CN117774279A - Flexible strain sensor vulcanization packaging method, sensor and intelligent tire strain monitoring system - Google Patents
Flexible strain sensor vulcanization packaging method, sensor and intelligent tire strain monitoring system Download PDFInfo
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Abstract
The invention belongs to the technical field of intelligent tires and flexible electronics, and discloses a flexible strain sensor vulcanization packaging method, a sensor and an intelligent tire strain monitoring system. The invention comprises the following steps: preparing a plurality of flexible sensor monomers and an L-shaped flexible multi-channel adapter plate for interconnection with the outside, and electrically connecting the flexible sensor monomers and the L-shaped flexible multi-channel adapter plate; preparing a rubber final rubber compound for vulcanization encapsulation, grooving the positions of the flexible sensor monomers, and arranging the flexible sensor monomers and the L-shaped flexible multi-channel adapter plate on the rubber final rubber compound; the flexible sensor monomer is protected and fixed by adopting rubber vulcanization package, and the flexible strain sensor packaged by vulcanization is suitable for the tire preparation process, is convenient for actual production, and can be attached to the inner wall of the tire or completely embedded into the tire. The invention is beneficial to improving the sensitivity and reliability of the sensor, combines the flexible strain sensor with the traditional tire to form the intelligent tire, and is beneficial to feeding back the working condition of the automobile tire, the road surface perception and the like.
Description
Technical Field
The invention relates to the technical fields of intelligent tires, micro-nano sensing technology and flexible electronics, in particular to a flexible strain sensor vulcanization packaging method, a sensor and an intelligent tire strain monitoring system.
Background
The intelligent tire strain monitoring system integrates the technologies of sensors, communication, control, management and the like, can monitor the state and performance of the tire in real time, transmits data to a vehicle or a cloud for analysis and processing, and provides real-time tire health condition and running performance information. The intelligent tire strain monitoring system can help a driver to better know the running condition of a vehicle, improve running safety, prolong the service life of tires and improve fuel efficiency. The sensor is one of key components in the intelligent tyre strain monitoring system and is mainly used for monitoring the pressure, temperature, strain and other working condition parameters of the tyre. The contact sensor used in the intelligent tire in the market mainly comprises an accelerometer sensor, a piezoelectric sensor, a surface acoustic wave sensor and a fiber bragg grating sensor, wherein the non-contact sensor comprises an optical sensor and an ultrasonic sensor, some of the sensors can damage the internal structure of the tire so as to reduce the mechanical reliability of the tire, some of the sensors are expensive and huge in size and are not beneficial to data acquisition, and the non-contact sensor lacks contact information between the tire and the road surface and is not suitable for practical application. To overcome these limitations, researchers have begun exploring the use of flexible materials to fabricate strain sensors. The flexible strain sensor can be used as a core component of an intelligent tire strain monitoring system, has intelligent, high-precision, cooperative and multifunctional feedback control capability, has good deformability, can better adapt to the deformation of the surface of a tire, and provides accurate strain quantity.
The package plays an important role in the flexible strain sensor, and can not only protect the sensor device from physical and environmental damage, but also provide functions such as signal processing, circuit connection, standardized interfaces and the like. Flexible packages typically use flexible materials and thin film circuits that preserve the flexibility and bending properties of the sensor while accommodating bending or wearable applications. With the continuous development of technology and the continuous expansion of application, sensor packaging technology is also advancing continuously so as to meet the requirements of different fields and applications. For working environments like intelligent tire movement, efficient packaging of the sensor is particularly important. The inability of conventional sensor packages to accommodate the harsh operating environment of a tire can lead to a number of problems such as differences in compatibility of conventional rigid electronics with the tire, high process costs, and inability to effectively crosslink with the tire.
To summarize, conventional packaging methods (e.g., injection molding and plastic packaging) have the following drawbacks:
1. conventional packaging materials have a degree of stiffness that contradicts the softness and bending characteristics that flexible strain sensors should possess, and rigid packaging can limit the flexibility and comfort of the sensor in applications such as tire curvature, wearable or human contact.
2. The manufacturing process of conventional packaged flexible sensors is relatively complex, involves multiple steps and materials, requires precise process control and fine assembly skills, and increases manufacturing difficulty and cost. 3. Conventional packaging may place limitations on the performance of the sensor. For example, the electrical conductivity, thermal conductivity, etc. characteristics of the encapsulation material may affect aspects of the sensor's sensitivity, response time, stability, etc. 4. In conventional packaging, a rapid, accurate and repeatable packaging process for the flexible sensor cannot be achieved, which may lead to non-uniformity in packaging quality and performance, affecting the reliability and stability of the sensor inside the tire.
