Conductive Ink for Moisture Sensing in Garments
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Solution Overview
Problem
Existing conductive garments incorporating conductive threads or fibers are not compatible with high-volume manufacturing, limiting their practical application in textiles and paper products for moisture sensing.
Innovation Solution
A method for integrating conductive inks and electrodes into garments, such as diapers and underwear, to detect moisture through electrical property measurements, compatible with high-volume manufacturing processes, using flexographic printing and specialized printers to ensure efficient production and low per unit cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conductive threads or fibers are incorporated into garments for moisture sensing, then moisture detection capability is achieved, but manufacturing compatibility and productivity are reduced
Solution Approach 1:
The patent replaces mechanical incorporation of conductive threads/fibers with a printing-based application method. Conductive ink is printed directly onto the garment substrate to form conductive patterns and electrodes, eliminating the need for mechanical thread integration while maintaining moisture sensing functionality. This substitution enables compatibility with high-volume manufacturing processes.
Solution Approach 2:
The patent changes the physical state and form of the conductive material from discrete threads/fibers to a liquid ink formulation that can be deposited in controlled patterns. This parameter change allows for precise placement of conductive elements during the printing process, improving manufacturing efficiency and enabling high-volume production while retaining moisture detection capabilities.
2Adaptability or versatility
If conductive threads or fibers are used for moisture sensing, then sensing functionality is achieved, but per unit cost increases
Solution Approach 1:
The patent employs conductive ink that can be applied in thin, disposable layers directly onto the garment. This approach uses inexpensive conductive materials in the ink formulation, allowing for cost-effective moisture sensing without the need for expensive conductive threads or fibers. The printed conductive patterns provide sufficient functionality at a lower material cost.
Solution Approach 2:
The printing-based application method replaces costly mechanical thread integration processes. The conductive ink can be applied using standard printing equipment, reducing labor and material costs associated with thread handling, stitching, and alignment, thereby lowering the per unit cost while maintaining sensing functionality.
3Adaptability or versatility
If existing conductive garment methods are used, then moisture sensing is possible, but manufacturing complexity and device complexity increase
Solution Approach 1:
The conductive ink serves multiple functions: it creates conductive patterns for sensing, forms electrodes for moisture detection, and can be integrated with other garment layers during the same printing process. This multi-functionality reduces the need for separate components and assembly steps, simplifying the overall manufacturing process while maintaining comprehensive moisture sensing capability.
Solution Approach 2:
The patent merges the conductive element application with the garment manufacturing process itself. The conductive ink is printed onto the garment substrate during production, combining what would traditionally be separate steps (garment fabrication and conductive element integration) into a single unified process, thereby reducing manufacturing complexity.
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
Enables effective moisture detection and low-cost production of garments capable of sensing bodily fluids and environmental moisture, suitable for mass manufacturing and real-time monitoring, reducing the need for excessive absorbent filler and enhancing comfort and hygiene.
Implementation Method 1
The ink mixture comprises a conductive pigment, a binder, and a solvent. The conductive ink is printed onto a substrate to form a conductive pattern. Electrical properties of the electrodes are measured to determine if the garment has contacted moisture.
Implementation Method 2
The specialized printer is a flexographic printer. A first layer of the conductive ink is printed onto a substrate using a first set of printing plates and a first set of anilox rollers.
Data Source
AI summary
An ink mixture is manufactured by mixing carbon, graphite, and solvents in a mixing system which may include a Cowles disperser. The conductive portions (e.g. carbon, graphite) are evenly and universally dispersed, because an even dispersal means the conductivity of the resulting conductive strip (electrode) will be even, consistent, and reliable. The various embodiments of the ink mixture comprise a blend of different conductive pigments, including but not limited to carbon black and graphite. These embodiments must be grinded until below 6.5 Microns in particle size.