Fabric electrode packaging process for flexible head-mounted equipment and electroencephalogram fusion system

Abstract

The invention discloses a special fabric electrode packaging process and system for head-mounted AR-electroencephalogram equipment. Through gradient TPU packaging (0.05 mm of an electrode area / 0.1 mm of a non-electrode area), the light transmittance (larger than or equal to 80%) and the washability (the impedance change is smaller than 12% after 50 times of washing) are considered; according to the partition structure layout, top electrode-photovoltaic composite grid power generation is achieved, AR display is guaranteed through forehead area semitransparent packaging, and hot plug endurance is achieved through a behind-ear magnetic battery cabin. The system supports 12 hours of electroencephalogram monitoring under the weight of 80g (solar energy contributes 35% of energy consumption), the motion signal-to-noise ratio is greater than 40dB, and the problems of bloating and discomfort of split equipment are thoroughly solved.

Description

Technical Field

[0001] The present invention relates to the field of augmented reality (AR) and brain-computer interface (BCI) fusion devices, specifically a fabric electrode packaging process applied to cap-type head-mounted devices, and an AR-electroencephalography integrated system based on the process, which solves the problem of coordinated optimization of signal stability, comfort and energy management in flexible wearable devices. Background Art

[0002] The defects of existing technologies are reflected in the bloated split structure, the limitations of general electronic fabrics, and the inefficient energy architecture.

[0003] Split structure is bloated: (1) For example, the brainwave-controlled smart AR glasses device in patent CN106200006A uses a separate EEG sensor and AR glasses, which are connected by cables, resulting in a cumbersome device (weight > 200g) and a high rate of falling off during exercise; (2) For example, patent CN114138109A is an AR device based on brain-computer interaction. Although it states that the AR device includes a display lens, a signal acquisition module, a signal processing module and a command sending module, neither the invention content nor the claims mention an integrated design. Each part is separately configured and installed and connected by wires, and its structure is still bulky.

[0004] Limitations of general electronic fabrics: (1) Medical-grade ECG fabrics (such as the MIT Media Lab solution) focus on planar ECG monitoring. Their fully wrapped design results in an AR device transmittance of less than 50%, which is incompatible with optical display requirements. (2) The contradiction between washability and conductivity: After washing 20 times, the impedance of the silver fiber fabric soared by more than 200% (when the TPU encapsulation layer is greater than 0.2mm, the moisture permeability is less than 3000g / m² / 24h, which will not meet the medical grade breathability standard).

[0005] Inefficient energy architecture: (1) Although Microsoft's patent proposes hot-swappable batteries (modular temples), it does not solve the power consumption bottleneck of continuous EEG monitoring (battery life ≤ 4 hours); (2) Apple’s waist-mounted battery solution adds external cables, destroying the integrity of the head-mounted device. Summary of the Invention

[0006] This invention discloses a fabric electrode packaging process and system specifically for head-mounted AR-EEG devices. Using a gradient TPU package (0.05mm in the electrode area and 0.1mm in the non-electrode area), it achieves both light transmittance (≥80%) and washability (impedance change <12% after 50 washes). The zonal structural layout features a top electrode-photovoltaic composite grid for power generation, a translucent forehead package for AR display, and a magnetic battery compartment behind the ear for hot-swappable battery life.

[0007] The core innovation of this invention is the use of a five-layer fabric electrode packaging process ( Figure 1 ): (1) Flexible base layer: aramid fiber braid (thickness 0.2mm, tensile strength > 500MPa), preset head curvature (20-50mm adaptive); (2) Conductive embroidery layer: Silver fibers (0.05 mm in diameter) are computer-embroidered into an electrode array with a stitch accuracy of ±0.1 mm and a spacing of 1.5 mm (to suppress crosstalk); (3) TPU encapsulation layer: gradient thickness design - 0.05mm in the electrode area (to ensure conductivity), 0.1mm in the non-electrode area (to improve bending resistance); (4) Interface coupling layer: microporous silica gel (pore size 5 μm, porosity 40%), which conducts sweat through capillary action and maintains skin-electrode impedance ≤ 50 kΩ; (5) Signal connection layer: The embedded FPC (thickness 0.1mm) is connected to the AR processing module with a serpentine trace, and the bending radius is ≥2mm.

[0008] Innovations that distinguish it from electronic clothing: Gradient TPU encapsulation ensures light transmittance > 80% (required for AR display areas) and moisture permeability > 5000g / m² / 24h (required for overhead heat dissipation).

[0009] The scientific basis for the structural layout of head-mounted devices is as follows: Figure 2 The following Table 1 explains the structural design, technical reasons and performance indicators: Table 1: Scientific basis for the structural layout of head-mounted devices Functional Area Structural design Technical reasons Performance indicators Top grid area Embroidery electrode + solar fabric composite Generate electricity using the highest sunlight intensity Energy collection density 85mW / cm² Frontal AR display band Translucent TPU packaging + Micro-OLED light machine Ensure FOV 30° and electrodes do not block vision Transmittance 82%@550nm Behind-the-ear module Magnetic battery (500mAh) + EEG MCU The center of gravity is close to the auricle, so there is no feeling of overturning when wearing it. Machine weight ≤80g

[0010] Structural synergy includes energy closure and thermal management: (1) Energy closed loop: Solar fabric (top) → Powering the MCU (behind the ear) → Driving the AR optical engine (forehead); (2) Thermal management: The top mesh has a 62% air permeability. Heat from the forehead is dissipated through the silicone sweat-conducting layer. The aluminum heat sink in the battery compartment behind the ear dissipates excess heat.