In addition, the flexible strain sensor packaged by the conventional packaging method is easy to have the following defects when being applied to the intelligent tire:
1. the packaging of conventional sensors does not provide good protection performance and does not ensure that the sensor is not compromised by the external environment. For example, conventional packages do not have dustproof, waterproof, and shock resistance capabilities and cannot cope with various road conditions and environments. 2. Intelligent tire sensor packages need to consider the ability to accommodate different temperatures, humidities and chemicals. Tires are subjected to extreme conditions in everyday use, and conventional package designs are not capable of meeting these requirements. 3. Conventional sensor packages have no way to provide an interface with the vehicle system or external devices, which may involve wireless communication modules, electronic interfaces and connectors, and thus cannot enable transmission and interaction of data. 4. The traditional package has poor reliability and durability, and cannot cope with long-term use and severe road conditions.
With the continuous development of technology, new packaging methods and materials are continuously emerging, and methods such as vulcanized rubber packaging and the like gradually overcome the problems, so that the flexible strain sensor has better practical value in the field of intelligent tires.
Disclosure of Invention
The invention aims to provide a flexible strain sensor vulcanization packaging method, which is used for protecting a flexible sensor element and providing mechanical strength and environmental isolation for the flexible sensor element by vulcanizing and packaging the flexible sensor element.
In order to achieve the above purpose, the invention adopts the following technical scheme:
a flexible strain sensor vulcanization packaging method comprises the following steps:
step 1, preparing a plurality of flexible sensor monomers and an L-shaped flexible multichannel adapter plate for interconnection with the outside; the method comprises the steps that a plurality of flexible sensor monomers are respectively and electrically connected with an L-shaped flexible multi-channel adapter plate in a parallel connection mode;
step 2, preparing a layer of rubber final rubber sheet for vulcanization encapsulation, wherein grooves for realizing the installation of the flexible sensor monomers are formed in positions corresponding to each flexible sensor monomer, and the grooves are arranged in parallel on the rubber final rubber sheet;
step 3, arranging each flexible sensor monomer and the L-shaped flexible multi-channel adapter plate on the rubber final rubber sheet, smearing and fixing the flexible sensor monomers and the L-shaped flexible multi-channel adapter plate by epoxy resin glue, and covering a layer of rubber final rubber sheet;
and step 4, putting the whole obtained in the step 3 into a mold for vulcanization packaging to obtain the flexible strain sensor.
In addition, the invention also provides a flexible strain sensor for the intelligent tire strain monitoring system, and the flexible strain sensor is prepared by adopting the flexible strain sensor vulcanization packaging method.
In addition, the invention further provides an intelligent tire strain monitoring system, which comprises a controller and a strain sensor. The strain sensor adopts the flexible strain sensor for the intelligent tire strain monitoring system.
The flexible strain sensor is attached to the inner wall of the tire or is completely embedded into the tire;
each flexible sensor monomer in the flexible strain sensor is distributed along the width direction of the tire and is respectively used for monitoring strain signals of the tire wall position, the two side positions of the tread width direction and/or the middle position of the tread width direction;
the L-shaped flexible multi-channel adapter plate is connected to a controller of the intelligent tire strain monitoring system through flexible wires.
The invention has the following advantages:
as described above, the invention relates to a flexible strain sensor vulcanization packaging method, a sensor and an intelligent tire strain monitoring system. The flexible strain sensor formed by vulcanization packaging is attached to the inner wall of the tire or is completely embedded into the tire (for example, is arranged between the inner layer of the tire and the cord layer) in combination with the tire preparation process, and is used for monitoring and measuring parameters and data related to the tire in real time so as to provide accurate vehicle monitoring and optimizing driving experience.
Drawings
Fig. 1 is a schematic flow chart of a flexible strain sensor vulcanization packaging method in an embodiment of the invention.
Fig. 2 is a schematic diagram showing the arrangement of each flexible sensor monomer on a rubber final adhesive before vulcanization encapsulation in the embodiment of the invention.
FIG. 3 is a diagram of a rubber vulcanization package process in an embodiment of the invention.
