Flexible Sensor Belt Manufacturing for Neonatal Monitoring

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Solution Overview

Problem

Conventional methods for monitoring vital signs in premature babies using adhesive electrodes are painful, cause skin damage, and are costly due to the need for frequent replacement, especially when made of materials that attract dirt and require cumbersome manufacturing processes.

Innovation Solution

A flexible sensor belt is manufactured using a method that involves casting electrodes into a flexible material within a mould, using retaining elements to prevent movement or deformation during the casting process, resulting in a sealed and durable product that is easy to produce and maintain.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive electrodes are used to monitor vital signs, then reliable continuous monitoring is achieved, but skin damage and patient discomfort occur

Engineering Contradiction:

Improvemonitoring reliabilityVSAvoidskin damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The harmful adhesive layer is extracted and removed from the electrode structure. The patent uses a self-adhering belt made of elastic material that secures electrodes through mechanical fastening rather than skin adhesives, eliminating the source of skin damage while maintaining monitoring reliability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

An elastic belt acts as an intermediary element between the electrodes and the patient's body. The belt provides the securing function that previously required adhesive, thereby protecting the skin while ensuring reliable electrode contact and signal acquisition

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If adhesive electrodes are replaced frequently, then skin damage is prevented, but manufacturing costs increase

Engineering Contradiction:

Improveskin protectionVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The belt and electrodes are merged into a single integrated assembly. The electrodes are permanently attached to the elastic belt through ultrasonic welding or adhesive bonding, creating a reusable unit that eliminates the need for frequent replacement and reduces manufacturing costs

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention reverses the disposable approach by creating a durable, reusable belt-electrode assembly. Instead of discarding electrodes after brief use, the robust construction allows repeated use, reducing the frequency of replacement and associated costs

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If multiple materials are integrated into the belt, then functionality is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvefunctional versatilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The belt is segmented into distinct functional layers: an elastic base layer for comfort and fit, a non-woven fabric layer for moisture absorption, and an electrode layer for signal acquisition. Each layer is manufactured separately and then bonded together, simplifying the overall manufacturing process while maintaining functional versatility

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The belt uses composite construction combining different materials (elastic material, non-woven fabric, conductive elements) that are bonded together through ultrasonic welding or adhesive. This composite approach enables multiple functions in a single structure while using standardized manufacturing processes

Inventive Principle:

Principle #40Composite materials

4Stability of the object's composition

If electrodes are secured with adhesive, then electrode stability is improved, but patient comfort deteriorates

Engineering Contradiction:

Improveelectrode stabilityVSAvoidpatient comfort

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

Skin adhesive is extracted and replaced with a mechanical fastening system. The elastic belt provides continuous gentle pressure to secure electrodes in place through mechanical means, eliminating adhesive-related discomfort while maintaining electrode stability for reliable monitoring

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS20230270385A1Method of Manufacturing a Flexible Sensor Belt and a Flexible Sensor Belt

Publication Date: 2023.08.31 BAMBI BELT HOLDING BV

AI summary

The present document relates to a method of manufacturing a flexible sensor belt suitable for being worn around an abdominal part of a human body, in particular a baby. The method comprising casting of a support layer using a flexible material in a first mould part, such that the support layer comprises one or more holes. Then, one or more electrodes are applied onto the support layer, such that these protrude the one or more holes. The electrodes are made of an electrically conductive material. The method further includes casting of a longitudinal belt section onto the support layer using a second mould part complementary to the first mould part, the casting applying the flexible material. The one or more electrodes are covered with the belt section formed on the support layer. The step of casting the belt section comprises a step of retaining the one or more electrodes using one or more retaining elements.