Nonwoven smart cushion with in-place functionalized pressure sensing and thermoplastic heat sealed multi-region measurement coupling

A method for functionalizing a compressible nonwoven material (CNM) cushion, into a functionalized pressure-varying electrical conductance (PVEC) CNM cushion with a conductive ink printed-on-thermoplastic film (CPT), multi-area PVEC conductance measurement coupling, comprising steps of:

• functionalizing the CNM cushion into a PVEC CNM cushion, including a forming within the CNM cushion of a three-dimensional (3D) CNM PVEC region, having a PVEC surface area on a surface of the CNM cushion, the 3D CNM PVEC region having a structure comprising conductive polymer carrying CNM fibers, at least partially covered with a thin film of solidified conductive polymer, and elastically separated by a pressure dependent distribution of empty spaces;
• and
• forming the CPT multi-area PVEC conductance measurement coupling by steps comprising conductive ink printing a configuration of conductive elements on disposition surfaces of a surface of a thermoplastic film, the configuration of conductive elements including a first conductive contact pad and a second contact pad mutually spaced by a pad spacing, and including a first pad connection trace that extends from a first pad connection trace terminal end to the first contact pad, and a second pad connection trace that extends from a second pad connection trace terminal end to the second conductive contact pad,
• adhering, in an alignment, the CPT multi-area PVEC conductance measurement coupling to a surface of the PVEC CNM cushion, including the PVEC surface area, wherein
• the adhering comprises heat and pressure urging of portions of the surface of the thermoplastic film to extend over upper surfaces of the conductive elements and onto adjacent areas of the surface of the functionalized CNM PVEC cushion,
• the alignment includes the first conductive contact pad and the second conductive contact pad each being in direct electrical contact with the PVEC surface area, and
• the insulation is configured to electrically insulate the first pad connection trace at least from the PVEC surface area, and to electrically insulate the second pad connection trace at least from the PVEEC surface area.

A method of provisioning a functionalized compressed nonwoven material (CNM) cushion having integer N three-dimensional (3D) functionalized pressure-varying electrical conductance (PVEC) regions, with a conductive ink printed-on-thermoplastic film (CPT), multi-area PVEC measurement coupling, comprising steps of:

• forming the CPT multi-area PVEC conductance measurement coupling, comprising conductive ink printing a configuration of conductive elements on disposition surfaces of a surface of a thermoplastic film, the configuration of conductive elements including integer N conductive contact pad pairs, each nth contact pad pair including a first conductive contact pad and a second contact pad mutually spaced by a pad spacing, and including integer N pad connection trace pairs, each nth pad connection trace corresponding to an nth conductive pair and pair including a first pad connection trace that extends from a first pad connection trace terminal end to the first contact pad of the nth conductive contact pad pair, and a second pad connection trace that extends from a second pad connection trace terminal end to the second conductive contact pad of the nth conductive contact pad pair,
• adhering, in an alignment, the CPT multi-area PVEC conductance measurement coupling to a surface of the PVEC CNM cushion, including the PVEC surface area, wherein
• the adhering comprises heat and pressure urging of portions of the surface of the thermoplastic film to extend over upper surfaces of the conductive elements and onto adjacent areas of the surface of the functionalized CNM PVEC cushion,
• the alignment includes the first conductive contact pad and the second conductive contact pad of each nth conductive contact pad pair each being in direct electrical contact with the associated nth PVEC surface area, and
• the insulation is configured to electrically insulate the first pad connection trace and the second pad connection trace of each nth pad connection trace pair from at least from the nth PVEC surface area.

A method of provisioning a functionalized nonwoven material (NWM) cushion having a three-dimensional (3D) functionalized pressure-varying electrical conductance (PVEC) region forming a PVEC surface contact and measuring coupler, by steps with a PVEC surface area on an external surface of the functionalized NWM cushion, with a secured, flexible configuration of conductive contact pads and pad connection traces, comprising:

• positioning, in an alignment on an outer surface of the functionalized NWM cushion, an arrangement of contact pads and pad connection traces disposed on an underside of an overlaying thermoplastic film, the arrangement and alignment including
• a first contact pad and a second conductive pad, spaced apart and in respective direct electrical contact with the PVEC surface area,
• a first pad connection trace extending from the first contact pad to a first trace terminal, in insulated contact with the PVEC surface area via a first insulation coating, and
• a second pad connection trace extending from the second contact pad to a second trace terminal, in insulated contact with the PVEC surface area via a second insulation coating;
• and
• securing, in the alignment, the arrangement of contact pads and pad connection traces to an outer surface of the functionalized NWM, by operations comprising heat and pressure adhering portions of the thermoplastic film to the outer surface.