Flexible EMG Sensor Integration in Prosthetic Liners
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Solution Overview
Problem
Commercially available surface electromyography (sEMG) systems are inadequate for use with prosthetic wearable devices due to sensors and electronics that cannot accommodate dynamic surface loading within weight-bearing sockets, leading to costly and impractical replacement of custom liners and sockets.
Innovation Solution
Integration of flexible EMG sensors with conventional or custom liners, featuring a low-profile design with dry, passive electrodes and a flexible substrate that conforms to the skin, allowing for non-invasive EMG signal capture without modifying the socket, and enabling wireless or hardwired communication with prosthetic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sEMG sensors and electronics are integrated into prosthetic wearable devices, then EMG signal capture capability is improved, but the device becomes too complex and costly to accommodate dynamic surface loading within weight-bearing sockets
Solution Approach 1:
The EMG sensor system is segmented into discrete components: flexible substrate, electrodes, leads, and connector. This segmentation allows each component to be optimized independently and facilitates integration into the prosthetic liner without requiring complex integrated circuits or rigid sensor assemblies.
Solution Approach 2:
The EMG sensor employs a flexible substrate with thin-film electrodes and leads that can conform to the dynamic surface of the residual limb within the prosthetic socket. This flexibility allows the sensor to accommodate movement and deformation without compromising signal quality or requiring complex mechanical support structures.
2Adaptability or versatility
If custom liners and sockets are modified to accommodate conventional sEMG systems, then EMG functionality is achieved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The flexible EMG sensor system is designed to be universally compatible with existing prosthetic liners and sockets. The sensor can be integrated into conventional liners without requiring custom-molded sockets or specialized components, allowing the same sensor design to be used across different prosthetic configurations and reducing manufacturing costs.
Solution Approach 2:
The EMG sensor uses inexpensive, disposable components such as flexible printed circuit boards, adhesive electrodes, and standard medical-grade connectors. These components can be easily replaced if needed and do not require expensive customization or specialized materials, significantly reducing manufacturing costs compared to rigid, integrated sensor systems.
3Stability of the object's composition
If rigid EMG sensors are used in prosthetic devices, then structural stability is improved, but comfort and adaptability to skin surface deteriorate
Solution Approach 1:
The EMG sensor utilizes a flexible substrate with thin-film electrodes and leads that can conform to the dynamic surface of the residual limb. This flexibility maintains structural integrity while adapting to skin movements and contours, providing both stability and comfort during prosthetic use.
Solution Approach 2:
The sensor system is designed to be dynamically adaptable rather than statically rigid. The flexible components can deform with the residual limb during movement, maintaining optimal contact and signal quality throughout the range of motion while preserving structural stability through the inherent strength of the flexible substrate and lead construction.
Data Source
AI summary
An electromyography (EMG) sensor for a wearable device, such as a prosthetic device attachable to a residual limb, includes a flexible substrate comprising an elongated portion and an electrode portion. At least two electrodes are disposed at a surface of the electrode portion of the flexible substrate, and leads from the at least two electrodes extend through the elongated portion of the flexible substrate.