Wearable Biosensor Microneedle Array Skin Conformance

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing wearable biosensor devices face challenges in the placement and anchoring of microneedles in the skin, skin conformance and flexibility, and manufacturing, which affect their performance and user experience.

Innovation Solution

The development of a wearable biosensor device with a microneedle array made from nonconductive materials, featuring a substrate with integral microneedles covered by an electrically conductive layer, and a cover with openings aligned with the microneedles to enhance skin conformance and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If microneedles are made from conductive materials (e.g., silicon) using MEMS manufacturing processes, then electrical signal detection is enabled, but skin conformance and flexibility are reduced

Engineering Contradiction:

Improveelectrical signal detectionVSAvoidskin conformance and flexibility

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The microneedle array uses composite materials combining nonconductive substrate material (e.g., polymer) with conductive coatings (e.g., metal or conductive polymer layers). This allows the microneedles to maintain flexibility and skin conformance from the nonconductive base while achieving electrical signal detection capability through the conductive coating layers.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent replaces traditional silicon-based microneedles (rigid, MEMS-manufactured) with polymer-based microneedles that are cast in molds. This substitution of material system and manufacturing approach enables superior flexibility and skin conformance while incorporating conductive layers for sensing functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If microneedles are anchored deeply in the skin for stable sensing, then measurement reliability is improved, but insertion force and user discomfort increase

Engineering Contradiction:

Improvemicroneedle anchoring stabilityVSAvoidinsertion force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The patent changes the physical parameters of microneedles including reducing their diameter to micrometer scale, using flexible polymer materials that can deform during insertion, and optimizing length to achieve stable anchoring in the epidermis with minimal insertion force and discomfort.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If the device structure is made complex to improve skin conformance, then adaptability is improved, but manufacturing difficulty increases

Engineering Contradiction:

Improveskin conformanceVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The device is segmented into modular components: a microneedle array substrate, a separate cover, and a flexible backing layer. This segmentation allows each component to be manufactured independently using simple processes (mold casting for microneedles, cutting for cover) while achieving complex overall skin conformance when assembled.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs flexible thin film structures including a flexible substrate for the microneedle array and a flexible cover that can conform to skin contours. These thin flexible components achieve adaptability through material properties rather than complex structural designs, simplifying manufacturing.

Inventive Principle:

Principle #30Flexible shells and thin films

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The improved device achieves better skin conformance, extended wear life, reduced warm-up time, enhanced durability of microneedles, superior user experience, and improved manufacturability, leading to more efficient and accurate biosensing.

Implementation Method 1

At least one of the microneedles is configured as a working electrode functionalized with at least one chemical layer in at least one sensing region to detect an electrical signal from a reaction with a target analyte in a biofluid

Methodology Applied

Scientific EffectElectrochemical reaction:

Implementation Method 2

The electrically conductive layer on the microneedles is thin and applied by techniques selected from the group consisting of sputtering or other physical vapor deposition, chemical vapor deposition, electroplating and the like

Methodology Applied

Scientific EffectSputtering: Sputtering

Implementation Method 3

The curable resin is pushed as a flowable liquid into a gap between the microneedle array and the cover with or without microfluidic channels on the cover or the microneedle array

Methodology Applied

Scientific EffectCapillary flow: Capillary Action

Data Source

PatentUS12318224B2Wearable biosensor device

Publication Date: 2025.06.03 AQUILX INC

AI summary

An improved wearable biosensor device having emergent properties such as extended wear life, elimination or significant reduction of warm-up time, a user-friendly insertion process that ensures secure skin-locking immediately post-insertion, enhanced durability of microneedles against breakage, superior user experience and comfort during wear, and improved scalable manufacturability. Together, these innovations not only elevate the sensor's overall performance but also its accuracy, functionality, and reliability. This novel design and functionality guarantees that the wearable biosensor device is more efficient, provides a better experience for users and establishes a new benchmark in the industry.