Electrode structure and method for manufacturing same

Abstract

The present invention provides an electrode structure including conductive threads (2) and an electrically insulating material (4), wherein the conductive threads (2) are disposed in a central part of the electrode structure to form an electrode, the electrically insulating material (4) is disposed around the electrode to hold the electrode in place, and the structure is as described in any one selected from the group consisting of A to E below. A: Both surfaces of the electrode are exposed. B: One surface of the electrode is exposed, while the other surface is covered by an electrically insulating material. C: One surface of the electrode is covered by a conductive material, while the other surface is covered by an electrically insulating material. D: The electrode is coiled, with one or both surfaces of the electrode covered by an electrically insulating material. E: The electrode is an electronic substrate in which a semiconductor and / or an electronic component is mounted on a circuit formed from the conductive threads, with one or both surfaces of the electrode covered by an electrically insulating material.

Description

Electrode structure and manufacturing method thereof

[0001] The present invention relates to an electrode structure useful for bioelectrodes, antennas, electronic substrates, etc., and a method for manufacturing the same.

[0002] Biometric information acquisition means attached to clothing such as work clothes and sportswear are useful for health management because they can acquire biometric information such as heart rate, body temperature, and blood pressure while the wearer is still wearing the clothing. As conventional examples, Patent Documents 1 and 2 propose the use of protruding electrodes. Patent Document 3 proposes providing a resin layer on the back side of the electrode surface that comes into contact with the living body. Patent Document 4 proposes conductive threads such as carbon-based conductive threads, metal or alloy plated threads, conductive resin fiber threads, and metal fiber threads. Patent Document 5 proposes nylon threads with conductive carbon microparticle threads kneaded into them.

[0003] JP 2015-070917 A JP 2016-036642 A JP 2018-114302 A JP 2016-129115 A JP 2017-201063 A

[0004] However, the conventional bioelectrodes described above have poor adhesion to the human skin, making it difficult to obtain accurate biometric information, and they are also difficult to use as antennas, power transmission and reception coils, electronic boards, etc.

[0005] In order to solve the above-mentioned conventional problems, the present invention provides an electrode structure and a method for manufacturing the same that have good adhesion to the human skin, can acquire accurate biometric information, and is useful for antennas, power transmitting and receiving coils, electronic substrates, etc.

[0006] One embodiment of the present invention relates to an electrode structure including a conductive thread and an electrically insulating material, wherein the conductive thread is disposed in the center of the electrode structure to form an electrode, and the electrically insulating material is disposed around the electrode to hold the electrode, and the electrode structure has a structure described in any one of the following groups A to E. A: Both surfaces of the electrode are exposed. B: One surface of the electrode is exposed, and the other surface is covered with an electrically insulating material. C: One surface of the electrode is covered with a conductive material, and the other surface is covered with an electrically insulating material. D: The electrode is coil-shaped, and one or both surfaces are covered with an electrically insulating material. E: The electrode is an electronic substrate in which semiconductors or electronic components are mounted on a circuit made of conductive thread, and one or both surfaces are covered with an electrically insulating material.

[0007] Another embodiment of the present invention relates to a method for manufacturing the electrode structure described above, which comprises using a sewing machine to sew a conductive thread into an electrode pattern on a backing containing a removable material, attaching the conductive thread to an object other than the backing or sewing it across to secure it, and then removing the backing, disposing the conductive thread in the center of the electrode structure to form an electrode, and disposing the electrically insulating material around the electrode to hold it in place, and the electrode structure has a structure described in any one of the group consisting of A to E below: A: Both surfaces of the electrode are exposed. B: One surface of the electrode is exposed, and the other surface is covered with an electrically insulating material. C: One surface of the electrode is covered with a conductive material, and the other surface is covered with an electrically insulating material. D: The electrode is coil-shaped, and one or both surfaces are covered with an electrically insulating material. E: The electrode is an electronic substrate in which a semiconductor or electronic component is mounted on a circuit made of the conductive thread, and one or both surfaces are covered with an electrically insulating material.

[0008] The electrode structure of the present invention is an electrode structure comprising a conductive thread and an electrically insulating material, the conductive thread being arranged in the center of the electrode structure to form an electrode, the electrically insulating material being arranged around the electrode and holding the electrode, and A: both surfaces of the electrode are exposed, B: one surface of the electrode is exposed and the other surface is covered with an electrically insulating material, C: one surface of the electrode is covered with a conductive material and the other surface is covered with an electrically insulating material, or D: the electrode is coil-shaped and one or both surfaces are covered with an electrically insulating material, or E: the electrode is an electronic board having semiconductors or electronic components mounted on a circuit made of conductive thread and one or both surfaces are covered with an electrically insulating material, so that when used as a bioelectrode, for example, it has good adhesion to human skin and can acquire accurate bioinformation, and when used as an antenna, power transmitting / receiving coil or electronic board, it can be an easy-to-use electrode structure.