Fig. 4 is a schematic structural diagram of a flexible strain sensor after vulcanization encapsulation in an embodiment of the present invention.
Fig. 5 is a schematic diagram showing signal waveform changes at different positions under different loads.
Fig. 6 is a schematic structural diagram of a flexible sensor unit according to an embodiment of the invention.
FIG. 7 is a schematic view of the location of a flexible strain sensor embedded as a sensing layer within a tire in an embodiment of the invention.
Fig. 8 is a schematic diagram of a structure of an interface between a conductive button and a flexible wire of a flexible sensor unit according to an embodiment of the invention.
FIG. 9 is a block flow diagram of a flexible strain sensor vulcanization packaging method in accordance with an embodiment of the present invention.
The flexible multi-channel patch panel comprises a 1-flexible sensor unit, a 2-L-shaped flexible multi-channel patch panel, a 3-lower rubber final rubber sheet, a 4-groove, a 5-upper rubber final rubber sheet, a 6-Ecoflex substrate, a 7-multi-wall carbon nanotube, an 8-conductive layer copper electrode, a 9-conductive button, a 10-flexible lead, an 11-flexible strain sensor, a 12-tire inner layer, a 13-channel patch panel opening, a 14-covering cord layer, a 15-tire wall layer, a 16-steel belt layer, a 17-tread layer, an 18-upper conductive button unit, a 19-lower conductive button unit and a 20-ring pad interface.
Detailed Description
The invention is described in further detail below with reference to the attached drawings and detailed description:
example 1
The embodiment provides a flexible strain sensor vulcanization packaging method for an intelligent tire strain monitoring system. The sensor prepared by the packaging method not only can meet the requirements of severe working environments in the tire, but also is suitable for the tire preparation process, is beneficial to actual production, truly realizes embedding into the tire, and can be used for meeting the requirements of an intelligent tire strain monitoring system on strain monitoring. The packaging method can realize accurate measurement and real-time monitoring of the tire strain, can help to improve the safety and drivability of the vehicle, and simultaneously reduces the manufacturing cost of the intelligent tire strain monitoring system.
As shown in fig. 1 and 9, the flexible strain sensor vulcanization packaging method in this embodiment includes the following steps:
step 1, preparing a plurality of flexible sensor monomers 1 and an L-shaped flexible multi-channel adapter plate 2 for interconnection with the outside; and electrically connecting the plurality of flexible sensor monomers with the L-shaped flexible multichannel adapter plate in a parallel connection mode through flexible wires respectively.
The flexible sensor unit 1 preferably adopts the flexible sensor unit of the Ecoflex substrate 6 and the multi-wall carbon nano tube conductive layer 7. The preparation process of the flexible sensor monomer of the Ecoflex substrate and the multi-wall carbon nano tube conductive layer is as follows:
and 1.1. Weighing Ecoflex glue A and Ecoflex glue B in the mass ratio of 1:1, fully stirring and mixing, then placing the stirred Ecoflex solution into a vacuum chamber (the pressure is-0.06 MPa, for example) for vacuum removal of redundant bubbles, and vacuumizing for 5 minutes.
Step 1.2. The bubble-removed and uncured Ecoflex gel was spin coated onto a glass sheet with surface sandpaper using a spin coater, then placed in an oven at 60 ℃ for 30 minutes, and the cured Ecoflex film was peeled from the glass sheet.
The spin coating time is, for example, 10s, and the spin coating speed is 50rad/min.
Step 1.3. The peeled Ecoflex film is cut into the length required by the sensor, and the multi-wall carbon nanotube powder is brushed on the Ecoflex surface until the brush is saturated.
The flexible sensor unit may be manufactured in a strip shape, for example, with a size of 1cm×5cm, as shown in fig. 6. Of course, the flexible sensor unit may have other shapes, such as a serpentine structure, which will not be described herein.
Step 1.4. Uniformly brushing conductive silver paste on the end part of the Ecoflex strip of the multi-walled carbon nanotube, applying the conductive silver paste by using a copper electrode (for example, cutting the copper electrode into a strip size of 1cm multiplied by 2 cm), and then placing the copper electrode in an oven for heating and curing.
Wherein the heating temperature of the oven is 120 ℃ and the heating time period is 30 minutes.
And 1.5, after the conductive silver paste is solidified and cooled, weighing Ecoflex glue A and Ecoflex glue B in a mass ratio of 1:1, and pouring the Ecoflex glue A and the Ecoflex glue B into the multi-wall carbon nano tube after brushing in vacuum to be used as a first package.
