Flexible pressure-sensing pad and manufacturing method

• US 10,856,737 B2
• Filed: 07/20/2018
• Issued: 12/08/2020
• Est. Priority Date: 07/24/2017
• Status: Active Grant

• Current Assignee: Contin Technology Limited
• Original Assignee: Contin Technology Limited
• Inventors: Au, Chungwing
• Primary Examiner(s): Noori, Max H
• Application Number:
  US16/465,062
• Publication Number:
  US 20190290132A1
• Time in Patent Office: 872 Days
• Field of Search: 73774
• CPC Class Codes: A47C 27/12 with fibrous inlays, e.g. made of wool, of cotton
• CPC Class Codes: A47C 31/123 for beds or mattresses
• CPC Class Codes: A47C 31/126 for chairs
• CPC Class Codes: A61B 2562/0247 Pressure sensors
• CPC Class Codes: A61B 5/0053 by applying pressure, e.g. compression, indentation, palpation, grasping, gauging
• CPC Class Codes: A61B 5/1115 Monitoring leaving of a patient support, e.g. a bed or a wheelchair
• CPC Class Codes: A61B 5/6843 Monitoring or controlling sensor contact pressure
• CPC Class Codes: A61B 5/6892 Mats
• 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 1/205 using distributed sensing elements
• CPC Class Codes: G01L 5/00 Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes

Abstract

The present invention relates to a flexible pressure-sensing pad and manufacturing method thereof. The flexible pressure-sensing pad includes a first fabric substrate layer, a second fabric substrate layer, and a fabric barrier layer provided between the first fabric substrate layer and the second fabric substrate layer. The first fabric substrate layer includes a first electrode and the second fabric substrate layer includes a second electrode. The fabric barrier layer has multiple through holes. The first electrode and the second electrode are electrically connected with a controller. Compared with the current pressure-sensing pad, the present invention is thinner and more flexible, has superior breathability and waterproofness, does not generate an irritating noise, creates a quiet recuperative environment for patients and can sense an external force over the entire pressure sensing pad without any blind spots, thereby providing better user experience.

Claims

1. A flexible pressure-sensing pad comprising a first fabric substrate layer, a second fabric substrate layer, and a fabric barrier layer provided between the first fabric substrate layer and the second fabric substrate layer;

the first fabric substrate layer comprising a first electrode on a side facing toward the fabric barrier layer, and the second fabric substrate layer comprising a second electrode on a side facing toward the fabric barrier layer;

the fabric barrier layer comprising multiple through holes;

the first electrode and the second electrode are electrically connected with a controller, the first electrode and the second electrode are capable to contact each other via the through holes of the fabric barrier layer.

2. The flexible pressure-sensing pad of claim 1, wherein the first fabric substrate layer and the second fabric substrate layer are two separate fabrics in a same size with one being superimposed on the other, or are one fabric folded symmetrically from a middle line of the fabric.

3. The flexible pressure-sensing pad of claim 1, wherein fabrics for the first fabric substrate layer and the second fabric substrate layer are one of flexible or bendable synthetic textile, vegetable textile, animal textile and mineral textile.

4. The flexible pressure-sensing pad of claim 1, wherein the first electrode covers a lower surface of the first fabric substrate layer, and the second electrode covers an upper surface of the second fabric substrate layer;

or the first electrode is distributed on the lower surface of the first fabric substrate layer in a form of parallel lines, cross lines or grid lines, and the second electrode is distributed on the upper surface of the second fabric substrate layer in a form of parallel lines, cross lines or grid lines.

5. The flexible pressure-sensing pad of claim 1, wherein the first electrode and the second electrode both are formed by applying a conductive material to the first fabric substrate layer and the second fabric substrate layer;

the conductive material is conductive ink printed on the first fabric substrate layer and the second fabric substrate layer or a solid flexible conductive material adhered to the first fabric substrate layer and the second fabric substrate layer.

6. The flexible pressure-sensing pad of claim 5, wherein the conductive ink is metal Ag, metal Cu, metal Au, carbon or conductive polymer or a composition of more than one of them;

the solid flexible conductive material is a conductive fabric or a thin metal strap.