[0009] FIGS. 1A-C are schematic plan views showing a method for fixing a sewing pattern according to one embodiment of the present invention. FIGS. 2A-B are schematic plan views showing a method for fixing a sewing pattern according to another embodiment of the present invention. FIGS. 3A-B are schematic plan views showing a method for fixing a sewing pattern according to yet another embodiment of the present invention. FIGS. 4A-C are schematic plan views showing a method for removing a substrate according to one embodiment of the present invention. FIGS. 5A-D are schematic plan views showing a method for removing a substrate according to another embodiment of the present invention. FIG. 6 is a planar photograph showing conductive threads in a predetermined pattern disposed on the surface of a curable resin. FIG. 7 is a planar photograph showing embroidery threads sewn around the conductive threads in a predetermined pattern. FIGS. 8A-D are photographs showing an electrode structure connected to a heart rate detector in which a heart rate sensor and a transmitter are integrated. FIG. 9A is a photograph showing an LED joined to the exposed conductive threads in a predetermined pattern by ultrasonic soldering, and FIG. 9B is a photograph showing the LEDs joined to the conductive threads in a predetermined pattern by ultrasonic soldering and then covered with a waterproof, electrically insulating adhesive film. Figure 10A shows the electrode structure of Figure 9B attached to the back of a hand, Figure 10B shows the electrode structure connected to a power source, and Figure 10C shows the LED lit with current flowing through it. Figure 11 shows a photograph of a chain stitch sewing machine used to sew a coated wire into a baking sheet coated with a silicone release agent, with a non-conductive bobbin thread used to sew the coated wire into a spiral shape. Figure 12 shows a photograph of the spiral coated wire of Figure 11 attached to a hand and connected to a battery power source. Figure 13 is a schematic perspective view of an antenna according to one embodiment of the present invention.

[0010] The present invention provides an electrode structure comprising a conductive thread and an electrically insulating material. The conductive thread may be any material, such as copper wire, aluminum wire, stainless steel wire, tungsten (W), molybdenum (Mo), or metal-plated fiber. The wire may be a bare wire or a coated wire. The conductive thread is disposed in the center of the electrode structure, and may be exposed on one or both sides of the conductive thread to form an electrode pattern, or may be an electrode pattern in which both sides of the conductive thread are not exposed. The electrically insulating material is disposed at least around the periphery of the electrode structure to hold the electrode pattern. This provides good adhesion to the skin of the human body, enabling accurate acquisition of biometric information, and providing a user-friendly electrode structure when used as an antenna, a power transmitting / receiving coil, or an electronic circuit board.

[0011] The electrode is suitable as a biological electrode, for example, for use in biological sensing applications that measure biological signals such as heart rate, electrocardiogram, myoelectric potential, electroencephalogram, body temperature, and blood pressure.

[0012] The electrically insulating material is preferably a structure made only of embroidery thread and / or sewing thread to which the electrically conductive thread is directly sewn and tightly fixed, a mount structure in which the electrically conductive thread is sewn from a portion of the mount where a part has been removed to a portion where the mount remains without being removed, a gel to which the electrically conductive thread is tightly fixed without being directly sewn, an adhesive tape, an adhesive film, or a structure coated with an adhesive resin, a curable resin, a thermoplastic resin, or a combination thereof. These electrically insulating materials are arranged at least around the periphery of the electrode structure and are easy to handle for holding the electrode pattern.

[0013] The electrode structure may have a stretchable structure as a whole, for example, by using a stretchable embroidery thread, backing paper, gel, adhesive tape, adhesive film, adhesive resin, curable resin, thermoplastic resin, or the like as the electrical insulating material.