Step 1.6. Intermediate punching is performed at the end copper electrode 8 and conductive buttons 9 are attached for interconnection with the outside.
Of course, the flexible sensor unit 1 in the present embodiment is not limited to the Ecoflex substrate 6 and the flexible sensor unit of the multi-walled carbon nanotube conductive layer 7, and any flexible and stretchable strain sensor may be used.
Other common flexible stretchable strain sensors also include, for example: a rubber-based sensor based on a molybdenum disulfide and multi-wall carbon nano tube composite assembly network, a flexible sensor based on a laser-induced graphene film, and the like.
The flexible sensor is generally composed of a flexible substrate film and a conductive sensitive layer, wherein the substrate can be Ecoflex, PDMS and the like, and the conductive sensitive layer can be multi-walled carbon nanotube, graphene, carbon black and the like, including but not limited to the materials described above.
The L-shaped flexible multi-channel adapter plate is a flexible circuit board with a 90-degree bending angle, and can be connected with a flexible sensor unit and a controller through a flip buckle interface.
The plurality of flexible sensor units are electrically connected with the L-shaped flexible multi-channel adapter plate through flexible wires 10 in parallel. Fig. 8 shows a schematic diagram of the interface structure of the conductive button and the flexible wire of the flexible sensor unit.
Wherein one end of the flexible wire 10 is provided with a flexible wire annular pad interface 20.
The conductive button comprises an upper conductive button unit 18 and a lower conductive button unit 19. The upper conductive button unit 18 and the lower conductive button unit 19 in this embodiment may adopt a snap-and-snap structure in a hidden button.
Specifically, the upper conductive button unit 18 is annular, the flexible wire annular pad interface 20 is also annular, and the radius of the inner and outer circles of the annular pad interface 20 is the same as the radius of the upper conductive button unit, and the same size is convenient for signal transmission and electrical connection.
The connection relation between them is: the lower conductive button unit 19 passes through the hole obtained after punching treatment in the middle of the copper electrode 8, the ring pad interface 20 is sleeved on the lower conductive button unit 19, and then the upper conductive button unit is covered.
The other end of the flexible wire is connected with (the buckle of) the L-shaped flexible multi-channel adapter plate 2 by welding or a bonding pad. The button interface can ensure the reliability of electrical connection and mechanical connection in the signal transmission process.
And defining the number of the flexible sensor monomers 1 as M, wherein the total number of channels of the L-shaped flexible multi-channel adapter plate is M+1, and connecting the flexible sensor monomers 1 by using a lead in a common ground mode.
The ground wire is connected to the 1 channel of the L-shaped flexible multi-channel adapter plate, and each flexible sensor monomer is correspondingly connected to the remaining M channels of the L-shaped flexible multi-channel adapter plate one by one through flexible wires; m is a natural number, and M is more than or equal to 2.
The process of curing and packaging 4 flexible sensor units to form a flexible strain sensor is shown in fig. 2.
Specifically, one end of each of the 4 sensor conductive buttons is connected with a flexible wire in a common ground mode, the ground wire is connected to the 1 channel of the adapter plate, and the other ends of the 4 sensors are respectively led to the 2, 3, 4 and 5 channels of the adapter plate.
And 2, preparing a lower layer of rubber final rubber sheet 3 for vulcanization packaging, and arranging a groove 4 at the arrangement position corresponding to each flexible sensor monomer for realizing the fixation of the flexible sensor monomers.
Wherein, each groove 4 is arranged in parallel on the rubber final refining sheet; the width W and the thickness S of each groove are matched with the flexible sensor monomer, so that the flexible sensor monomer is flush with the surface of the rubber final rubber piece after being placed.
Each flexible sensor unit 1 can be arranged on the rubber final rubber sheet according to actual needs and has a certain position rule.
Taking the flexible strain sensor (assuming 4 flexible sensor units are used) for 235/50ZR18 tires as an example:
the dimensions of the rubber final film were 19cm long and 9cm wide, and the arrangement of 4 flexible sensor monomers on the rubber final film was as follows:
the individual flexible sensor units 1 are arranged in parallel on a rubber finishing strip as shown in fig. 2.
