System and method for flexible multi-variable sensor

A multi-variable sensor comprising:

• a first trace extending from a first end at a first terminal to a second end at a second terminal, the first trace having a first sensitivity to a first variable of a measured system, the first and second terminals providing contacts to measure the first variable using the first trace;
• and
• a second trace extending from a third end at the second terminal to a fourth end at a third terminal, the second trace having a second sensitivity to the first variable that is less than the first sensitivity, the second and third terminals providing contacts to measure a second variable of the measured system using the second trace, the second variable being different from the first variable;
• wherein:
• the first trace is formed from a first electrically conductive ink and the second trace is formed from a second electrically conductive ink that is different from the first electrically conductive ink;
• and
• the first electrically conductive ink includes metal particles of silver and one or more secondary conductive particles, and the second electrically conductive ink includes metal particles of silver particles without secondary conductive particles.

A method of forming a multi-variable sensor, the method comprising:

• printing a first trace onto a flexible substrate, the first trace having a first sensitivity to a first variable of a measured system;
• and
• printing a second trace onto the flexible substrate, the second trace having a second sensitivity to the first variable that is different than the first sensitivity;
• wherein:
• the first trace extends from a first end at a first terminal to a second end at a second terminal, the first and second terminals providing contacts to measure the first variable using the first trace;
• the second trace extends from a third end at the second terminal to a fourth end at a third terminal, the second and third terminals providing contacts to measure a second variable of the measured system using the second trace;
• the first trace includes a plurality of primary first trace lines connected by secondary first trace lines to form a single continuous path between the first terminal and the second terminal;
• the second trace includes a plurality of primary second trace lines connected by secondary second trace lines to form a single continuous path between the second terminal and the third terminal;
• and
• the primary first trace lines are configured as a plurality of parallel trace lines extending in the first direction, and the primary second trace lines are configured as a plurality of non-linear, serpentine trace lines extending in the first direction.

A method of measuring characteristics of a fluid flow, comprising the steps of:

• providing a multi-variable sensor, the multi-variable sensor including first and second traces;
• installing the multi-variable sensor to extend into a fluid flow;
• and
• measuring a change in resistance of the first trace of the multi-variable sensor and a change in resistance of the second trace of the multi-variable sensor to determine a first variable of the fluid flow and a second variable of the fluid flow, respectively;
• wherein:
• the first trace includes a plurality of primary first trace lines connected by secondary first trace lines to form a single continuous path between a first terminal and a second terminal;
• the second trace includes a plurality of primary second trace lines connected by secondary second trace lines to form a single continuous path between the second terminal and a third terminal;
• and
• the primary first trace lines are configured as a plurality of parallel trace lines extending in the first direction, and the primary second trace lines are configured as a plurality of non-linear, serpentine trace lines extending in the first direction.

A method of measuring characteristics of a fluid flow, comprising the steps of:

• providing a multi-variable sensor, the multi-variable sensor including first and second traces;
• fabricating the first trace from a first electrically conductive ink and the second trace from a second electrically conductive ink that is different from the first electrically conductive ink;
• installing the multi-variable sensor to extend into a fluid flow;
• and
• measuring a change in resistance of the first trace of the multi-variable sensor and a change in resistance of the second trace of the multi-variable sensor to determine a first variable of the fluid flow and a second variable of the fluid flow, respectively;
• and wherein the first electrically conductive ink includes metal particles of silver and one or more secondary conductive particles, and the second electrically conductive ink includes metal particles of silver particles without secondary conductive particles.