Unique pressure indicating sensor film

Sensor Products Inc. presents Pressurex®, a tactile pressure indicating sensor film that quickly and accurately maps and measures pressure distribution and magnitude between any mating or contacting surfaces.

Sensor Products Inc. presents Pressurex, a tactile pressure indicating sensor film that quickly and accurately maps and measures pressure distribution and magnitude between any mating or contacting surfaces.


Recently a major manufacturer of circuit breakers searched for a mechanical method of checking contact alignment and surface pressure of a series of moving contacts that mated to a stationary contact bar.


Aligning Contacts in a Circuit Breaker Using Pressurex Film


They used Pressurex to see whether each contact was making at least a 70% mating of contact surfaces. If it was found to be less than 70%, the manufacturer made a series of adjustments to correct the alignment, each time verifying the markings the contacts made on the Pressurex film.  The manufacturer said they knew of no other product that could let them see markings of the individual pressure distribution of the contacts so that they could manually assemble the circuits.  Pressurex is now being used as part of their quality control protocol.


Pressurexfilm measures pressure from 2 – 43,200 PSI (0.14 – 3,000 kg/cm2) and is available in seven pressure ranges. When placed between two contacting or mating surfaces, it instantaneously and permanently changes color. This color change is directly proportional to the actual pressure applied.  Precise pressure magnitude is easily determined by comparing the resultant color intensity to a color correlation chart (conceptually similar to interpreting Litmus paper). No training or instrumentation is required. 


Color Intensity Reveals Pressure Distribution of Pressurex


The circuit board manufacturer asked Sensor Products to scan the film using Topaq its powerful interpretive system that renders high resolution color-calibrated images of impact density on Pressurex.



In the bottom row, the manufacturer saw that just one contact in a set of four made a mark on the Pressurex.  On further adjustments, 2nd row from bottom shows fair markings, possibly 60 – 70% contact area.  3rd row from bottom shows even more contact markings, 70% +.  The 4th and 5th rows from bottom show further adjustments made significant changes in area of contact marking.  The top or 5th row could be considered 70%, even though the right hand mark was slight.  After a series of test operations, the markings would look like the 3rd row.


Pressurex is ideal for dozens of electronic and industrial applications, such as assessing contact inconsistencies in heat sinks, gaskets, clamps, connector, bolted joints, heat sealing elements, nip rolls and welding heads. 


It is also a useful tool for analyzing contact uniformity in the design and production of printed circuit boards (PCB) assemblies.  In wafer fabrication, Pressurex is often used to verify flatness, revealing lamination press problems caused by inconsistent bonding pressures. It can successfully predict and evaluate load distribution, revealing problems such as the overloading of connector contacts, standoffs, and component solder joints.


New uses for Pressurexare discovered daily.  For a free sample of Pressurex, contact Sensor Products Inc. at 1.973.884.1755 (USA), email them at info@sensorprod.com, or visit their website at www.sensorprod.com/sample.   The entire line of products and applications can be viewed online.

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