The sensors 1a and 1c correspond to both side positions in the tread width direction with a spacing of 7cm (width of the sensor is 1 cm); the sensor 1b is spaced 3cm from the sensors 1a and 1c corresponding to the intermediate position in the tread width direction.
The sensor 4 is used to measure the sidewall position deformation signal, so the distance between the sensor 1d and the sensor 1a is 11cm.
When the flexible strain sensor manufactured in this embodiment 1 is applied to a tire, each flexible sensor unit (e.g., the sensors 1a to 1 d) is used for measuring data signals at corresponding positions, and the arrangement of each sensor is shown in fig. 2.
The above is merely exemplary, and the interval between the sensors 1a to 1d may be determined according to the actual tire size, and in addition, the number of sensors is not limited to the above 4, and other numbers may be provided as needed.
The L-shaped flexible multi-channel adapter plate 2 extends to the outer side of the edge of the lower rubber final rubber sheet 3, and is not vulcanized and packaged. And the flexible strain sensor is needed to be embedded into the tire in the later period, and then the inner layer rubber of the tire needs to be cut into the opening of the channel adapter plate, so that the L-shaped flexible multi-channel adapter plate 2 is conveniently connected into the inner wall of the tire and connected with the controller.
And 3, arranging each flexible sensor monomer 1 and the L-shaped flexible multi-channel adapter plate 2 on the rubber final rubber sheet 3, smearing and fixing the flexible sensor monomers and the L-shaped flexible multi-channel adapter plate by epoxy resin adhesive, and covering an upper layer of the rubber final rubber sheet 5.
Wherein, each flexible sensor monomer is attached to the rubber final rubber with the open groove at the bottom layer according to the appointed sequence.
And 4, putting the whole obtained in the step 3 into a mold for vulcanization packaging to obtain the flexible strain sensor, wherein the flexible strain sensor performs signal transmission with external communication equipment through the L-shaped flexible multi-channel adapter plate.
The specific vulcanization process of the flexible strain sensor is as follows:
and 4.1. Placing the bottom rubber final mixing sheet with the adhered and arranged sensor into a groove of a vulcanizing tank die, placing the whole into the vulcanizing tank, introducing 2.0-3.0Mpa steam to form a high-pressure effect, heating the two layers of rubber final mixing sheets in the die to a temperature 15-25% higher than the conventional vulcanizing temperature, and accelerating the crosslinking reaction.
And 4.2, switching and introducing high-pressure nitrogen after preset time (for example, after 10 minutes), wherein the pressure in the vulcanizing tank reaches 5Mpa, and the temperature is 160 ℃ and floats up and down to form the heat preservation and pressure maintaining effects.
At this time, no high temperature medium is introduced, the inlet valve and the outlet valve are closed, and the time lasts for 10 minutes, so that the sensor is completely vulcanized and packaged.
After the vulcanization is completed, the vulcanizing tank is opened and the vulcanized and encapsulated flexible strain sensor is allowed to cool, which helps to cure and stabilize the crosslinked rubber, as shown in FIG. 3.
And 4.4, trimming the edge of the rubber product by using the sensor array subjected to vulcanization encapsulation, and performing surface cleaning.
The rationality of the vulcanization package of the flexible sensor unit 1 in this embodiment is that:
firstly, the rubber final rubber mixing material has the flexible and stretchable characteristic, so that the flexibility of a flexible sensor monomer in the intelligent tire in strain is not limited; secondly, the rubber final rubber compound has no conductivity, and the vulcanization package has no influence on the sensitivity and response time of the sensor; finally, due to the maturation of the rubber vulcanization packaging process, the reliability of the flexible strain sensor is enhanced, and the service life of the device in the intelligent tire is greatly prolonged.
The sensor element can be provided with long-term effective reliability through rubber vulcanization encapsulation, and the method is specifically characterized in that:
first, the vulcanization encapsulation prevents the sensor element from being affected by adverse environmental factors such as physical damage, moisture intrusion, or oxidation, which further enhances its reliability for a sensor having high stability itself.
And secondly, the sensor subjected to rubber vulcanization packaging is attached or completely embedded into a whole with the traditional tire, so that the sensor array has good environmental isolation and mechanical protection performance, can be used in a severe working environment of an automobile tire, and is convenient to be efficiently produced by combining with a tire preparation process.
The flexible strain sensor manufactured by rubber vulcanization encapsulation is combined with a traditional tire to form an intelligent tire strain detection system, and can be used for monitoring and measuring various parameters of the inside and the side wall of the tire, such as tire pressure, load, vehicle speed and the like.
