Flat Dermal Sensor Package with Hydrogel and Hydrocolloid Adhesion
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Solution Overview
Problem
Existing skin sensors face challenges in achieving flat package configurations, improved adhesion to fragile skin, protection of electrical components, non-invasive monitoring, ease of use, and reliability, especially under humid conditions, while ensuring phthalate-free insulation and radiolucent properties.
Innovation Solution
A sensor package comprising a hydrogel layer, hydrocolloid sections, a thin conductive carbon layer, phthalate-free insulated electrical leads, and a cover layer with adhesive, allowing for excellent signal tracing and long-term adhesion without the need for straps, and ensuring radiolucency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If traditional electrodes are used for skin monitoring, then basic signal transmission is achieved, but adhesion duration is limited to less than a day and they fail under humid conditions
Solution Approach 1:
The patent uses a composite adhesive structure combining hydrogel and hydrocolloid materials. The hydrogel layer provides initial tack and comfort against the skin, while the hydrocolloid layer provides long-term adhesion and moisture management. This composite approach enables the sensor to maintain reliable signal transmission for several days even under humid conditions, resolving the contradiction between extended wear duration and signal reliability.
2Reliability
If larger sensor packages are used, then more robust signal transmission is achieved, but they cannot be placed on small body areas like infant limbs
Solution Approach 1:
The patent employs thin-film construction for all sensor layers including the conductive layer, hydrogel layer, and protective cover layer. This thin-film approach maintains signal transmission quality through adequate conductive material thickness while enabling the sensor to be scaled down to small sizes suitable for infant limbs and other limited body surfaces.
3Reliability
If conventional adhesive materials are used, then initial attachment is achieved, but they cannot prevent premature fall-off under moist or humid conditions
Solution Approach 1:
The patent changes the chemical and physical parameters of the adhesive system by using hydrocolloid material that forms a moisture-resistant barrier. This material undergoes parameter changes in response to humidity, maintaining its adhesive properties and preventing sensor detachment even in sweaty or humid conditions, thus resolving the contradiction between adhesion stability and humidity resistance.
4Ease of operation
If radiopaque materials are used in sensors, then component visibility on X-ray is achieved, but they obstruct X-ray procedures and require removal
Solution Approach 1:
The patent uses radiolucent materials for all sensor components including the conductive layer, hydrogel layer, and protective cover layer. These materials are essentially transparent to X-rays, allowing continuous X-ray imaging procedures without requiring sensor removal. This resolves the contradiction between ease of operation during X-ray procedures and the complexity of selecting appropriate radiolucent materials.
5Object-affected harmful factors
If phthalate-containing insulation is used on lead wiring, then cost-effective manufacturing is achieved, but it creates harmful chemical exposure risk
Solution Approach 1:
The patent specifies phthalate-free insulation materials for lead wiring to eliminate harmful chemical exposure risks, particularly for infant applications. While phthalate-free materials may have slightly different manufacturing considerations, the patent maintains ease of manufacture by using standard medical-grade insulation materials that are readily available and compatible with existing manufacturing processes, thus resolving the contradiction between chemical safety and manufacturing ease.
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 reliable, long-term adhesion and effective signal transmission, preventing premature fall-off under humid conditions, with phthalate-free insulation and radiolucent properties, enabling secure attachment to infants without obstructing X-ray procedures.
Implementation Method 1
adhesive adhering the lead to the thin conductive layer
Implementation Method 2
hydrogel has a strong initial tact
Implementation Method 3
hydrocolloid provides the long term adhesion to skin
Implementation Method 4
a thin conductive third layer directly overlying and contacting the top of the first layer
Implementation Method 5
adhesive adhering the lead to the thin conductive layer
Data Source
AI summary
A sensor apparatus in the form a substantially flat package for receiving and transmitting physiologic electronic signals, to be monitored or recorded, comprising in combination, a first layer consisting of hydrogel and having opposite ends, second layer sections projecting oppositely relative to the opposite ends, and consisting of hydrocolloid, a thin conductive third layer directly overlying and contacting the top of the first layer, an electrical lead in contact with the thin conductive layer, and extending to the exterior of the layers, there being phthalate-free insulation on said lead, adhesive adhering the lead to said thin conductive layer, and a cover layer extending over the first, second and third layers, and over the lead.