All-fabric electrode-skin sensing array

Abstract

The invention relates to a full fabric electrode-skin sensing array. The array comprises a front end angle interlocking structure and a rear end angle interlocking structure, and a spacing layer and an electrode layer are arranged between the front end angle interlocking structure and the rear end angle interlocking structure; wherein the spacing layer is located 0.5 mm-1. 5mm above the electrode layer, the left sides of the spacing layer and the electrode layer are connected through a front end angle linkage structure, and the right sides of the spacing layer and the electrode layer are connected through a rear end angle linkage structure; spacing layer holes are distributed in the spacing layer in a matrix manner; an array electrode of the electrode layer is prepared from silver-plated nylon fibers and nylon fibers; nylon yarns are arranged in the warp direction; silver-plated nylon yarn is only located under the projection of the holes in the spacing layer in the weft yarn direction. And the rest is nylon yarns. While excellent wearing comfort is kept, accurate detection of physiological signals such as limb movement and plantar pressure distribution can be achieved, and the intelligent health monitoring system is suitable for long-term and continuous health state monitoring scenes.

Description

Technical Field

[0001] This invention relates to the field of wearable fabric sensor technology, and in particular to an ion-capacitive sensor integrated on a flexible fabric in the form of an array of microelectrodes, its large-scale fabrication method, and its application in health monitoring textiles. Background Technology

[0002] With the advancements in biomedicine, health monitoring, and sports science, epidermal electronic systems capable of acquiring human signals in real-time, continuously, and non-invasively have become a focal point of wearable technology research. While traditional rigid electrodes offer excellent electrochemical performance, prolonged wear can lead to skin irritation, signal drift, and limited mobility. Emerging flexible electrodes, such as thin-film metals, conductive polymers, and graphene, improve fit, but are mostly based on non-breathable substrates like polyimide and silicone, which can cause skin inflammation, sweat buildup, and discomfort with prolonged wear. Therefore, ensuring the acquisition of physiological electrical signals while simultaneously achieving breathability, flexibility, stretchability, washability, and compatibility with clothing fabrics remains a critical challenge that urgently needs to be addressed.

[0003] Fabrics, due to their inherent porous structure, flexibility, stretchability, and tailorability, are considered ideal substrates for "second skin." Integrating conductive functional materials with fibers / yarns / fabrics enables large-area, multi-point, long-term monitoring without adding extra burden to the wearer. Existing fabric electrodes mainly use conductive polymer coatings to form a flexible conductive layer on the fiber surface, but the conductivity decreases significantly after long-term washing. Carbon nanomaterial impregnation / printing (carbon nanotubes, graphene) is low-cost and simple to process, but uniformity and interface stability still need improvement. From the perspective of weaving electrode array sensors, commercially available silver-plated nylon fibers combine "high conductivity, low impedance, flexibility and stretchability, complete specifications, and ready-to-use." Their submicron-level silver plating provides low resistance comparable to metal foil, allowing high-density microelectrode arrays to be woven directly on standard looms at arbitrary row and column densities. This enables long-term stable acquisition of medium-to-low impedance physiological electrical signals without additional encapsulation, significantly shortening the R&D cycle and lowering the mass production threshold for arrayed fabric electrodes.

[0004] Currently, most fabric electrode array sensor structures remain at the "single-point" or "single-channel" level, unable to achieve high-density array sampling with spatial resolution, and thus failing to meet the needs of multidimensional physiological signals such as skin ion distribution detection. Furthermore, the long-term stability of the skin-electrode interface impedance is significantly affected by sweat ion concentration, stratum corneum condition, and movement. Previous studies have attempted to introduce ion-electron transduction layers (hydrogels, ionic liquid gels, silk fibroin membranes) onto the surface of fabric electrodes to reduce interface impedance and motion artifacts. However, these gel layers are prone to dehydration, cracking, or detachment during repeated bending, friction, and washing, leading to a sharp decline in performance. The paper "Large-Scale, Cuttable, Full Tissue-Based Capacitive Pressure Sensor for the Detection of Human Physiological Signals and Pressure Distribution" (published in the American academic journal *ACS Omega*, 2021, Vol. 6, pp. 27208-27215) reports a fabric capacitive sensor that uses coated electrodes and PI tape encapsulation. While it achieves pressure detection, it suffers from poor air permeability, and the electrodes are not fiber-level integrated, lacking a three-dimensional woven structure, resulting in poor stability. Furthermore, existing fabric electrodes lack systematic array design; for example, row and column wiring, warp and weft distribution, flexible interconnection, and back-end signal acquisition algorithms have not yet formed standardized solutions, hindering their large-scale application in clinical medicine, rehabilitation engineering, and wearable smart clothing.