[0014] The method for manufacturing an electrode structure of the present invention includes the following steps: (1) Using a sewing machine, a step of sewing a conductive thread into a predetermined electrode pattern on a backing sheet containing a removable material is used. The sewing machine may be a lockstitch sewing machine or a chainstitch sewing machine. In the case of a lockstitch sewing, there is an upper thread and a lower thread. If the upper thread and lower thread do not need to be entangled later, the thread not required for current conduction in the electrode pattern on one side of the conductive thread used as the upper or lower thread is later removed. In the case of a chainstitch, the lower thread forms the base of the stitching, and then an additional conductive thread is inserted as a decorative thread as the upper thread, or the conductive thread is used for a circular stitch. In either case, if the upper thread and lower thread do not need to be entangled later, the thread not required for current conduction in the electrode pattern on one side of the conductive thread used as the upper or lower thread is later removed. Loop stitching or chain stitching can be used as a method of sewing the conductive thread into a predetermined electrode pattern using only a lower thread structure without using an upper thread. Removable refers to the ability to tear, dissolve in water, etc. Examples of tearable backing sheets include parchment paper coated on one surface with a silicone release agent, and examples of water-soluble paper include paper containing polyvinyl alcohol. The conductive thread preferably has a diameter of 0.005 to 10 mm. The conductive thread may be any material, such as copper wire, aluminum wire, stainless steel wire, tungsten (W), molybdenum (Mo), or metal-plated fiber. The electric wire may be either a bare wire or a coated wire. In the case of a coated wire, the coating may be any material, such as rubber, resin, rubber with reinforced fiber, or resin with reinforced fiber. For example, a polyester fiber and tungsten wire may be used as the core thread, and a conductive thread may be formed by covering and twisting water-soluble vinylon as the holding thread. After sewing, the water-soluble vinylon may be dissolved to form an electrode pattern. (2) A process of fixing the sewing position and stitch shape of the conductive thread for the mount portion to be removed by adhering it to an object other than the mount to be removed or sewing it across and fixing it, and then removing the mount, so that the predetermined electrode pattern at the time of sewing is maintained without relying on the presence of the mount in the portion where there is no mount to which the conductive thread is sewn. The object other than the mount to be removed is preferably, for example, a gel, an adhesive tape, an adhesive film, a structure coated with an adhesive resin, a structure containing a curable resin, or a thermoplastic resin, and a structure made only of sewing thread created on a mount by sewing, or a mount material that is not intentionally subjected to the removal process can also be used.After sewing the conductive thread into a predetermined electrode pattern onto a backing, a gel, adhesive tape, adhesive film, or adhesive resin-coated structure, curable resin, or thermoplastic resin is attached to cover the conductive thread, thereby developing the adhesiveness and curability of these materials. After this, unnecessary backing and sewing thread tangles are removed, allowing the predetermined conductive pattern to be transferred to a structure containing gel, adhesive tape, adhesive film, or adhesive resin-coated structure, curable resin, or thermoplastic resin. Fixation by sewing means that the predetermined electrode pattern is sewn from the removed backing to a portion of the structure created on the backing by sewing, or to a backing material that is not intentionally removed. This allows the sewing position and stitch shape of the predetermined electrode pattern to be fixed without relying on the presence of the removed backing. In this state, unnecessary backing and sewing thread tangles can be removed to obtain an electrode that retains the desired pattern. This allows for the formation of conductive thread portions exposed on one or both sides, which can be used as electrode structures useful for bioelectrodes, antennas, power transmission / reception coils, electronic substrates, etc. (3) A process of placing a conductive or electrically insulating material on the other side of the electrode pattern made of conductive threads with one side exposed. After the transfer, the other side of the exposed electrode pattern is covered with a conductive or electrically insulating gel, adhesive tape, adhesive film, or adhesive resin-coated structure, curable resin, or thermoplastic resin, resulting in a shape sandwiched between the electrode pattern on both sides. This provides waterproofing to prevent sweat and moisture from seeping into the electrode pattern from both sides, gas barrier properties to prevent the metal used in the conductive thread from oxidizing or sulfiding when exposed to oxygen or sulfur-based gases in the air, and protection against electrode damage due to friction, making the structure suitable for outdoor use where it is susceptible to rain and humidity, and for repeated washing of the electrode for hygienic use. If the covering material is conductive, the entire surface will be conductive almost uniformly, while if it is electrically insulating, the structure will be resistant to leakage and short circuits. These can be used as electrode structures useful for bioelectrodes, antennas, power transmission and reception coils, electronic substrates, etc.

[0015] The conductive thread is preferably tungsten wire. Tungsten wire constantly forms an oxide film on its surface in the atmosphere of everyday life. When used as a bare wire in a bioelectrode, the wire surface is protected by the oxide film already formed. Even if the surface oxidizes due to sweat or washing, the resulting oxide film has a change in electrical resistance within a range that is tolerable for use as a bioelectrode, allowing for stable conductive performance, making it suitable. Tungsten wire forms an oxide film on its metal surface, which reduces its ionization tendency and resistance to elution. This makes it a highly biocompatible material that is unlikely to cause allergic reactions. It is also used in medical surgical instruments and is a preferred material for bioelectrodes. Furthermore, tungsten wire has a higher tensile strength than copper wire, aluminum wire, and stainless steel wire at the same wire diameter. As a thin, break-resistant conductive wire, it maintains its flexibility when used as a monofilament, when bundled together, or when twisted with fibers of different materials, making it suitable for producing electrodes and conductive circuits using such wires. The wires used in the parts that come into contact with the skin are preferably thin so as not to damage the skin surface, and preferably include tungsten wires with a diameter of 20 μm or less per wire. Copper wires, aluminum wires, and stainless steel wires of the same diameter may easily break during processing or when used as electrodes, making them unsuitable for practical use.