7. The flexible pressure-sensing pad of claim 1, wherein the fabric barrier layer is 0.01 mm-10 mm thick;

the through holes of the fabric barrier layer are round holes, triangular holes, rectangular holes, pentagonal holes, hexagonal holes or irregular holes, or a combination of more than one of them.

8. The flexible pressure-sensing pad of claim 1, wherein the flexible pressure-sensing pad further comprises a first flexible film provided between the first fabric substrate layer and the first electrode, and a second flexible film provided between the second fabric substrate layer and the second electrode.

9. The flexible pressure-sensing pad of claim 8, wherein the first flexible film and the second flexible film are 10 μ

m-500 μ

m thick thermoplastic films;

the thermoplastic films are made of one of TPU, PET and PE.

10. The flexible pressure-sensing pad of claim 8, wherein the flexible pressure-sensing pad further comprises a third flexible film provided around an edge of the first fabric substrate layer and around an edge of the second fabric substrate layer, as a sealing edge cover.

11. A manufacturing method of a flexible pressure-sensing pad, wherein the method comprises,

laminating a first flexible film on a first fabric substrate layer, and a second flexible film on a second fabric substrate layer;

laminating a first electrode on the first flexible film and facing away from the first fabric substrate layer, and a second electrode on the second flexible film and facing away from the second fabric substrate layer;

connecting a cable with the first electrode and the second electrode;

assembling the first fabric substrate layer laminated with the first flexible film and the first electrode, a fabric barrier layer, and the second fabric substrate layer laminated with the second flexible film and the second electrode;

the fabric barrier layer being between the first electrode and the second electrode, the fabric barrier layer comprising multiple through holes and the first electrode and the second electrode are capable to contact each other via the through holes of the fabric barrier layer.

12. The manufacturing method of a flexible pressure-sensing pad of claim 11 further comprising a step of providing the first fabric substrate layer and the second fabric substrate layer, the step of providing comprising:

preparing a fabric, cleaning the fabric, then cutting the fabric into two fabrics of a same shape and a same size as a first fabric substrate layer and a second fabric substrate layer respectively;

or, using a fabric and symmetrically folding the fabric from a middle line to form the first fabric substrate layer and the second fabric substrate layer.

13. The manufacturing method of a flexible pressure-sensing pad of claim 11, wherein the step of laminating the first flexible film on the first fabric substrate layer, and the second flexible film on the second fabric substrate layer comprises:

pasting thermoplastic films on a lower surface of the first fabric substrate layer and an upper surface of the second fabric substrate layer respectively.

14. The manufacturing method of a flexible pressure-sensing pad of claim 11, wherein the step of laminating the first electrode on the first flexible film and facing away from the first fabric substrate layer, and the second electrode on the second flexible film and facing away from the second fabric substrate layer comprises:

applying conductive ink to the lower surface of the first fabric substrate layer and the upper surface of the second fabric substrate layer by an adhesive or silk-screen printing to form the first electrode and the second electrode;

or, printing a solid flexible conductive material to the lower surface of the first fabric substrate layer and the upper surface of the second fabric substrate layer by an adhesive or hot pressing or silk-screen printing to form the first electrode and the second electrode.

15. The manufacturing method of a flexible pressure-sensing pad of claim 11, wherein the step of connecting a cable with the first electrode and the second electrode comprises:

using a copper strip with adhesive/a conductive fabric with adhesive to fix the cable to the first electrode, and using a copper strip with adhesive/a conductive fabric with adhesive to fix the cable to the second electrode;

or, opening eyeholes/eyelets on the first electrode and the second electrode, and fixing the cable to the first electrode or the second electrode via fixing parts and the eyeholes/eyelets.

16. The manufacturing method of a flexible pressure-sensing pad of claim 11, wherein the step of assembling comprises:

placing the barrier layer between the first fabric substrate layer and the second fabric substrate layer, aligning edges of the first fabric substrate layer and the second fabric substrate layer or the first electrode and the second electrode; and

then fixing the first fabric substrate layer coated with the first flexible film and the first electrode, the second fabric substrate layer coated with the second flexible film and the second electrode, and the barrier layer together.