[0005] The ability to achieve human gesture recognition and foot motion capture by creating a high-density, stretchable, breathable, and stable microelectrode array on a large-area fabric substrate through three-dimensional structural design is of great significance to human life and health. Summary of the Invention

[0006] The purpose of this invention is to address the limitations of current technologies by providing an all-fabric electrode-skin sensing array. This array employs a three-dimensional interlocking structure weaving process to integrate the upper / lower encapsulation layers, spacer layers, and electrode layers. The spacer layers are created using a "warp-weft discontinuity" weaving process, significantly improving the multi-level contact stability and breathability of the electrode-skin interface, achieving a skin-electrode ionization sensing mechanism with multi-level contact between fibers, yarns, and fabric. The electrode layer is constructed from interwoven silver-plated nylon fibers, eliminating the need for any post-processing or bonding steps. This solves industry challenges related to breathability, washability, elasticity recovery, and high spatial resolution, while also addressing the technical difficulties of existing wearable sensing devices in terms of long-term wearing comfort, high sensitivity, and signal stability. While maintaining excellent wearing comfort, it enables accurate detection of physiological signals such as limb movements and foot pressure distribution, making it suitable for long-term, continuous health monitoring scenarios.

[0007] The technical solution of this invention is as follows: A full-fabric electrode-skin sensing array includes a front corner interlocking structure and a rear corner interlocking structure, with an energy spacer layer and an electrode layer disposed between the two. The spacer layer is located 0.5mm-1.5mm above the electrode layer. The two are connected on the left side by a front corner interlocking structure and on the right side by a rear corner interlocking structure. The spacer layer and the electrode layer have the same dimensions, 1.5-2.5 cm in length and 1.5-2.5 cm in width; The spacer layer has a matrix distribution of spacer layer voids, with the void size being 1-4mm × 1-4mm, preferably 2mm; the row spacing between adjacent spacer layer voids is 2-6mm; the column spacing is 2-6mm; and the total area of ​​the voids accounts for 30%-70% of the area of ​​the spacer layer, preferably 40%.

[0008] The number of interlayers is 1-4.

[0009] The holes in the spacer layer are square or rectangular in shape.

[0010] The front and rear corner interlocking structures are made of nylon fibers, with warp and weft yarns as the main components; the horizontal width of the corner interlocking structure is 2-5mm. The spacer layer is made of nylon fibers as warp and weft yarns; The warp direction of the spacer layer, the front corner interlocking structure, and the rear corner interlocking structure is longitudinal (along the length of the fabric) and parallel to the selvage; the weft direction is transverse (perpendicular to the warp) and spans the width of the fabric. The array electrodes of the electrode layer are made of silver-plated nylon fibers and nylon fibers; the silver plating layer in the silver-plated nylon fibers is 0.1-0.3 μm thick; the warp direction is nylon yarn; the weft direction is only silver-plated nylon yarn located directly below the projection of the spacer layer holes; the rest are nylon yarn. The array electrodes are prepared by the warp-weft disconnection method.

[0011] The nylon fibers in the spacer layer, electrode layer, front-end corner interlocking structure, and rear-end corner interlocking structure may have the same or different dimensions, ranging from 150D to 250D. 200D is preferred.