[0016] The mount is preferably paper, release paper, a resin sheet, a resin film, a resin mesh, a net, a water-soluble sheet, a water-soluble film, a nonwoven fabric, a water-soluble nonwoven fabric, a woven fabric, a knitted fabric, a felt sheet, or a combination thereof. These can be removed after the sewing position and stitch shape of the conductive thread relative to the mount portion to be removed are fixed by adhering it to an object other than the mount to be removed or by sewing it across.

[0017] The sewing position and stitch shape are preferably fixed by adhesion using gel, adhesive film, adhesive tape, adhesive resin, curable resin, or thermoplastic resin, or by sewing the conductive thread from the portion of the backing sheet to which the conductive thread is sewn to the completely removed portion to the fiber structure made of only the sewing thread or the remaining portion of the backing sheet. This allows for the formation of an exposed portion of the conductive thread while maintaining the specified electrode pattern in the portion where the backing sheet to which the conductive thread is sewn to is completely removed, and this can be used as a bioelectrode. The fixing material may also be hot melt resin, hot melt sheet, hot melt film, thermoplastic film, or the like, and fixed by applying heat.

[0018] In the electrode pattern on one side of the conductive thread used for the upper or lower thread of the sewing thread, threads that are not necessary for current flow may be removed by pulling them out, cut off, or dissolved and removed using a dissolvable material. When a conductive thread is used only for the upper thread portion of the sewing thread, entanglement between the lower thread and the upper thread can be eliminated by pulling out and removing the lower thread, cutting off the lower thread, or dissolving and removing it using a dissolvable material as the lower thread. Conversely, when a conductive thread is used only for the lower thread portion of the sewing thread, entanglement between the upper thread and the lower thread can be eliminated by pulling out and removing the upper thread, cutting off the upper thread, or dissolving and removing it using a dissolvable material as the upper thread. The conductive thread may be bare wire or coated wire. In the case of a coated wire, the coating can be later removed to form an electrode. Alternatively, a conductive thread may be twisted with a non-conductive thread, or a conductive thread may be twisted with a conductive thread. In the case of a twisted product of conductive and non-conductive threads, if the conductive thread is bare wire, by using a soluble thread such as water-soluble vinylon thread as the non-conductive thread and dissolving and removing it after sewing, or by using a monofilament, the bare wire in the twisted state can be exposed without being covered with fluff caused by the non-conductive thread, making it easier to ensure electrical contact with the bare wire.

[0019] The conductive thread can also be attached to an adhesive gel layer for wiring. The conductive thread can be sewn around with non-conductive thread, with an opening formed in the center, and the conductive thread placed in the opening. When any portion of the backing used for sewing is removed, the exposed surface area of ​​the conductive material sewn to that portion increases compared to the state before the backing was removed. This increases the surface area available for crimping, soldering, or adhesive bonding with conductive resin to the object to be connected, which has the effect of stabilizing the electrical connection when an electrical contact is established.

[0020] In biosensing applications that measure biosignals, to prevent deviation from the measurement position, non-conductive or conductive adhesive gels, adhesive-coated films, urethane rubber sponges, silicone rubber materials, etc. are used, and even when the backing is removed and the exposed surface area is increased and the electrode is pressed against the skin, the lack of interference from the backing increases adhesion, making it less likely to shift position even when moving, and offering the advantage of enabling highly accurate measurement of biosignals. This is also true for electrode applications that pass electricity through the human body, making it less likely to shift position.

[0021] Many of the above-mentioned misalignment prevention materials are soft, and when pressed against the area where the backing has been removed, the material can seep into the gap created by the removal of the backing, burying the electrodes. However, by using a loop stitch, an embroidery technique, to sew conductive thread, metal wire, or tape-like conductive material onto the surface of the backing before removal to form a forest of loops, the loops protrude from the misalignment prevention material at a certain height, making it difficult for the electrodes to be buried even when pressed against it, and providing a good adhesion effect. Because the conductive material in the loop area is continuously connected, it is difficult to fall off even when rubbed, ensuring a stable conduction path.

