Microfluidic Sweat Capture Structure for Disposable Wearable Sensing

The patent implements a disposable perspiration capture device that is replaced after each use or when degraded. This approach accepts the device as a consumable item rather than attempting to make it indefinitely durable, reducing the need for complex protective mechanisms while maintaining reliability during the service period. The device is designed to be inexpensive enough to justify single-use or limited-use scenarios.

The device is designed as an inexpensive, disposable unit that can be manufactured using simple multilayer structures and standard fabrication techniques. Rather than investing in complex, durable construction, the device accepts limited lifespan in exchange for low manufacturing cost, making it economically viable for single-use applications during physical exercise sessions.

The device is segmented into distinct functional layers: a contact surface layer that interfaces with the skin and a separate electronic component layer. This segmentation allows the contact surface to be soft, flexible, and comfortable against the skin, while electronic components are positioned away from the skin contact area. The layers are connected through conductive elements that pass through intermediate layers, enabling functional separation without compromising electrical connectivity.

The patent employs universal microfabrication techniques and standard multilayer construction methods that can be applied to produce multiple identical devices efficiently. The multilayer structure serves multiple functions: mechanical support, fluid routing, electrical insulation, and component mounting. By using standardized fabrication processes and multi-functional layer design, the patent achieves high manufacturing precision while controlling complexity through reuse of proven manufacturing approaches.