[0012] The fabrication method of the all-fabric electrode-skin sensing array includes the following steps: First, the interlaced electrode layer is formed by the warp and weft yarns; Secondly, a perforated structure is formed in the spacer layer by using the "warp-through weft-discontinuity" method according to the preset aperture size; Finally, the electrode layer and the spacer layer are connected by weft insertion to form an integral structure with a three-dimensional interlocking structure, spacer layer, and electrode layer. The aforementioned all-fabric electrode-skin sensor array is used for one or more applications, including gesture recognition, plantar pressure distribution detection, electromyography signal acquisition, or heart rate variability monitoring.

[0013] The essential features of this invention are: Currently, the main approach in the field of fabric electrode-skin array sensor structures is to form electrode patterns on the surface of fabric through post-processing methods (such as coating, printing, or laminating conductive materials). The detection of physiological electrical signals or pressure distribution is achieved by utilizing the mechanism of contact resistance changes or capacitive coupling between the conductive layer and the skin. However, due to the fact that the conductive coating is prone to cracking and peeling, the gel interface layer is not resistant to washing and repeated bending, and the lack of active control over the electrode-skin interface by the three-dimensional weaving structure, there is still a lack of a fully fabric electrode-skin sensing array that combines high spatial resolution, excellent mechanical durability, washability, and arrayed spatial resolution.

[0014] This invention utilizes a three-dimensional angular interlocking structure within a three-dimensional woven structure to integrally form an upper / lower encapsulation layer, a spacer layer, and an electrode layer made of fiber conductive material. This achieves a fabric electrode-skin sensing array with high spatial resolution, excellent mechanical durability, washability, and arrayed spatial resolution. The square holes in the spacer layer enable multi-level contact between skin-borne ions and the electrodes at the electrode-skin interface, achieving high-resolution and highly stable detection of gestures and plantar pressure. The provided all-fabric electrode-skin sensing array can effectively detect physiological signals such as human gestures and plantar pressure, enabling the monitoring of human health.

[0015] The beneficial effects of this invention are as follows: The fabric structure of this invention's all-fabric electrode-skin sensing array significantly improves breathability compared to traditional silicone and hydrogel-based sensors; within a pressure range of 1-13000 kPa, the linearity of the relative capacitance change rate reaches R0. 2 =0.998, repeatability error less than 3%; electrical performance degradation less than 5% after 2500 cycles; by adjusting the reed number, threading count, and heald frame number, electrode size, spacer layer thickness, and hole shape can be flexibly adjusted, making it suitable for multiple physiological signal sensitive areas such as finger joints, wrists, and soles of the feet. It is applicable to various health monitoring scenarios such as gesture recognition, gait analysis, electromyography signal acquisition, and heart rate variability detection. Its all-fabric structure exhibits excellent skin affinity, breathability, and mechanical durability, supporting repeated machine washing and long-term use, demonstrating significant practical value and promising prospects for widespread adoption. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the sensor array of the present invention; Figure 2 This is a schematic diagram of the spacer layer structure; Figure 3 This is a schematic diagram of the electrode layer structure; Figure 4 A schematic diagram of the front and rear end corner interlocking structure and the spacer electrode layer; Figure 5 A schematic diagram illustrating the principle of the invention of a sensor array; Figure 6 The relative capacitance change curves of the sensor array under pressures ranging from 1 to 13000 kPa were obtained during implementation. Figure 7 The relative change curve of capacitance was measured five times under different pressures during the implementation process. Figure 8 The curves show the relative change of capacitance under different loading rates during implementation.

[0017] Among them, 1-front end corner connection structure, 2-rear end corner connection structure, 3-spacer layer, 4-electrode layer, 5-spacer layer pores, 6-electrode. Detailed Implementation

[0018] The nylon yarn of the 200D nylon fiber material involved in this embodiment of the invention comes from Dongguan Dongcheng VIVI Wire & Tape Processing Plant; The silver-plated 200D nylon fiber is a commercially available product from Qingdao Tianyin Textile Technology Co., Ltd.; the silver plating thickness is 1.0 ± 0.2 μm.

[0019] The two types of fabrics mentioned above are not limited to these.