[0022] When producing an electrode in which the exposed area is increased by removing the backing paper of the present invention, if conductive thread, metal wire, or tape-like conductive material is sewn to the backing paper using a loop stitch, chain stitch, or the like, and if the non-conductive thread used for sewing is also removed at the same time as the backing paper, the electrode will have a structure characterized by electrical continuity between the front and back surfaces, and can be used as a double-sided electrode with stable continuity between the front and back surfaces.

[0023] The conductive material-containing portion of the present invention, from which the mount has been removed, has the advantage that when it is placed on the surface or inside of a molded structure, it can be integrated without being affected by the thickness or material of the mount, and can be placed on a flexible substrate without impairing its flexibility to use a predetermined electrode pattern. This is useful for producing electrodes, electrical connectors, conductive wiring, power transmitting and receiving coils, electronic substrates, antennas, sensors, heaters, electromagnetic wave shielding materials, etc., which are subject to bending, stretching, or shape deformation. In particular, a stretchable electrode structure can be produced by removing the mount while a portion in the form of conductive thread, metal wire, or tape-like conductive material is sewn to the mount before removal so as to have a structure that includes room for stretch, such as a loop, slack, or spiral, and then placing the portion on the surface or inside of the stretchable molded structure.

[0024] Furthermore, when multiple electrodes or conductive wires produced by the present invention are stacked together or covered with an electrically insulating material or a waterproof material, the part containing the conductive material from which the backing has been removed is not affected by the thickness or material of the backing, and so the processed part can be made thin and small.As a result, in wearable clothing, etc., the wearer will find it difficult to notice the presence of the electrodes or conductive wires, resulting in a comfortable fit, and in environments where electromagnetic waves are used, the effects of electromagnetic wave reflection and absorption caused by the backing can be reduced.

[0025] When the electrodes or conductive wires produced by the present invention from which the backing has been removed are fixed to the surface of a material such as a sheet, film, or nonwoven fabric, or inside a layered structure, using an adhesive or curable resin, there is no reduction in material strength due to pinholes and they are difficult to tear. Therefore, this is useful when the part containing the conductive material is cut, slit, punched, or otherwise formed into any shape to separate the electrodes or conductive wires together with the material, or for die-cutting production of parts of the same shape.

[0026] To use the circuit board as an electronic substrate, first, a sewn-on backing sheet (later removed) is made of a material such as silicone resin that is peelable and heat- and chemical-resistant. Conductive thread, metal wire, or tape-like conductive material is sewn onto the surface of the peelable backing sheet in a specific circuit pattern. Next, electronic components are mounted on the sewn-on circuit pattern using solder or conductive adhesive. The circuit pattern is then transferred from the sewn-on backing sheet to a structure or adhesive-coated surface, including gel, adhesive tape, adhesive sheet, curable resin, or thermoplastic resin. This leaves the electronic components mounted on the structure or material after the transfer, eliminating needle holes in the structure or material after the transfer, making it easier to maintain the circuit's electrical insulation and waterproofing. Furthermore, even if the structure or material after the transfer is susceptible to degradation due to thermal melting caused by solder or chemical reactions with conductive adhesives, because the electronic components are already mounted on the circuit before the transfer, the structure or material after the transfer is free of degradation resulting from the process of mounting the electronic components on the circuit, thereby maintaining good electrical conductivity throughout the circuit. By using a thin, easily bendable material for the transferred structure or material, it is possible to create an electronic substrate with mounted electronic components that can be stretched, contracted, or folded to freely change shape.

[0027] The electrodes and conductive wires produced by this invention do not have the conductive material fixed to the mount by a printing or plating method, so even if the mount is deformed, cracks in the conductive material that cause instability in the electrical resistance value do not occur.When this invention is attached to a flexible substrate other than the mount, the shape of the substrate can be deformed, such as by folding it to make it smaller, so it can be installed in narrow areas.

[0028] The following examples are provided for explanation purposes. The present invention is not limited to these examples. <Conductive thread> In the following examples, a tungsten wire with a diameter of 13 μm was used as the conductive thread. <Embroidery thread> The embroidery thread used was a twisted thread made of cotton fiber material with a cotton count of 20.

