Conformable Heater Ink Set for Fluid Bag Temperature Control
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Solution Overview
Problem
Conventional heaters for wearables and medical fluid bags are bulky, expensive, and unreliable due to complex fabrication processes, and existing temperature and fluid level measurement methods are inaccurate and inadequate, often relying on external components prone to human error and environmental interference.
Innovation Solution
A flexible, conformable heater system integrated into wearables and medical fluid bags using additive printing processes, featuring a conductive layer, resistive layer, and dielectric layer with a matched ink set to prevent detrimental interactions, along with a driver circuit for controlled heat delivery and integrated sensors for accurate temperature and fluid level monitoring, with data logging capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heaters are used for wearables and medical fluid bags, then heating function is provided, but the system becomes bulky, expensive, and unreliable due to complex fabrication processes
Solution Approach 1:
The patent replaces conventional mechanical fabrication processes with additive printing processes. The heater is created by depositing conductive, resistive, and dielectric inks in sequential layers using printing techniques, eliminating complex mechanical assembly and fabrication steps while improving reliability and reducing cost.
Solution Approach 2:
The patent changes the physical and chemical parameters of the heating system by using printable ink formulations with specific viscosities, conductivities, and curing characteristics. The conductive ink provides electrical pathways, the resistive ink generates heat through Joule heating, and the dielectric ink provides insulation, all achieved through controlled printing parameters and material composition.
2Measurement precision
If conventional temperature and fluid level measurement methods are used, then measurement is provided, but accuracy is reduced due to human error and environmental interference
Solution Approach 1:
The patent merges temperature sensing, fluid level sensing, and data logging capabilities directly into the wearable device structure. Sensors are integrated with the heater and substrate, eliminating separate external measurement devices that are prone to human error and environmental interference. The integrated system automatically logs and transmits data, removing manual measurement steps.
Solution Approach 2:
The integrated sensor system performs self-measurement and self-monitoring of temperature and fluid level parameters. The system automatically detects and logs data without requiring external intervention, reducing human error. The sensors are positioned to directly monitor the fluid and heating conditions, providing accurate real-time measurements immune to environmental interference.
3Ease of manufacture
If printed electronics are used on flexible substrates, then conformability and cost are improved, but substrate roughness and absorbency may present printing issues
Solution Approach 1:
The patent applies local quality control by optimizing ink formulation and printing parameters for specific substrate types. Different ink compositions are used for conductive, resistive, and dielectric layers, each tailored to adhere to and print on the flexible substrate's surface characteristics. The printing process parameters are locally adjusted based on substrate roughness and absorbency properties to ensure consistent layer deposition.
Solution Approach 2:
The patent uses composite material structures with multiple functional ink layers deposited on flexible substrates. The conductive ink contains metallic or conductive polymer particles, the resistive ink uses carbon-based or metallic formulations, and the dielectric ink provides insulation. These composite ink formulations are specifically designed to adhere to flexible substrates while maintaining electrical and thermal properties despite substrate roughness and absorbency.
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 solution provides a cost-effective, reliable, and accurate heating system that is less bulky, more conformable, and integrated into diverse applications, reducing human error and environmental interference while enhancing patient care and monitoring capabilities.
Implementation Method 1
a resistive layer electrically associated with the at least one conductive layer and comprising a plurality of heating elements capable of generating heat upon receipt of the current flow
Data Source
AI summary
The disclosure is and includes at least an apparatus, system and method for a flexible heater sensor suitable for association with a fluid bag. The apparatus, system and method may include a conformable substrate on a ply of the fluid bag opposite a printed flexible heater; and a matched function ink set, printed onto at least one substantially planar face of the substrate. The matched function ink set forms: at least one conductive layer capable of receiving current flow from at least one power source; and at least one dielectric layer capable of at least partially insulating and at least partially limiting conductivity of the at least one conductive layer; wherein the matched ink set is matched to preclude detrimental interactions between the printed inks of each of the at least one conductive and dielectric layers, and to preclude detrimental interactions with the conformable substrate; and wherein the at least one conductive layer and the at least one dielectric layer comprise a sensing circuit that senses at least the temperature of fluid within the fluid bag.