Flexible sEMG Sensor Durability for Dysphagia Telehealth
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Solution Overview
Problem
Current wearable surface electromyography (sEMG) sensors for dysphagia management are often large, expensive, and lack durability, making them unsuitable for home use and telehealth applications, while existing portable solutions have short lifetimes and low durability.
Innovation Solution
A flexible, non-stretchable sEMG sensor unit with a polymeric and metallic substrate, featuring a triangular shape for easy placement on the submental area, and including active and ground electrodes connected via vias, which maintains high technical performance and durability through multiple uses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If portable wearable sEMG sensors are developed for home use, then accessibility and ease of use improve, but durability and lifetime deteriorate
Solution Approach 1:
The sensor uses a flexible substrate that can be conformally applied to the submental area, combining portability with robust construction. The flexible nature allows the sensor to adapt to skin contours while maintaining structural integrity through repeated wear and removal cycles.
Solution Approach 2:
The sensor integrates multiple materials including flexible substrate, conductive traces, and electrode materials into a composite structure that balances flexibility for comfort with structural reinforcement for durability, enabling both home accessibility and clinical-grade reliability.
2Ease of operation
If sensor complexity is reduced for home use, then ease of application improves, but signal quality deteriorates
Solution Approach 1:
The sensor is designed as a self-contained unit with integrated electrodes, traces, and substrate that simplifies application to a single placement action. Despite the simplified single-piece design, the internal segmentation of functional layers maintains signal quality through proper electrical isolation and signal pathways.
Solution Approach 2:
Multiple functional components (electrodes, traces, adhesive layers, and protective elements) are merged into a single integrated sensor unit, eliminating complex assembly steps for the user while preserving the specialized function of each component for high-quality signal acquisition.
3Ease of manufacture
If sensor design is simplified for manufacturing, then production cost decreases, but durability deteriorates
Solution Approach 1:
The flexible substrate serves as both the structural foundation and the mounting platform for all sensor components, eliminating the need for separate rigid housings or complex assembly fixtures during manufacturing, thereby reducing production costs while maintaining durability through the substrate's inherent flexibility and strength.
Data Source
AI summary
A wearable surface electromyography (sEMG) sensor unit and associated methods. The sensor unit has a flexible non-stretchable substrate comprising a first layer defining a first side of the substrate and a second layer defining a second side of the substrate, one or more sensor electrodes including at least a first pair of active electrodes and a ground electrode disposed on the first side, a plurality of traces disposed on the second side, and vias connecting the traces and sensor electrodes. The substrate may include one or more reinforcing layers at areas of high stress to increase durability of the sensor unit.