[0029] Example 1 An example of the present invention will be described with reference to the drawings. In the following drawings, the same reference numerals represent the same parts. FIG. 1A is a schematic plan view showing a pattern in which conductive thread according to one embodiment of the present invention is sewn into a predetermined shape on a backing sheet. FIG. 1B is a schematic plan view of FIG. 1A with the backing sheet removed. FIG. 1C is a schematic plan view of the same pattern after removal. As shown in FIG. 1A, conductive thread 2 was sewn into a predetermined pattern on a backing sheet 1a, such as a baking sheet with one surface coated with a silicone release agent, using a lockstitch sewing machine, and a fixing means 3, such as a pressure-sensitive adhesive, adhesive, or curable resin, was placed around the periphery. Next, as shown in FIG. 1B, the backing sheet 1a was removed, leaving the sewn thread 2 in the predetermined pattern so that it was in partial contact with the fixing means 3. Alternatively, as shown in FIG. 1C, the backing sheet 1a was removed, leaving the conductive thread 2 in the predetermined pattern so that it was in full contact with the fixing means 3. This allowed the conductive thread 2 in the predetermined pattern to be used as an electrode. 1b shows the backing sheet after removal. Water-soluble vinylon thread was used as the non-conductive thread, which was later removed.

[0030] (Example 2) Fig. 2A is a schematic plan view showing a pattern in which conductive thread 2 in another embodiment of the present invention is sewn into a predetermined shape on a backing sheet 1a and the periphery is sewn with embroidery thread 4, and Fig. 2B is a schematic plan view with the backing sheet removed from Fig. 2A. As shown in Fig. 2B, the periphery of the conductive thread 2 in the predetermined pattern is fixed with the embroidery thread 4, and the conductive thread 2 in the predetermined pattern in the center can be used as an electrode.

[0031] 3A is a schematic plan view of yet another embodiment of the present invention, in which conductive threads are sewn in a predetermined pattern so that stitches reach both the areas that need to be removed and the areas that are to remain, and FIG. 2B is a schematic plan view showing the state in which only the central portion 1b of the backing paper is removed and the periphery 1a of the backing paper is left. In this example, the periphery of the conductive threads 2 in the predetermined pattern is fixed with embroidery thread 4, and the conductive threads 2 in the predetermined pattern in the center can be used as electrodes.

[0032] Example 4 Figures 4A-C are schematic plan views showing a method for removing a substrate according to one embodiment of the present invention. Using a lockstitch sewing machine or a chainstitch sewing machine, conductive threads 2a and 2b were sewn in a predetermined pattern onto a substrate such as a dissolvable or tearable backing 1, as shown in Figure 4A. An adhesive tape 5 was then applied over the conductive threads 2a and 2b to secure them, as shown in Figure 4B. The substrate, such as the backing 1, was then removed, leaving the conductive threads 2a and 2b in the predetermined pattern secured to the adhesive tape 5 exposed, as shown in Figure 4C. In this case, there were cases where both upper and lower threads were included, cases where only the upper thread was included after the lower thread used for sewing was removed, and cases where only the lower thread was included without the upper thread used for sewing. At least one of these cases involved the use of a conductive thread. The threads other than the conductive thread were twisted polyester yarn with a cotton count of 40.

[0033] Example 5 Figures 5A-5D are schematic plan views showing a method for removing a substrate according to another embodiment of the present invention. Using a lockstitch sewing machine or a chainstitch sewing machine, an upper thread of conductive thread 2 and a lower thread of non-conductive thread 6 were sewn in a predetermined pattern onto a substrate such as a dissolvable or tearable backing paper 1, as shown in Figure 5A. An adhesive tape 5 was then applied over the conductive thread 2 to secure it, as shown in Figure 5B. The lower thread 6 was then cut and removed, as shown in Figure 5C. Next, as shown in Figure 5D, the substrate such as the backing paper 1 was removed, leaving the conductive thread 2 in the predetermined pattern secured to the adhesive tape 5 exposed. In the cases of Figures 5A-5D, the substrate may be a woven fabric, knitted fabric, nonwoven fabric, resin sheet, resin film, or the like, in addition to the backing paper.

[0034] Example 6 Figure 6 is a plan view of conductive threads arranged in a predetermined pattern on the surface of a curable resin. In Figure 6, 2 represents the conductive threads in the predetermined pattern, and 7 represents the curable resin. Gel, foam, or the like can be used instead of the curable resin. The conductive thread used in Figure 6 was made by covering and twisting one 50 denier polyester fiber core thread, five 13 μm diameter tungsten wires as the filament threads, and one 40 denier water-soluble vinylon as the holding thread, and after sewing, the water-soluble vinylon was dissolved to create an electrode pattern.

[0035] (Example 7) Fig. 7 is a plan view of a conductive thread in a predetermined pattern with embroidery thread sewn around it. In Fig. 6, 2 is the conductive thread in the predetermined pattern, and 4 is the surrounding embroidery thread sewn part.

