Resistance-based textile impact sensor systems
An innovative and unique method to create a resistance-based textile impact sensor has been demonstrated. The sensor is comprised of very low-cost materials and can detect impact and pressure. The sensor is highly conformable and constructed in such a way that make it tailorable for applications on varying geometries, detection sensitivity and ruggedness requirements. The impact sensor system includes a non-conductive carrier material. A pair of conductive wire traces are attached to the carrier material. A plurality of threads are provided to attach the conductive traces to the carrier material. A non-conductive covering material is positioned over the conductive traces opposite the carrier material. A conductive sheet is disposed over the covering material. The covering material is applied to the conductive traces to at least partially cover the surface of the at least two conductive traces facing the conductive sheet.
1 . An impact sensor system, comprising:
a non-conductive carrier material;
at least two conductive traces attached to the carrier material;
a plurality of threads, the threads attaching the at least two conductive traces to the carrier material;
a non-conductive covering material; and
a conductive sheet disposed over the non-conductive covering material;
wherein the non-conductive covering material is applied to the at least two conductive traces to at least partially cover the surface of the at least two conductive traces facing the conductive sheet
wherein an electrical continuity between the at least two wire traces being induced through the conductive sheet in response to an impact force allowing electrical current to flow between the at least two wires traces; and
wherein a measured amount of pressure of the impact force is determined based on a change in resistance between the at least two wire traces.
2 . The impact sensor system of claim 1 , wherein the plurality of threads comprises cotton, polymer or mixtures thereof.
3 . The impact sensor system of claim 1 , further comprising a conductive thread or yarn; and wherein the threads are attached by stitching the threads over the conductive traces into the carrier material.
4 . The impact sensor system of claim 1 , wherein the threads are attached by technical embroidery.
5 . The impact sensor system of claim 1 , wherein the non-conductive covering material is attached to the carrier material to secure the at least two conductive traces by embroidery.
6 . The impact sensor system of claim 1 , wherein the at least two conductive traces are separated by a separation distance.
7 . The impact sensor system of claim 6 , wherein the separation distance varies over at least a portion of the carrier material.
8 . The impact sensor system of claim 1 , wherein the conductive traces comprise one or more of a metal, a polymer material, a carbon nanotube material, or carbon nanotube yarn.
9 . The impact sensor system of claim 1 , wherein the conductive sheet further comprises a semi-flexible backing material forming a composite film system, the backing material being flexible and configured to return the conductive sheet to an original position after an impacting force is removed; and to distribute the force of impact across the sensor system.
10 . The impact sensor system of claim 1 , wherein an electrical continuity between the at least two wire traces being induced through the conductive sheet in response to an impact force allowing electrical current to flow between the at least two wires traces; and
wherein the impact force is determined based on a change in resistance between the at least two wire traces.
11 . The impact sensor system of claim 1 , wherein a sensitivity level of the sensor system is adjusted based on the stitching density of the threads.
12 . The impact sensor system of claim 1 , further comprising: a mesh material; the mesh material disposed between the at least two wires traces, and the conductive sheet to adjust a sensitivity level of the sensor system.
13 . The impact sensor system of claim 1 , wherein the at least two wire traces are sewn into the carrier material in a serpentine path and separated at opposing ends by a tape material to form respective continuous wire paths.
14 . A monitoring apparatus, comprising:
a sensor system attached to the article;
the sensor system comprising:
a non-conductive carrier material;
at least two conductive traces attached to the carrier material;
a plurality of threads, the threads attaching the at least two conductive traces to the carrier material;
a non-conductive covering material; and
a conductive sheet disposed over the non-conductive covering material;
wherein the non-conductive covering material is applied to the at least two conductive traces to at least partially cover the surface of the at least two conductive traces facing the conductive sheet
wherein an electrical continuity between the at least two wire traces being induced through the conductive sheet in response to an impact force allowing electrical current to flow between the at least two wires traces; and
wherein a measured amount of pressure of the impact force is determined based on a change in resistance between the at least two wire traces.
15 . The article of claim 14 , wherein the article is a martial arts uniform component.
16 . A system, comprising:
a non-conductive carrier material;
at least two conductive traces attached to the carrier material;
a plurality of threads, the threads attaching the at least two conductive traces to the carrier material;
a non-conductive covering material; and
a conductive sheet disposed over the non-conductive covering material;
wherein the non-conductive covering material is applied to the at least two conductive traces to at least partially cover the surface of the at least two conductive traces facing the conductive sheet;
wherein the at least two wire traces are sewn into the carrier material in a serpentine path in which the two wire traces overlap and are prevented from contacting each other by a tape
wherein an impact force is determined based on the at least two wire traces.
17 . The system of claim 16 , wherein the at least two wire traces are sewn into the carrier material in a serpentine path in which the two wire traces overlap at a bend and are prevented from contacting each other at the bend by a tape.