Breathable Wireless Wound Sensor for Static-Resistant Flatness Detection
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Solution Overview
Problem
Existing flexible sensors are susceptible to static interference and mechanical mismatch with the substrate, and they fail to meet the air permeability requirements necessary for effective wound flatness detection, which is crucial for wound healing.
Innovation Solution
A wireless sensor is developed with a sensing element formed by molecular reconstruction using low-energy and high-energy lasers, encapsulated in elastomer and breathable fiber layers to improve sensitivity and breathability, converting wound flatness into resistance signals for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If capacitive sensors are used to obtain higher sensitivity, then sensitivity is improved, but the sensor becomes extremely susceptible to interference from external environment and human body static electricity
Solution Approach 1:
The patent changes the sensing mechanism from capacitive to resistive by using carbon-based polymer materials. The carbon-based polymer solution is coated on the substrate and annealed to form a thin film with specific resistance properties. When laser is applied, molecular reconstruction occurs creating a resistance-sensitive layer that detects pressure through resistance changes rather than capacitance, thereby eliminating susceptibility to static electricity interference while maintaining sensitivity.
2Reliability
If traditional flexible sensors are used, then sensing function is achieved, but mechanical mismatch between sensing layer and substrate occurs
Solution Approach 1:
The patent employs composite material structure consisting of substrate, carbon-based polymer sensing layer, and elastomer encapsulation layer. The carbon-based polymer is coated and annealed to form a thin film that is mechanically compatible with the substrate. The elastomer encapsulation layer further enhances mechanical matching by providing flexibility and adhesion, ensuring that the sensing layer moves harmoniously with the substrate during stretching and deformation without delamination or mechanical mismatch.
3Measurement precision
If traditional flexible sensors are used, then detection function is provided, but air permeability requirements for wound detection cannot be met
Solution Approach 1:
The patent uses elastomer encapsulation layers that form a flexible, thin protective shell around the sensing element. The elastomer material provides mechanical protection while maintaining flexibility and allowing the sensor to conform to wound surfaces. The encapsulation layer is designed to be thin enough to permit air permeability while still providing structural integrity and protection for the underlying carbon-based polymer sensing layer.
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 wireless sensor effectively resists environmental interference, ensures mechanical matching, and meets breathability requirements, enabling accurate and comfortable wound flatness detection and monitoring.
Implementation Method 1
step 2: using a low-energy laser to induce molecular reconstruction of carbon-based groups on surfaces of the thin film to form a resistance-sensitive layer
Implementation Method 2
step 3: using a high-energy laser to modify, carbonize and cut the resistance-sensitive layer to form a patterned sensing element
Implementation Method 3
step 3: using a high-energy laser to modify, carbonize and cut the resistance-sensitive layer
Implementation Method 4
the sensing element is manufactured by the following steps: step 1: preparing a thin film using a carbon-based polymer solution; step 2: using a low-energy laser to induce molecular reconstruction of carbon-based groups on surfaces of the thin film to form a resistance-sensitive layer
Data Source
AI summary
The present disclosure provides a wireless sensor, a manufacturing method thereof and a wound flatness detection system. The wireless sensor includes a sensing element, two elastomer-made encapsulation layers and a breathable fiber-made encapsulation layer; wherein the sensing element is manufactured by the following steps: step 1: preparing a thin film using a carbon-based polymer solution; step 2: using a low-energy laser to induce molecular reconstruction of carbon-based groups on surfaces of the thin film to form a resistance-sensitive layer; step 3: using a high-energy laser to modify, carbonize and cut the resistance-sensitive layer to form a patterned sensing element. The present disclosure solves the problems that existing pressure or tension sensors are extremely susceptible to static interference from the external environment and the human body, and the mechanical mismatch between the sensing layer and the substrate, as well as the impermeability problem.