[0020] Example 1: The overall structure of the all-fabric electrode-skin sensing array of the present invention is as follows: Figure 1 As shown, it includes a front corner interlocking structure 1 and a rear corner interlocking structure 2, with an energy spacer layer 3 and an electrode layer 4 disposed between them; Among them, the spacer layer 3 is located 1 mm above the electrode layer 4, and the two are connected on the left side by the front corner interlocking structure 1 and on the right side by the rear corner interlocking structure 2. The spacer layer 3 and the electrode layer 4 have the same dimensions, 2cm in length and 2cm in width; The front corner interlocking structure 1, the rear corner interlocking structure 2, and the spacer layer 3 are all made of 200D nylon fiber as warp and weft yarn; the electrode layer 4 is made of partially silver-plated 200D nylon fiber. Both the spacer layer 3 and the electrode layer are single-layer yarns; The size of the spacer layer hole 5 is 2mm*2mm; the row spacing between adjacent spacer layer holes is 2mm; the column spacing is 2mm; the total area of ​​the holes accounts for 40% of the area of ​​the spacer layer.

[0021] The electrode 5 in electrode layer 4 is located directly below the projection of the spacer hole 5 in spacer layer 3, and the size is the same. The electrode layer 4 includes multiple arrayed fabric electrode units. Each row of electrode units is connected by continuous silver-plated nylon fiber warp yarns 6 to form row conductors. Each column of electrode units is formed by silver-plated nylon fiber weft yarns entangled or interwoven to form column conductors, which together constitute a row and column addressing signal acquisition circuit, so as to realize that the skin's own ions at the electrode-skin interface have multi-level contact with the electrodes to form an arrayed signal acquisition circuit.

[0022] The front corner interlocking structure 1 and the rear corner interlocking structure 2 are both 5mm*2cm in size; The thickness of the spacer layer 3 and the electrode size of the electrode layer 4 are adjustable to meet the physiological signal detection needs of different parts of the human body.

[0023] The all-fabric electrode-skin sensing array described in this invention is specifically implemented using a "flattening-weaving-restoration" weaving process. First, the yarn is wound according to the total number of warp threads, followed by threading and reeding operations, and finally weft insertion and beat-up. During the weaving process, the warp yarns need to be sorted after passing through the reed, ensuring consistent tension of the yarns in the same layer through yarn combing. Given the difference in yarn usage between the spacer layer and the electrode layer during weaving, to maintain tension balance between the two layers, the spacer layer warp yarns are individually connected to the warp beam via springs, while the electrode layer yarns are sequentially bound and fixed from top to bottom and from the middle to both ends according to the layer number. The electrode layer warp yarns are made of silver-plated nylon yarn, and the weft yarns are made of nylon yarn; both the warp and weft yarns of the spacer layer fabric are made of nylon yarn.

[0024] (1) 4-page, 6-page, 8-page, and 10-page heddle frames are required to match different layer structures. The heddle is threaded sequentially: one layer of spacer structure with 4-page heddle frames, two layers with 6-page frames, three layers with 8-page frames, and four layers with 10-page frames. Nylon yarn is used as the warp yarn for each spacer layer. Laboratory looms commonly equipped with 16-page heddle frames can meet the weaving requirements of this full-fabric electrode-skin sensor array. Because the spacer layer has a mesh-like perforated structure, every two sets are left unthreaded during heddle threading, laying the foundation for the subsequent formation of the perforated structure.

[0025] (2) The selection of reed tooth specifications is crucial to avoid yarn tangling and ensure the stability of the fabric structure. In this implementation, a steel reed of 100 reeds / 10cm was used, with each reed tooth inserted into one loop. The reed insertion method adopted the straight insertion method according to the plain weave design. If the reed size is too large, it will lead to increased warp wear, increased hairiness, and yarn tangling, affecting the opening operation; if the reed size is too small, it will easily lead to insufficient warp density and uneven arrangement, affecting the flatness of the fabric. The upper, lower, and joint layers of the three-dimensional fabric can be regarded as independent weave layers. All samples uniformly used a reed size of 100 reeds / 10cm. In the single-layer interlayer structure, 4 warp yarns were inserted into each reed, 6 yarns for two layers, 8 yarns for three layers, and 10 yarns for four layers.

