3D Printed Intelligent Insole With Integrated Sensors
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Solution Overview
Problem
Conventional insoles fail to simultaneously monitor pressure, temperature, and humidity levels inside shoes, leading to potential foot health issues due to inadequate protection and ventilation, which can result in foot deformation and discomfort.
Innovation Solution
An intelligent insole with integrated 3D-printed pressure, temperature, and humidity sensors that transmit data wirelessly to a mobile device for real-time monitoring and health advice, using thin and comfortable micro-sensors formed during the same 3D printing process as the insole body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors (pressure, temperature, humidity) are integrated into the insole, then monitoring capability is improved, but device complexity increases
Solution Approach 1:
The patent combines pressure sensors, temperature sensors, and humidity sensors into a single integrated insole unit. All three types of sensors are embedded within the same insole structure, allowing simultaneous monitoring of multiple parameters without requiring separate devices. This merging approach improves comprehensive monitoring capability while managing device complexity through unified integration.
Solution Approach 2:
The insole is designed as a multi-functional device that simultaneously performs pressure monitoring, temperature monitoring, and humidity monitoring. This universal approach allows a single device to provide comprehensive foot health monitoring across multiple parameters, improving overall monitoring capability while avoiding the need for multiple separate devices.
2Ease of operation
If sensors are made thin to improve comfort, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs thin-film sensor technology where pressure, temperature, and humidity sensors are constructed as thin films or layers integrated into the insole structure. This thin-film approach ensures the sensors remain sufficiently thin to provide comfort during wear while enabling precise manufacturing through advanced thin-film deposition and patterning techniques during the 3D printing process.
3Productivity
If 3D printing is used to form sensors and insole body simultaneously, then productivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent merges the manufacturing of the insole body and the sensors into a single 3D printing process. The insole body and all sensors are printed simultaneously in one continuous operation, eliminating separate assembly steps and significantly improving manufacturing efficiency. This integrated approach allows the sensors to be formed directly within the insole structure during the same printing cycle.
Solution Approach 2:
The 3D printing process is configured to pre-position and pre-form all sensor components within the insole body during the initial printing stage. By preliminary establishing the exact positions and structures of the sensors alongside the insole body, the system achieves high positioning accuracy without requiring subsequent manual assembly or adjustment operations.
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 intelligent insole provides real-time feedback on pressure, temperature, and humidity levels, preventing foot health issues by alerting users to anomalies and offering personalized healthcare advice, enhancing comfort and durability by minimizing sensor thickness and protrusion.
Implementation Method 1
The pressure sensor is formed on the surface of the insole body via 3D printing to sense the pressure signal from the insole body in contact with the foot
Implementation Method 2
The pressure sensor measures the variation of electric potential caused by the foot exerting force on the insole body to obtain the pressure signal
Implementation Method 3
The temperature sensor is formed on the surface of the insole body via 3D printing for sensing the temperature signal of the insole body
Implementation Method 4
The temperature sensor is formed on the surface of the insole body via 3D printing for sensing the temperature signal of the insole body
Implementation Method 5
The humidity sensor is formed on the surface of the insole body via 3D printing to sense the humidity signal of the insole body
Implementation Method 6
The humidity sensor is formed on the surface of the insole body via 3D printing to sense the humidity signal of the insole body
Data Source
AI summary
An intelligent insole is provided. The intelligent insole includes an insole body, a pressure sensor, a temperature sensor, a humidity sensor and a signal collector. The pressure sensor, the temperature sensor and the humidity sensor are formed on the surface of the insole body, and the above sensors and the insole body are manufactured via the same 3D printing process. The pressure sensor senses the pressure signal from the insole body in contact with the foot. The temperature sensor and the humidity sensor respectively sense the temperature signal and the humidity signal of the insole body. The signal collector is respectively electrically connected to the pressure sensor, the temperature sensor and the humidity sensor to receive the pressure signal, the temperature signal and the humidity signal and then transmit the signals to a signal receiver via wireless transmission.