Thermoresistive Strain Sensor and Positioning Method for Roll-to-Roll Processes

This study uses the Joule heating effect-generated temperature difference to monitor in real-time and localize both compressive and tensile strains for the polymer substrates used in the roll-to-roll process. A serpentine gold (Au) line was patterned on a polyethylenenaphthalate (PEN) substrate to form the strain sensor based on thermoresistive behavior. This strain sensor was then subjected to either current or voltage to induce the Joule heating effect on the Au resistor. An infrared (IR) detector was used to monitor the strain-induced temperature difference on the Au and PEN surfaces and the minimal detectable bending radius was 0.9 mm with a gauge factor (GF) of 1.46. The proposed design eliminates the judgment ambiguity from conventional resistive strain sensors where resistance is the only physical quantity monitored. This study precisely and successfully indicated the local strain quantitatively and qualitatively with complete simulations and measurements.