[0026] (3) The total number of warp threads is determined by the number of warp yarns in each layer, the fabric width, the reed number, and the number of threads inserted into each reed. The required total number of warp threads can be accurately calculated based on the given fabric structure parameters. Input the preset pattern diagram into the semi-automatic loom, and weave according to the machine process parameters to finally obtain a full-fabric electrode-skin sensor array with different spacer layer thicknesses and electrode sizes.

[0027] (4) The weaving of the spacer layer borrows from the "warp-interlacing" method in kesi (silk tapestry) technology, where the weft yarn does not run through the entire width but only interlaces with a portion of the warp yarn to form holes. The size of the holes is precisely controlled by adjusting the number of warp yarns and the frequency of weft interlacing. During weaving, the spacer layer warp yarns are wefted separately, and the unthreaded warp yarns are not wefted. The structure of the mesh holes can be customized by adjusting the number of weft beats. The electrode layer uses one shuttle for weft interlacing. When the yarn is mounted on the loom, the warp tension should be moderate, with the spacer layer tension being appropriate: too much tension will cause the holes to enlarge and deviate from the design; too little tension will easily cause the holes to shrink, the yarns to become tangled, and the surface to become uneven. Uneven tension of individual yarns can be finely adjusted by hanging a weight. After weaving, the fabric is removed from the loom and subjected to finishing processes such as yarn breakage treatment, cleaning and stain removal, inspection and repair, and folding and packaging to ensure the integrity and performance of the fabric.

[0028] The "flattening-weaving-reduction" process specifically includes the following steps. Silver-plated nylon fibers are equilibrated for 24 hours at 25±2℃ and 65±5% relative humidity to avoid electrode resistance drift caused by uneven tension. The temperature in the weaving workshop is controlled at 22±3℃ and the humidity at 60±5%RH to reduce static electricity buildup and yarn fuzz. The warp tension is controlled at 0.25–0.35 cN / tex, and the weft tension is 0.18–0.22 cN / tex to ensure the stability of the electrode layer and spacer layer structure; The clarity of the hole edges is controlled by adjusting the weft insertion force (0.6–1.0 N / weft), thus preventing hole collapse or electrode fiber breakage. After weaving, the fabric is gently rinsed in 40°C deionized water for 10 minutes to remove static electricity and oil introduced during the weaving process, and then dried in 60°C hot air for 30 minutes to restore the fabric's three-dimensional thickness and elasticity.

[0029] The weaving techniques used in the above-mentioned spacer layer, electrode layer, front corner interlocking structure, and rear corner interlocking structure are common methods in the textile industry, and ordinary technicians in the textile field can weave them according to the relevant parameters.

[0030] Figure 2 and Figure 3 This is a schematic diagram of the spacer layer and electrode layer structure of the all-fabric electrode-skin sensor array. The weaving process requires 40 sets of warp yarns and consists of three steps: First, the interlaced electrode layer is formed by the warp and weft yarns; Secondly, a perforated structure is formed in the spacer layer by using the "warp-through weft-discontinuity" method according to the preset aperture size; Finally, the electrode layer and the spacer layer are connected by weft insertion to form an integral structure with a three-dimensional interlocking structure, spacer layer, and electrode layer, such as... Figure 4 As shown. By adjusting the number of warp yarn groups or threads, weaving with different spacing layer apertures can be achieved.

[0031] Among 1-4 spacer layers and 1mm*1mm-4mm*4mm electrodes, the all-fabric electrode-skin sensing array exhibits the best performance when it has 1 spacer layer and an electrode size of 2mm*2mm. Figure 5 This is a schematic diagram illustrating the different states of contact between the all-fabric electrode-skin sensing array and the skin. Initially, there is no contact between the human skin and the electrodes, and the capacitance signal remains unchanged. As pressure increases, the skin makes contact with the electrode layer through the spacer layer pores, resulting in skin-fiber contact and an increase in capacitance. With continued pressure increase, the skin makes contact with the electrode layer through the spacer layer pores, resulting in skin-yarn contact and a continued increase in capacitance. Finally, with increasing pressure, the skin makes contact with the fabric through the spacer layer, achieving complete skin-to-fabric contact with the electrodes of the electrode-skin sensing array. The capacitance signal reaches its peak value. When the skin is removed, the system returns to its initial state. The all-fabric electrode-skin sensing array utilizes the synergistic effect of multi-level contact between the fibers / yarns / fabric and the skin in a three-dimensional fabric.

