polymeric foam. The voltage detector is coupled to the portion of the conductive element and detects a charge generated by the deformation sensor responsive to an impact to the polymeric foam.

Claims

1. An apparatus, comprising:

a deformation sensor that includes at least two conductive elements disposed in a polymeric foam, a portion of each of the at least two conductive elements extending beyond an outer wall of the polymeric foam; and

a voltage detector coupled to the at least two conductive elements for detecting a charge generated by the deformation sensor in response to an impact to the polymeric foam within a sensing radius of the respective conductive element, wherein a charge generated by an impact to the polymeric foam is a function of the surface area of the conductive element that is disposed in the polymeric foam, and wherein the at least two conductive elements are adjacently spaced in the polymeric foam so that the respective sensing radii of the at least two conductive elements overlap.

2. The apparatus of claim 1, wherein the polymeric foam is a composite foam that includes conductive fillers.

3. The apparatus of claim 1, further comprising a voltage collector that stores the charge generated by the deformation sensor.

4. The apparatus of claim 1, wherein at least one of the at least two conductive elements is copper wire.

5. The apparatus of claim 1, wherein at least one of the at least two conductive elements is a wire coil.

6. The apparatus of claim 1, wherein at least one of the at least two conductive elements includes conductively coated film.

7. The apparatus of claim 1, further comprising:

a wireless controller operably coupled to the voltage detector; and

a computing device operably coupled to the wireless controller, the computing device configured to analyze data collected by the voltage detector.

8. The apparatus of claim 1, wherein the impact generates the charge via a triboelectric effect.

9. An apparatus, comprising:

at least two conductive elements disposed in a polymeric foam; and

at least two voltage detectors, each voltage detector being coupled to a respective conductive element, the voltage detector configured to detect a charge generated by an impact to the polymeric foam within a sensing radius of the respective conductive element, wherein the at least two conductive elements are adjacently spaced in the polymeric foam so that the sensing radii overlap.

10. The apparatus of claim 9, wherein the polymeric foam is a composite foam that includes conductive fillers, the conductive fillers being up to 25 percent by weight of the composite foam.

11. The apparatus of claim 9, further comprising:

a memory communicatively coupled to the at least two voltage detectors, the memory configured to store voltage data collected by the at least two voltage detectors.

12. The apparatus of claim 9, further comprising:

a compression impact analysis module stored on a non-transitory computer readable medium and communicatively coupled to the at least two voltage detectors, the compression impact analysis module configured to use voltage data from at least two voltage detectors to determine a location of the impact.

13. The apparatus of claim 9, wherein each voltage detector is coupled to a portion of the respective conductive element that extends beyond an outer wall of the polymeric foam.

14. The apparatus of claim 9, wherein the conductive elements include a wire that enters an outer wall of the polymeric foam and is splayed.

15. The apparatus of claim 9, wherein the apparatus functions as padding in a consumer apparatus.

16. A method for measuring compression strain, the method comprising:

detecting, along a first axis, a charge generated in response to an impact to a polymeric foam having at least one conductive element disposed therein, the impact being along a second axis different from the first axis; and

determining a deformation of the impact based on the charge, the polymeric foam measuring up to 80% strain without permanent deformation of the foam.

17. The method of claim 16, wherein the conductive element has a sensing radius and the impact occurs within the sensing radius.

18. The method of claim 16, wherein the polymeric foam has at least two conductive elements disposed therein and the charge is a first charge and the method further comprises:

detecting, along a third axis different from the first axis and the second axis, a second charge generated by the impact; and

determining a location of the impact based on the first charge and the second charge.

19. The method of claim 16, wherein the charge generated is a function of the surface area of the at least one conductive element disposed therein.

20. The method of claim 16, further comprising determining a strain rate and deformation for the impact based on the charge generated.

21. The method of claim 16, wherein the polymeric foam is a uniform composite foam that includes conductive fillers.

22. The method of claim 16, wherein the polymeric foam is part of a wearable device and the method further comprises using the charge generated to extend battery life of the wearable device.

23. The method of claim 16, wherein the charge generated decreases with increasing distance of the impact from the conductive element.

24. The method of claim 16, further comprising providing auditory or visual feedback when the deformation meets a threshold.

25. An apparatus, comprising:

a deformation sensor that includes a conductive element disposed on a polymeric foam, the conductive element including conductive ink or conductive paint; and

a voltage detector, coupled to the conductive element, for detecting a charge generated by the deformation sensor responsive to an impact within a sensing radius of the conductive element.

26. The apparatus of claim 25, wherein the conductive element is one of a plurality of conductive elements and the plurality of conductive elements form circuitry.

27. The apparatus of claim 25, wherein the conductive element is one of a plurality of conductive elements and the plurality of conductive elements are disposed on the polymeric foam in a pattern that enables sensing radii of adjacent conductive elements to overlap.

28. The apparatus of claim 25, wherein the polymeric foam is a composite foam that includes conductive fillers.

29. The apparatus of claim 25, wherein the conductive element is a first conductive element of a plurality of conductive elements, each of the plurality of conductive elements being coupled to the voltage detector via a respective trace, wherein the first conductive element is closer to the voltage detector than a second conductive element of the plurality of conductive elements, and a trace for the second conductive element has lower voltage response than a trace of the first conductive element.

30. The apparatus of claim 25, wherein the deformation sensor generates the charge without a current producing device.