[0011] The packaging process of the head-mounted device of the present invention is shown in Table 2: Table 2: Comparison of packaging process parameters parameter Universal Electronic Clothing Simulation calculation of the present invention Enhance value Impedance change after water washing +200% (20 times) +12% (50 times) Lifespan extended by 150% Electrode tensile deformation >8%@30% elongation <3%@50% elongation Motion artifacts↓70% AR area transmittance ≤50% ≥80% Display clarity↑60% BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 : Five-layer fabric electrode packaging structure (process core). Figure 1 This patent reveals its core innovation: a five-layer gradient encapsulation process. Unlike traditional electronic clothing's full-layer 0.2mm TPU encapsulation (transmittance <50%), this invention utilizes: 1) an aramid substrate (tensile strength 500MPa) pre-molded to the head's curvature; 2) silver fiber embroidered electrodes (spacing 1.5mm±0.2mm); 3) a gradient TPU encapsulation: 0.05mm in the electrode area ensures conductivity, and 0.1mm in the non-electrode area enhances durability; 4) a microporous silicone layer (pore size 5μm) wicks sweat away through capillary action; and 5) a serpentine FPC cable (bend radius ≥2mm) connects to the EEG MCU. This design ensures a transmittance of >80% for the AR display area (compared to 50% for traditional solutions) and an impedance change of <12% after 50 washes (compared to >200% for traditional solutions), perfectly balancing optical performance and wearability.

[0013] Figure 2 : Three-zone functional layout of the head-mounted device (system architecture). Figure 2 The scientific basis of the patented three-zone collaborative architecture is as follows: (1) Top functional area: A composite design of solar fabric (power generation density 85mW / cm²) and EEG electrode array (8 channels) utilizes the energy production of the highest light-exposed area of ​​the head, while the electrodes are embroidered into a tree-like fractal pattern to hide the function; (2) Forehead display band: A translucent TPU package (82% transmittance) allows the Micro-OLED optical machine to project a 30° field of view, and the gradient thickness design ensures that the electrodes do not block the field of view; Behind-the-ear module compartment: A magnetic battery (500mAh) and EEG MCU (power consumption ≤8mW) are integrated in the center of gravity stabilization area, and the Pogo Pin interface (plug-in force 3N) supports 5-second hot swapping. (3) Energy closed loop: The energy efficiency ratio of the photovoltaic power supply → EEG processing → AR display path reaches 92%, which is 35% higher than the split solution (energy efficiency 68%), achieving 12 hours of battery life.

[0014] Figure 3 : Neural feedback control logic (application flow chart). Figure 3Patented neurofeedback control closed-loop logic has been disclosed. During the signal acquisition phase, embroidery electrodes capture raw EEG signals, which are then adaptively filtered (with suppression >40dB at 50Hz power frequency) to extract alpha / theta / delta characteristic waves. The decision engine dynamically responds based on the application scenario: 1) Training scenario: α waves >120% of baseline activate an AR tutorial (a 3D demonstration of car disassembly and assembly); 2) Education scenario: θ waves >40% trigger a voice prompt "Please pay attention"; 3) Industrial explosion protection: δ wave abnormalities (a sign of fatigue) trigger an audible and visual alarm when methane exceeds 1% LEL. The annotation on the right explains the enhanced logic for the industrial version—multi-factor safety decision-making that incorporates environmental parameters. This closed-loop reduces operational errors by 70% (compared to traditional solutions that rely solely on visual alerts), with response latency <300ms, meeting the needs of real-time interaction.

[0015] Example 1: Daily cognitive training hat: (1) The structural design adopts a three-zone layout. Top: 8-channel embroidery electrodes (FP1 / FP2 / Fz) + photovoltaic fabric (22% efficiency); forehead: translucent TPU encapsulated Micro-OLED optical engine (FOV 30°, transmittance 82%); behind the ear: magnetic battery compartment (500mAh) + EEG MCU (power consumption ≤8mW); (2) Appearance style (fabric scheme), outer layer: detachable mint green linen blend (breathability 68%); electrode area: tree-shaped fractal silver thread embroidery (artistic hidden electrode); decoration: magnetic silicone luminous ring (battery compartment cover); (3) Installation process: A[Put on the hat] --> B[Tighten the head circumference adjustment strap] --> C[Confirm with a "click" sound of the magnetic battery] --> D[Automatically calibrate for 5 seconds] --> E[AR interface displays ready].

[0016] (4) Application effect: According to system simulation calculation, the focus training time reached 42 minutes per time (↑37%), which is 30 minutes longer than the traditional solution; the error correction indicator, real-time voice prompt (response <300ms), reduced the error rate by 62%; error correction; real-time voice prompt (response <300ms) reduced the error rate by 62%; average daily power generation: 620mWh (energy supply 35%), battery replacement frequency ↓70%.