[0032] Figures 6-8It utilizes an LCR meter to test its relative capacitance change performance.

[0033] All electrical performance tests were conducted in a constant temperature and humidity environment (23±1℃, 50±5%RH). The testing instrument was a Tonghui TH2830 precision LCR meter. Pressure loading was performed using an XLD-100E single-column microcomputer-controlled universal testing machine with a loading rate of 1mm / min and a pressure range of 1–13000kPa. Cyclic durability tests were conducted for 2500 cycles at a constant pressure of 1300kPa.

[0034] Figure 6 The capacitance-pressure curves shown exhibit a highly linear relationship in the range of 1–13000 kPa (R0). 2 =0.998), indicating that the sensor has good sensitivity and stability over an extremely wide pressure range; Figure 7 The results show that the capacitance change curves highly overlap in 5 repeated load-unload cycles, indicating that the sensor has good repeatability and low hysteresis. Figure 8 The results show that the capacitive response is basically consistent under different loading rates of 1–5 mm / min, verifying its real-time response capability to dynamic pressure, and making it suitable for fast motion capture scenarios such as gait and gesture.

[0035] Example 2: The other steps are the same as in Example 1, except that the thickness of the spacer layer is changed from 1 layer to 2 layers. The obtained material properties show a sensitivity of 3.9151 kPa in the 0-1200 kPa range. -1 The sensitivity is 21.55675 kPa in the range of 1300 kPa to 9000 kPa. -1 The sensitivity in the 9100kPa-13000kPa range is 12.48892kPa. -1 ; Example 3: The other steps are the same as in Example 1, except that the thickness of the spacer layer is changed from 1 layer to 3 layers. The obtained material properties show a sensitivity of 2.64113 kPa in the 0-1200 kPa range. -1 The sensitivity is 21.90239 Pa in the range of 1300 kPa to 9000 kPa. -1 The sensitivity in the 9100kPa-13000kPa range is 7.50417kPa. -1 ; Example 4: The other steps are the same as in Example 1, except that the thickness of the spacer layer is changed from 1 layer to 4 layers. The obtained material properties have a sensitivity of 2.04046 kPa in the 0-1000 kPa range. -1 The sensitivity is 15.96805 kPa in the 1100 kPa-13000 kPa range. -1 ; Example 5: The other steps are the same as in Example 1, except that the size of the spacer layer pores and the size of the electrode layer electrodes are replaced with 1mm*1mm instead of 2mm*2mm; the linearity of the obtained material properties sensitivity is too low in the range of 0-5000kPa. Example 6: The other steps are the same as in Example 1, except that the size of the spacer layer pores and the size of the electrode layer electrodes are replaced with 3mm*3mm instead of 2mm*2mm; the linearity of the obtained material properties saturates at 5000-13000kPa. Example 7: The other steps are the same as in Example 1, except that the size of the spacer layer pores and the size of the electrode layer electrodes are replaced with 4mm*4mm instead of 2mm*2mm; the linearity of the obtained material properties saturates at 5000-13000kPa. As can be seen from the above embodiments, this invention is the first to integrate a "three-dimensional woven structure" with a "skin ion-capacitance sensing mechanism," achieving multi-level contact and ion coupling at the electrode-skin interface through the fabric structure itself, eliminating the need for additional hydrogel or conductive adhesive layers and solving the problems of easy shedding, dehydration, and poor durability of traditional gel layers. An integrated "flattening-weaving-reduction" molding process is proposed, simultaneously constructing the electrode layer, spacer layer, and encapsulation layer during the weaving process to achieve spatial registration of the electrode-pore-skin, avoiding interface mismatch and performance degradation caused by subsequent lamination or adhesive bonding. By adjusting the warp density and weft interlacing process parameters, sub-millimeter-level synchronous control of the pore size and electrode size is achieved, solving the signal crosstalk problem caused by "electrode-pore alignment deviation" in high-density arrays. By introducing "embedded silver-plated fibers as conductors" as a row and column addressing structure, an array-based signal acquisition loop without external conductors is realized within the fabric plane, improving system integration and wearability comfort.