[0036] (Example 8) Figures 8A-D are photographs of an electrode structure connected to a heart rate detector in which a heart rate sensor and a transmitter are integrated. In Figure 8A, 2 denotes a conductive thread with a predetermined pattern, 4 denotes the surrounding embroidery thread stitching, 8 denotes a central connector, 9 in Figure 8B denotes a snap button, and 10 in Figures 8C-D denotes a heart rate detector. In addition to heart rate, the detector may also detect electrocardiograms, myoelectric potentials, electroencephalograms, blood pressure, body temperature, etc. The detector can send detected signals via radio waves to a mobile phone, tablet computer, etc.

[0037] (Example 9) Figure 9A shows an electronic board with a semiconductor or electronic component mounted on a circuit made of conductive thread, one or both sides of which are covered with an electrically insulating material. This example shows a photograph of LED 12 joined by ultrasonic soldering after a predetermined pattern of conductive thread 2 has been sewn onto a baking sheet coated with a silicone release agent. Figure 9B shows an electrode structure in which LED 12 joined to the predetermined pattern of conductive thread 2 at ultrasonic soldering points 11a and 11b is covered and fixed with a waterproof electrically insulating adhesive film 13. Figure 10A shows the electrode structure of Figure 9B transferred from the baking sheet to the waterproof electrically insulating adhesive film 13 and attached to the back of a hand. Figure 10B shows the electrode structure connected to a power source. Figure 10C shows the LED 12 lit by current. 14a and 14b are conductive clips.

[0038] Example 10 Figure 11 is a photograph of a spirally sewn insulated electric wire sewn onto a baking sheet coated with a silicone release agent using a chain stitch sewing machine, with a non-conductive thread as the bobbin thread. An adhesive film is attached to the top of the insulated electric wire, the bobbin thread is removed, and the baking sheet paper is removed, revealing the spirally wound insulated electric wire. Figure 12 is a photograph of the spirally wound insulated electric wire of Figure 11 attached to the back of a hand and connected to a battery power source and a wireless power supply circuit using electromagnetic induction. The wireless LED in the center of the spiral electric wire is not directly connected to the wire, but it is lit. This is because the wireless LED is positioned across the magnetic field of the spiral electric wire, which acts as a coil on the power transmitting side and supplies power to the wireless LED on the power receiving side.

[0039] As described above, the electrode structures of Examples 1 to 10 have good adhesion to human skin and can acquire accurate biometric information. That is, in any part of an electrode or conductive wire made by sewing a conductive material such as conductive thread, metal wire, or tape to a substrate, even if part or all of the substrate used for sewing is removed, the sewn pattern can be maintained in an exposed state. This allows the electrode structure to be used as a biometric information acquisition electrode structure. Biometric information that can be acquired includes heart rate, electrocardiogram, myoelectric potential, electroencephalogram, body temperature, and blood pressure, which is useful for health management. Furthermore, when used as an antenna, a power transmitting / receiving coil, or an electronic circuit board, the electrode structure can be easy to use.

[0040] Example 11 Figure 13 is a schematic perspective view of an antenna 15 according to one embodiment of the present invention. This antenna 15 has a coil portion 16 covered on both sides with electrically insulating films 17a and 17b. The coil uses tungsten wire with a diameter of 20 μm. The electrically insulating films 17a and 17b are 10 μm thick polyurethane films coated with an acrylic adhesive. This antenna 15 is thin, flexible, and easy to use. Specifically, conductive threads with exposed conductive material on the surface undergo chemical reactions such as oxidation due to sweat, washing, and humidity, resulting in high surface resistance. Physical stimuli such as friction can cause peeling, cracking, and breakage. These factors can result in a deterioration of the conductive thread's inherent electrical conductivity, resulting in reduced performance as an electrode, conductive wiring, and antenna. However, to prevent this deterioration and maintain stable conductive performance, the conductive pattern can be protected by sandwiching it between a moisture-resistant film or paper coated with an adhesive resin.

[0041] The electrode structure of the present invention is suitable for use in wearable clothing, its auxiliary materials (for example, belts, reinforcing fabrics, protective fabrics, etc.), robot wiring, telephone wiring, electronic boards with electronic components mounted thereon, power supply lines, power transmitting and receiving coils, transmitting and receiving antennas, electromagnetic wave shielding materials, electrical stimulation devices, medical equipment, heaters, logistics machinery, health and safety management for workers, health and safety management for athletes, and other electrical and electronic devices.