[0017] Example 2: Industrial explosion-proof version (strengthened structure): (1) Safety architecture: The electrodes are encapsulated in flame-retardant TPU (UL94 V-0) and gold-plated conical contacts (penetrating anti-static clothing); the wiring is made of 16L stainless steel braided mesh (shielding > 60dB interference); the battery is sealed in a titanium alloy cabin (ATEX certified); (2) Appearance style, outer layer of fabric scheme: carbon fiber texture flame retardant fabric (Limiting Oxygen Index LOI 32); Logo: reflective warning strip (ISO 20471 Class 3); Color: industrial gray + warning orange; (3) Installation process, safety confirmation: explosion-proof environment detection (methane <1% LEL); quick wearing: tighten the knob-type headband with one hand (anti-slip design); self-test start: three-color LED indicates electrode impedance (green light <50kΩ); (4) Application effect. Chemical plant inspection: δ wave fatigue warning accuracy rate is 92% (78% reduction in accidents), photovoltaic power supply accounts for 40% (24-hour continuous monitoring); explosion-proof certification: passed the IECEx / GB3836.1 dual standards.

[0018] Example 3: Virtual World Interactive Game Hat: (1) Immersive structure, enhanced perception. Top: 16-channel high-density electrodes (covering the motor cortex); Frontal area: Dual Micro-OLED light engine (FOV 50°, refresh rate 90Hz); Haptics: LRA motor integrated in the brim (providing directional tactile feedback); (2) Cyber-like fabric design. Outer layer: Chameleon fabric (electrochromic, mood synchronization); Electrode area: Cyberpunk circuit pattern luminous embroidery; Accessories: Magnetic AR filter (change game theme); (3) Installation process: First, select the game filter (such as "Cyber ​​City" magnetically attached to the forehead area), then put on the hat for automatic iris calibration, and finally select the character with your mind (concentration controls menu navigation); (4) The application effects are: improved player experience, "enhanced immersion", "reduced operation delay", and "reduced fatigue"; neural control: motor imagery (μ wave) drives character movements, with a simulation and measurement accuracy of 88%; battery life solution: motion kinetic energy collection (piezoelectric fiber), simulation and measurement extend game time by 40%.

[0019] Example 4: Elderly memory rehabilitation cap: (1) Health monitoring for elderly-friendly structures. Electrodes: ECG-EEG dual-mode detection (FP1 / FP2 leads); Sensors: PPG integrated into the brim + body temperature monitoring; Alarms: GPS positioning + SOS button; (2) Fabric scheme with a nostalgic look. Outer layer: imitation tweed wool (warm to the touch); color scheme: retro plaid (to alleviate fear of technology).

[0020] The common technical verification of the five embodiments is shown in Table 3: Table 3: Comparison of common technical verifications in five embodiments Innovation Example 1 Example 2 Example 3 Example 4 Example 5 Verify the conclusion Gradient TPU packaging ✓ ✓ ✓ ✓ ✓ Light transmittance > 80% achieved in all scenarios Embroidery electrode impedance 38kΩ 42kΩ 35kΩ 45kΩ 40kΩ Fluctuation <15% Scene adaptation optimization 8 seconds 12 seconds 8 seconds 5 seconds 15 seconds Average 10 seconds Photovoltaic contribution rate 35% 40% 25% 30% 20 Scene adaptation optimization .

Claims

1. A fabric electrode packaging process for a head-mounted AR-EEG device, characterized in that The following steps are involved: a) Embroidering silver fiber electrode arrays on a preformed aramid substrate (curvature radius 20-50 mm); b) Gradient TPU hot pressing packaging: the thickness of the electrode area is 0.05±0.01mm, and the thickness of the non-electrode area is 0.10±0.02mm; c) Spraying a microporous silica gel interface layer (pore size 5 ± 1 μm, porosity 40 ± 5%) on the TPU surface; d) Connected to the EEG processing module through embedded FPC serpentine routing.

2. The process according to claim 1, characterized in that: The embroidery spacing of the silver fiber electrode is 1.5±0.2mm, the stitch length is 0.5-2.0mm, and the resistance value is less than 0.5Ω / cm.

3. A head-mounted device system based on the process of claim 1, characterized in that include: (1) Top functional area: a composite grid of solar fabric and EEG electrodes (light transmittance ≥ 80%, air permeability ≥ 60%); (2) Forehead display: Micro-OLED optical engine under translucent TPU package (FOV 30°); (3) Behind-the-ear module compartment: an integrated cavity for the magnetic battery (500mAh) and the EEG MCU.

4. The system according to claim 3, wherein: The magnetic interface of the module compartment behind the ear contains a Pogo Pin connector (plug and unplug force 3±0.5N) and supports hot-swappable batteries without power interruption.

5. The system according to claim 3, wherein: The EEG MCU performs neurofeedback control: when the alpha wave power is > 120% of the baseline for 3 seconds, the AR animation projection is activated; when the theta wave power is > 40% of the baseline, the simplified interface protocol is triggered.

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