Example 2
This embodiment 2 describes a flexible strain sensor prepared by the flexible strain sensor vulcanization packaging method described in embodiment 1.
In the embodiment, the flexible strain sensor is subjected to rubber vulcanization packaging, so that the sensor after rubber vulcanization can have excellent stretchability even if subjected to severe external force in the intelligent tire, and can adapt to various working conditions and road conditions.
The flexible strain sensor after the rubber vulcanization encapsulation has higher sensitivity and can capture tiny strain change (1%). By measuring the deformation of the sensor, high-precision strain information can be obtained when the tire is stressed or deformed, so that various parameters of the automobile are reflected, and the method has certain help to driving safety. The flexible strain sensor of the rubber vulcanization package has better environmental impact resistance and can work under different conditions of temperature, humidity, chemical medium and the like.
The vulcanization process of the rubber final rubber material enables the sensor to have higher durability and stability. Because the flexibility and the stretchability of the flexible strain sensor after the rubber vulcanization package are not reduced, the flexible strain sensor can be more convenient and flexible in practical intelligent tire application when being combined with tires of different shapes and structures.
In general, the flexible strain sensor is obtained by vulcanizing and packaging the rubber final rubber compound in the embodiment, so that the manufactured flexible strain sensor has the advantages of flexibility, high sensitivity, wide dynamic range, environmental impact resistance and the like. The characteristics enable the flexible strain sensor to have wide application potential in the fields of intelligent tire engineering and the like.
The flexible strain sensor obtained by vulcanizing and packaging can be directly attached and combined with the inner wall of the tire, and of course, the prepared flexible strain sensor can also be combined with the tire preparation process, and is completely embedded into the tire (for example, between the tire inner layer and the tire cord layer), so that the flexible strain sensor and the traditional tire are combined into a whole.
Example 3
Embodiment 3 describes an intelligent tire strain monitoring system including a controller and a strain sensor; wherein the strain sensor adopts the flexible strain sensor in the above embodiment 2.
The flexible strain sensor 11 is attached directly to the inner sidewall of the tire.
Each flexible sensor unit 1 in the flexible strain sensor is arranged along the width direction of the tire, and is respectively aligned with two sides, the middle position and/or the tire wall position of the tread width direction, and the like, and is used for monitoring the strain signal change at the corresponding position.
The flexible strain sensor 11 is applied to the tyre, for example by means of an epoxy glue. After the sensing array is attached to the inner wall of the tire, the sensing array is interconnected with the flexible sensor unit through the L-shaped flexible multi-channel adapter plate, and the other end of the L-shaped flexible multi-channel adapter plate is connected with a controller of the intelligent tire strain monitoring system through a flexible wire, so that strain signals can be conveniently transmitted.
The flexible strain sensor after rubber vulcanization packaging can realize signal identification under various working condition parameters of a plurality of positions in the tire, for example, signal output is carried out on two different load parameters of the plurality of positions.
The tires bear different loads in the movement process, and are further represented through deformation of the sensing arrays.
Fig. 5 shows the signal waveform variation at different positions under different loads. In fig. 5, (a), (b), and (c) show the change in signal waveforms of the sidewall position, the positions of both sides in the tread width direction, and the intermediate position in the tread width direction.
Wherein the difference between two different loads at the same location can be seen from fig. 5.
Due to the complex tire dynamics, the flexible sensor monomers on the two side positions in the tread width direction and the tire side wall have deformation amounts of different degrees and different displacements (the deformation of the middle position in the tread width direction and the deformation of the two side positions in the tread width direction are smaller), and the signal output difference of different positions under the same load condition can be seen.
The number of the flexible strain sensors attached to the inner sidewall of the tire is not limited to one set, and for example, there may be a plurality of sets, and the plurality of sets of flexible strain sensors may be uniformly arranged along the circumferential direction of the inner sidewall of the tire.
Wherein, each sensor unit 1 in each group of flexible strain sensors 11 is arranged along the width direction of the tyre, and each sensor unit 1 is respectively used for measuring two sides, the middle position, the position of the tyre wall and the like in the tread width direction.
It should be noted that the width dimension of the flexible strain sensor 11 manufactured in the above-mentioned embodiment 2 is consistent with the overall width dimension of the tire tread and the tire wall after being developed, so as to ensure that the flexible strain sensor 11 is fully applicable to the inner wall of the tire.