[0042] REFERENCE SIGNS LIST 1, 1a Mounting paper 2 Conductive thread 3 Fixing means 4 Embroidery thread 5 Adhesive tape 6 Lower thread 7 Hardening resin 8 Connector 9 Snap button 10 Heart rate detector 11a, 11b Ultrasonic soldering portion 12 LED 13 Waterproof electrically insulating adhesive film 14a, 14b Conductive clip 15 Antenna 16 Coil portion 17a, 17b Electrically insulating film

Claims

1. An electrode structure comprising a conductive thread and an electrically insulating material, wherein the conductive thread is arranged in the center of the electrode structure to form an electrode, and the electrically insulating material is arranged around the electrode to hold it, and characterized by having a structure described in any one of the following groups A to E: A: Both surfaces of the electrode are exposed. B: One surface of the electrode is exposed, and the other surface is covered with an electrically insulating material. C: One surface of the electrode is covered with a conductive material, and the other surface is covered with an electrically insulating material. D: The electrode is coil-shaped, and one or both surfaces are covered with an electrically insulating material. E: The electrode is an electronic board in which semiconductors or electronic components are mounted on a circuit made of conductive thread, and one or both surfaces are covered with an electrically insulating material.

2. The electrode structure according to claim 1, wherein the electrode is a bioelectrode.

3. The electrode structure according to claim 1 or 2, wherein the electrode is an antenna or a power transmitting / receiving coil.

4. The electrode structure according to any one of claims 1 to 3, wherein the electrode is an electronic substrate on which electronic components are mounted.

5. The electrode structure according to any one of claims 1 to 4, wherein the electrically insulating material is a structure made up of only embroidery thread and / or sewing thread, to which the conductive thread is directly sewn and intimately fixed, a mount structure in which the conductive thread is sewn from a portion of the mount where a part has been removed to a portion where the mount remains without being removed, a gel, adhesive tape, adhesive film or adhesive resin coated structure to which the conductive thread is intimately fixed without being directly sewn, a curable resin, a thermoplastic resin or a combination thereof.

6. The electrode structure according to any one of claims 1 to 5, wherein the electrode structure is stretchable.

7. An electrode structure according to any one of claims 1 to 6, wherein the conductive thread is a tungsten wire.

8. A method for manufacturing an electrode structure according to any one of claims 1 to 7, comprising using a sewing machine to sew conductive threads into an electrode pattern on a backing containing a removable material, attaching the conductive threads to an object other than the backing or sewing them across to secure them, and then removing the backing, the conductive threads being placed in the center of the electrode structure to form an electrode, and the electrically insulating material being placed around the electrode to hold it in place, and the structure being any one selected from the group consisting of A to E below: A: Both surfaces of the electrode are exposed. B: One surface of the electrode is exposed, and the other surface is covered with an electrically insulating material. C: One surface of the electrode is covered with a conductive material, and the other surface is covered with an electrically insulating material. D: The electrode is coil-shaped, and one or both surfaces are covered with an electrically insulating material. E: The electrode is an electronic substrate in which a semiconductor or electronic component is mounted on a circuit made of conductive threads, and one or both surfaces are covered with an electrically insulating material.

9. The method for manufacturing an electrode structure according to claim 8, wherein the backing is paper, release paper, a resin sheet, a resin film, a resin mesh, a net, a water-soluble sheet, a water-soluble film, a nonwoven fabric, a water-soluble nonwoven fabric, a woven fabric, a knitted fabric, a felt sheet, or a combination thereof.

10. A method for manufacturing an electrode structure according to claim 8 or 9, wherein the electrically insulating material is a structure made up of only embroidery thread and / or sewing thread, to which the conductive thread is directly sewn and intimately fixed, a backing structure in which the conductive thread is sewn from a portion of the backing paper where a part has been removed to a portion where the backing paper remains without being removed, a structure coated with gel, adhesive tape, adhesive film or adhesive resin, to which the conductive thread is intimately fixed without being directly sewn, a curable resin, a thermoplastic resin or a combination thereof.

11. The method for manufacturing an electrode structure according to any one of claims 8 to 10, wherein the sewing thread used in the sewing machine is either only conductive thread or both conductive and non-conductive thread.

12. The method for manufacturing an electrode structure according to any one of claims 8 to 11, wherein the conductive thread is a bare wire or a covered wire, and in the case of a covered wire, the covering layer is subsequently removed.

13. A method for manufacturing an electrode structure according to any one of claims 8 to 12, wherein the conductive thread is attached to an adhesive gel layer and wired.

14. A method for manufacturing an electrode structure according to any one of claims 8 to 13, wherein the conductive thread is sewn around with a non-conductive thread, an opening is formed in the center, and the conductive thread is placed in the opening.

15. The method for manufacturing an electrode structure according to any one of claims 8 to 14, wherein the sewing machine is a lock stitch sewing machine or a chain stitch sewing machine.

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