[0036] The signal electrode layer is made of highly conductive silver-plated nylon fiber through a textile process, which has good electrical properties and mechanical flexibility. The spacer layer is made of nylon fiber and is formed by warp knitting to form a regular square-shaped array of holes. While ensuring the overall structure's breathability and elasticity, it provides a stable multi-level contact mechanism for the electrode-skin interface.

[0037] This sensor integrates the electrode layer and spacer layer using three-dimensional textile technology, creating a composite functional textile with structural integrity, breathability, and elastic recovery properties. During sensing, human skin establishes a multi-level contact interface with the electrodes through the porous structure in the spacer layer, significantly improving the stability and signal-to-noise ratio of bioelectrical signal acquisition. Low-impedance signal transmission is achieved between the electrodes and the counter electrode via embedded silver-plated fiber wires, effectively suppressing motion artifacts.

[0038] Matters not covered in this invention are common knowledge.

Claims

1. A full-fabric electrode-skin sensing array, characterized in that, It includes a front corner interlocking structure and a rear corner interlocking structure, with an energy spacer layer and an electrode layer between them; The spacer layer is located 0.5mm-1.5mm above the electrode layer. The two are connected on the left side by a front corner interlocking structure and on the right side by a rear corner interlocking structure. The spacer layer and the electrode layer are the same size; the spacer layer has an array of spacer layer voids; the array electrodes of the electrode layer are located directly below the spacer layer voids. The spacer layer, the front corner interlocking structure, and the rear corner interlocking structure are made of nylon fibers, which are used as warp and weft yarns. The electrode layer is made of silver-plated nylon fibers and nylon fibers; the warp direction is nylon yarn; only the weft direction located directly below the projection of the spacer layer holes is silver-plated nylon yarn; the rest are nylon yarn. The array electrodes are prepared by the warp-weft disconnection method.

2. The all-fabric electrode-skin sensing array as described in claim 1, characterized in that, The spacer layer and electrode layer are 1.5-2.5 cm long and 1.5-2.5 cm wide. The horizontal width of the corner interlocking structure is 2-5mm; The size of the spacer layer pores is 1-4mm × 1-4mm; the row spacing between adjacent spacer layer pores is 2-6mm; the column spacing is 2-6mm; the total area of ​​the pores accounts for 30%-70% of the area of ​​the spacer layer; the thickness of the silver plating layer in the silver-plated nylon fiber is 0.1-0.3μm.

3. The all-fabric electrode-skin sensing array as described in claim 1, characterized in that, The holes in the spacer layer are square or rectangular in shape.

4. The all-fabric electrode-skin sensing array as described in claim 1, characterized in that, The warp direction of the spacer layer, the front corner interlocking structure, and the rear corner interlocking structure is longitudinal (along the length of the fabric) and parallel to the selvage; the weft direction is transverse (perpendicular to the warp) and spans the width of the fabric; the number of spacer layers is 1-4.

5. The all-fabric electrode-skin sensing array as described in claim 1, characterized in that, The nylon fibers in the spacer layer, electrode layer, front corner interlocking structure and rear corner interlocking structure are the same or different in size, ranging from 150D to 250D.

6. The method for fabricating the all-fabric electrode-skin sensing array as described in claim 1, characterized in that, Includes the following steps: First, the interlaced electrode layer is formed by the warp and weft yarns; Secondly, a perforated structure is formed in the spacer layer by using the "warp-through weft-discontinuity" method according to the preset aperture size; Finally, the electrode layer and the spacer layer are connected by weft insertion to form an integral structure with a three-dimensional interlocking structure, a spacer layer, and an electrode layer.

7. The application of the all-fabric electrode-skin sensing array as described in claim 1, characterized in that, It can be used for one or more applications in gesture recognition, plantar pressure distribution detection, electromyography signal acquisition, or heart rate variability monitoring.

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