Example 4
Embodiment 4 describes an intelligent tire strain monitoring system comprising a controller and a strain sensor; wherein the strain sensor adopts the flexible strain sensor in the above embodiment 2.
The difference from embodiment 3 described above is that the flexible strain sensor 11 in this embodiment is completely embedded inside the tire, i.e., the flexible strain sensor 11 is embedded inside the tire during the assembly process of the tire manufacturing process.
If the flexible strain sensor 11 is needed to be embedded into the tire, the rubber of the tire inner layer 12 is needed to be cut into the opening 13 of the channel adapter plate, so that the L-shaped flexible multi-channel adapter plate 2 can be conveniently connected into the inner wall of the tire, and the L-shaped flexible multi-channel adapter plate is connected with a controller.
It should be noted that the number of the flexible strain sensors embedded in the tire is not limited to one set, and for example, there may be a plurality of sets of flexible strain sensors, and the plurality of sets of flexible strain sensors may be uniformly arranged in the circumferential direction of the tire.
Wherein, each flexible sensor monomer 1 in each group of flexible strain sensors is arranged along the width direction of the tyre, and each flexible sensor monomer is respectively used for measuring the two sides, the middle position, the position of the tyre wall and the like in the width direction of the tyre surface.
As shown in fig. 7, the specific process of fully embedding the flexible strain sensor 11 inside the tire is as follows:
firstly, the inner tire layer 12 is required to be cut into the opening 13 of the channel adapter plate, and then the L-shaped flexible multi-channel adapter plate 2 is connected to the inner tire wall position so as to be connected with a controller of the intelligent tire strain monitoring system.
The flexible strain sensor is attached to the rubber of the inner tire layer 12 and then rolled together into a tire building machine, covering the cord layer 14, sidewall layer 15, steel band layer 16 and tread layer 17 in that order, forming a green tire by bonding multiple layers of rubber material.
Finally, the multi-layer materials are tightly combined through a vulcanization process, the rubber materials are cured, and the flexible strain sensor (the surface layer is made of rubber) is completely embedded into the tire and is interconnected with the controller through the L-shaped flexible multi-channel adapter plate 2.
It should be noted that the width dimension of the flexible strain sensor 11 manufactured in the above-mentioned embodiment 2 is consistent with the overall width dimension of the tire tread and the tire wall after being developed, so as to ensure that the flexible strain sensor 11 is fully applicable to the inner wall of the tire.
The foregoing description is, of course, merely illustrative of preferred embodiments of the present invention, and it should be understood that the present invention is not limited to the above-described embodiments, but is intended to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
Claims (10)
1. The flexible strain sensor vulcanization packaging method is characterized by comprising the following steps of:
step 1, preparing a plurality of flexible sensor monomers and an L-shaped flexible multichannel adapter plate for interconnection with the outside; the method comprises the steps that a plurality of flexible sensor monomers are respectively and electrically connected with an L-shaped flexible multi-channel adapter plate in a parallel connection mode;
step 2, preparing a layer of rubber final rubber sheet for vulcanization encapsulation, wherein grooves for realizing the installation of the flexible sensor monomers are formed in positions corresponding to each flexible sensor monomer, and the grooves are arranged in parallel on the rubber final rubber sheet;
step 3, arranging each flexible sensor monomer and the L-shaped flexible multi-channel adapter plate on the rubber final rubber sheet, smearing and fixing the flexible sensor monomers and the L-shaped flexible multi-channel adapter plate by epoxy resin glue, and covering a layer of rubber final rubber sheet;
and step 4, putting the whole obtained in the step 3 into a mold for vulcanization packaging to obtain the flexible strain sensor.
2. The flexible strain sensor vulcanization packaging method of claim 1,
in the step 1, the flexible sensor monomer is a flexible sensor based on a multi-wall carbon nano tube, a rubber-based sensor based on a composite assembly network of molybdenum disulfide and the multi-wall carbon nano tube, or a flexible sensor based on a laser-induced graphene film.
