Method of manufacturing multi-layer electrode for a capacitive pressure sensor and multi-layer electrodes formed therefrom
A multi-layer electrode for a capacitive pressure sensor is manufactured according to a method including co-extruding a conductive polymer layer and a dielectric foam layer and forming coextruded layers of the capacitive pressure sensor and pressure rolling an XY layer and the coextruded layers together and forming the multi-layer electrode.
1. A multi-layer electrode for a capacitive sensor, the multi-layer electrode comprising:
an XY layer including a conductive layer printed onto a polymer layer; and
coextruded layers of a conductive polymer layer and a dielectric foam layer,
wherein the dielectric foam layer is disposed adjacent to the conductive layer of the XY layer.
2. The multi-layer electrode according to claim 1 , wherein the conductive layer includes a conductive ink layer.
3. The multi-layer electrode according to claim 2 , wherein the conductive ink layer has a thickness between about 10 μm to about 100 μm.
4. The multi-layer electrode according to claim 2 , wherein the conductive ink layer comprises at least one of silver, graphene, carbon, and indium tin oxide.
5. The multi-layer electrode according to claim 1 , wherein the conductive polymer layer comprises polyethylene terephthalate (PET).
6. The multi-layer electrode according to claim 5 , wherein the PET is recycled PET.
7. The multi-layer electrode according to claim 1 , wherein the conductive polymer layer comprises a filler.
8. The multi-layer electrode according to claim 7 , wherein the filler comprises graphene and carbon nanostructures.
9. The multi-layer electrode according to claim 8 , wherein the carbon nanostructures comprise carbon nanotubes.
10. The multi-layer electrode according to claim 9 , wherein the conductive polymer layer comprises between about 2 wt. % to about 15 wt. % of the graphene and between about 0.01 wt. % and 5 wt. % of the carbon nanotubes.
11. The multi-layer electrode according to claim 10 , wherein the conductive polymer layer has a flexural modulus equal to or greater than 5,000 MPa.
12. The multi-layer electrode according to claim 10 , wherein the conductive polymer layer has an electrical resistivity less than or equal to 10 Ohm/mm 3 .
13. The multi-layer electrode according to claim 10 , wherein the conductive polymer layer has a flexural modulus equal to or greater than 5,000 MPa and an electrical resistivity less than or equal to 10 Ohm/mm 3 .
14. The multi-layer electrode according to claim 1 , wherein the conductive polymer layer comprises between about 2 wt. % to about 15 wt. % of graphene, between about 0.01 wt. % and 5 wt. % of carbon nanotubes, a flexural modulus equal to or greater than 5,000 MPa and an electrical resistivity less than or equal to 10 Ohm/mm 3 .
15. The multi-layer electrode according to claim 14 , wherein the conductive polymer layer comprises between about 8 wt. % to about 10 wt. % of the graphene and between about 0.01 wt. % and 1 wt. % of the carbon nanotubes.
16. A multi-layer electrode for a capacitive pressure sensor, the multi-layer electrode comprising:
a conductive polymer layer; and
a dielectric foam layer contacting the conductive polymer layer; and
an XY layer including conductive ink roll to roll rotogravure printed onto a polymer layer,
wherein the XY layer contacts the dielectric foam layer, and the dielectric foam layer disposed between the XY layer and the conductive polymer layer.
17. The multi-layer electrode according to claim 16 , wherein the conductive polymer layer comprises between about 2 wt. % to about 15 wt. % of graphene, between about 0.01 wt. % and 5 wt. % of carbon nanotubes.
18. The multi-layer electrode according to claim 17 , wherein the conductive polymer layer has a flexural modulus equal to or greater than 5,000 MPa and an electrical resistivity less than or equal to 10 Ohm/mm 3 .
19. A method of manufacturing a multi-layer electrode for a capacitive pressure sensor, the method comprising:
co-extruding a conductive polymer layer and a dielectric foam layer and forming coextruded layers of the capacitive pressure sensor; and
pressure rolling an XY layer and the coextruded layers together and forming the multi-layer electrode.
20. The method according to claim 19 , wherein the conductive polymer layer has a flexural modulus equal to or greater than 5,000 MPa and an electrical resistivity less than or equal to 10 Ohm/mm 3 .