Nanoscale Fracture Leak Sensor for Stoma Pouch Adhesive

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Solution Overview

Problem

The adhesive layer of stoma pouch flanges gradually loses effectiveness, leading to leakages and associated psychological burden and high costs due to frequent replacements, necessitating a reliable and cost-effective leak detection system.

Innovation Solution

A leak detection sensor comprising intertwined copper wires coated with a thermopolymer insulating coating, treated by laser ablation to create nanoscale fractures allowing fluid permeation and electrical conduction, integrated with a porous wick for increased sensitivity, triggering an alarm upon fluid contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the adhesive layer is used to secure the stoma pouch, then the pouch can be attached to the skin, but the adhesive gradually loses effectiveness leading to leakages

Engineering Contradiction:
Improveadhesive effectivenessVSAvoidadhesive durability
Core Design Contradiction:
ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent applies preliminary action by incorporating a leak detection sensor that proactively monitors the adhesive layer's condition before complete failure occurs. The sensor detects early signs of leakage through the adhesive, providing advance warning to the patient so they can replace the pouch before a actual leak happens, thus maintaining reliability while extending the effective duration of adhesive performance.

Inventive Principle:
Principle #10Preliminary action

2Reliability

If a leak detection sensor is implemented, then early warning of leaks can be provided, but the device complexity increases

Engineering Contradiction:
Improveleak detection capabilityVSAvoidsensor system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies the taking out principle by extracting only the essential leak detection function from a complex sensor system. The sensor comprises simple conductive elements (such as conductive adhesive traces or simple electrodes) that form a basic electrical circuit, detecting leakage through changes in electrical properties when fluid contacts the adhesive layer. This minimalistic approach provides reliable leak detection while keeping the device complexity low and the sensor easy to integrate into the pouch system.

Inventive Principle:
Principle #2Taking out (Extraction)

3Measurement precision

If the coating is completely removed by laser ablation, then maximum fluid contact is achieved, but electrical conduction becomes unreliable

Engineering Contradiction:
Improvefluid detection sensitivityVSAvoidelectrical conduction stability
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The patent applies local quality by creating selective, localized modifications in the coating rather than complete removal. The laser ablation process creates specific patterns such as arrays of micro-holes, trenches, or partial-thickness modifications at defined locations along the conductive element. This allows fluid to contact the conductive element at these specific local points for reliable detection, while the remaining intact coating maintains electrical conduction stability and provides protective insulation elsewhere along the conductor.

Inventive Principle:
Principle #3Local quality

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

Provides early warning of impending leaks, reducing the risk of pouch failure in public and lowering management costs by enabling timely replacement, while ensuring biocompatibility and preventing skin irritation.

Implementation Method 1

creating successive troughs at spaced intervals in the coating of the electrodes by laser ablation of the coating

Methodology Applied
Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

the transmission of heat along the length of the respective electrode during the creation of a respective trough results in the partial melting of the coating surrounding a previously ablated adjacent trough

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

the partial melting of the coating surrounding a previously ablated adjacent trough which recovers the previously exposed surface of the electrode, fractures arising in the remelted coating as it solidifies

Methodology Applied
Scientific EffectPhase change: Phase Change

Implementation Method 4

creating fractures in the coating of the electrodes having a breadth of less than 500nm, more preferably 100nm or less, through which fluid may permeate to enable current to flow between the electrodes

Methodology Applied
Scientific EffectPermeation: Permeation

Data Source

PatentEP3028025B1Leak detection sensor for a stoma pouch and a process for making same
Publication Date: 2019.04.17 UNIVERSITY OF ULSTER
  • EP3028025B1 patent drawingFigure 1
  • EP3028025B1 patent drawingFigure 2~3

AI summary

A leak detection sensor comprising a pair of electrodes, each electrode being coated with an electrically insulating coating having fractures formed therein having a breadth of less than 500nm, whereby a current can flow between the electrodes when the electrodes are exposed to an electrically conductive fluid.