3. The flexible strain sensor vulcanization packaging method of claim 1,
in the step 1, a flexible sensor monomer is electrically connected with an L-shaped flexible multi-channel adapter plate through a flexible lead;
the middle of the copper electrode at the end part of the flexible sensor unit is perforated and connected with a conductive button, wherein the conductive button is used for being interconnected with a flexible wire; the conductive button comprises an upper conductive button unit and a lower conductive button unit;
the upper conductive button unit and the lower conductive button unit adopt a snap-buckle structure in the hidden buckle;
one end of the flexible wire, which is connected with the flexible sensor unit, is provided with a circular ring bonding pad interface;
the lower conductive button unit passes through a hole formed by punching the middle of the copper electrode, a ring pad interface is sleeved on the lower conductive button unit, and the upper conductive button unit is covered, so that the connection between the flexible lead and the flexible sensor unit is realized;
the other end of the flexible wire is connected with the L-shaped flexible multi-channel adapter plate through welding or a welding pad.
4. The flexible strain sensor vulcanization packaging method of claim 1,
in the step 1, defining the number of the flexible sensor monomers as M, wherein the total number of the channels of the L-shaped flexible multi-channel adapter plate is M+1, and connecting the flexible sensor monomers by using a lead in a common ground mode;
the ground wire is connected to the 1 channel of the L-shaped flexible multi-channel adapter plate, and each flexible sensor monomer is correspondingly connected to the remaining M channels of the L-shaped flexible multi-channel adapter plate one by one through flexible wires; m is a natural number, and M is more than or equal to 2.
5. The flexible strain sensor vulcanization packaging method of claim 1,
in the step 4, the L-shaped flexible multi-channel adapter plate extends to the outer side of the edge of the rubber final rubber sheet and is not vulcanized and packaged.
6. The flexible strain sensor vulcanization packaging method of claim 1,
the step 4 specifically comprises the following steps:
step 4.1, putting the whole obtained in the step 3 into a groove of a vulcanization mold, then putting the whole into a vulcanization tank, introducing steam to form a high-pressure effect, heating two layers of rubber final rubber sheets in the mold, and accelerating a crosslinking reaction;
step 4.2, switching to introduce high-pressure nitrogen after reaching the preset time to form the effect of heat preservation and pressure maintaining, at the moment, no high-temperature medium is introduced into the vulcanizing tank, and closing the inlet and outlet valves to completely vulcanize and package the sensor;
and 4.3, after the vulcanization is completed, opening a vulcanizing tank to cool the vulcanized and packaged flexible strain sensor.
7. A flexible strain sensor prepared by the flexible strain sensor vulcanization packaging method as claimed in any one of claims 1 to 6.
8. An intelligent tire strain monitoring system comprises a controller and a strain sensor; characterized in that the strain sensor employs the flexible strain sensor of claim 7;
the flexible strain sensor is attached to the inner wall of the tire or is completely embedded into the tire;
each flexible sensor monomer in the flexible strain sensor is distributed along the width direction of the tire and is respectively used for monitoring strain signals of the tire wall position, the two side positions of the tread width direction and/or the middle position of the tread width direction;
the L-shaped flexible multi-channel adapter plate is connected to a controller of the intelligent tire strain monitoring system through flexible wires.
9. The intelligent tire strain monitoring system of claim 8, wherein,
at least one group of flexible strain sensors is embedded in the tire or attached to the inner wall of the tire; wherein, each group of flexible strain sensor is interconnected with the controller through corresponding L-shaped flexible multichannel keysets respectively.
10. The intelligent tire strain monitoring system of claim 8, wherein,
the specific process of fully embedding the flexible strain sensor inside the tire is as follows:
firstly, cutting an opening of a channel adapter plate from inner layer rubber of a tire so that the L-shaped flexible multi-channel adapter plate can be connected to the inner wall of the tire through the opening of the channel adapter plate and is connected with a controller of an intelligent tire strain monitoring system;
attaching a flexible strain sensor to the tire inner layer rubber, then rolling the tire inner layer rubber into a tire building machine, sequentially covering a cord layer, a tire wall layer, a steel belt layer and a tread layer, and combining multiple layers of rubber materials to form a green tire;
and finally, tightly combining the multi-layer materials through a vulcanization process, and completely embedding the flexible strain sensor into the tire.
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| CN202311850657.2A CN117774279A (en) | 2023-12-28 | 2023-12-28 | Flexible strain sensor vulcanization packaging method, sensor and intelligent tire strain monitoring system |
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| CN202311850657.2A CN117774279A (en) | 2023-12-28 | 2023-12-28 | Flexible strain sensor vulcanization packaging method, sensor and intelligent tire strain monitoring system |
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