Roll-to-roll manufacturing of wireless nanosensors
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Solution Overview
Problem
Conventional large-scale textile manufacturing processes for sensor systems are resource-intensive, labor-heavy, and time-consuming, involving multiple methodologies and equipment for screen printing, stitching, soldering, and mounting electronics, which limits efficiency and increases costs.
Innovation Solution
A continuous roll-to-roll process is implemented for manufacturing textiles with sensors, conductive tracks, and connectors, using a rotogravure printing machine, allowing for optimized production without the need for individual equipment and processes, enabling the deposition of vertically aligned nanostructures using electrostatic or pneumatic forces, and automated placement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional screen printing and stitching processes are used for manufacturing sensor systems on textiles, then manufacturing precision can be maintained, but productivity is low and device complexity is high due to multiple individual equipment and processes
Solution Approach 1:
The patent combines multiple discrete manufacturing operations (screen printing, stitching, soldering, mounting) into a single integrated roll-to-roll process that continuously manufactures sensor systems on textiles. This merging eliminates the need for separate equipment and processes, directly resolving the contradiction between productivity improvement and device complexity reduction.
Solution Approach 2:
The roll-to-roll manufacturing system performs multiple functions within a single continuous process: it prints conductive tracks, places sensors, creates interconnections, and assembles the complete sensor system. This multi-functionality allows one piece of equipment to replace multiple individual processes, improving throughput while reducing overall system complexity.
2Manufacturing precision
If conventional manufacturing processes are used, then manufacturing precision can be maintained, but loss of time is high due to labor-heavy and time-consuming operations
Solution Approach 1:
The patent implements a continuous roll-to-roll manufacturing process where the textile substrate moves continuously through multiple printing and assembly stages without interruption. This continuous action eliminates the start-stop nature of conventional batch processing, significantly reducing manufacturing cycle time while maintaining precision through controlled deposition and automated placement.
Solution Approach 2:
The process performs preliminary actions by pre-printing conductive tracks and adhesive patterns on the textile substrate before sensor placement. This preliminary preparation enables rapid sensor attachment and interconnection during the continuous process, reducing overall manufacturing time while ensuring precise positioning and alignment.
3Manufacturing precision
If conventional processes are used, then manufacturing precision can be maintained, but loss of energy is high due to resource-intensive operations
Solution Approach 1:
By merging multiple discrete manufacturing operations into a single continuous roll-to-roll process, the system eliminates redundant heating, drying, and setup cycles that occur in conventional batch processing. This consolidation reduces overall energy consumption while maintaining manufacturing precision through controlled environmental conditions and automated processes.
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
This approach significantly increases throughput efficiency, reduces costs, and eliminates the need for complex processes like via hole punching and lamination, enabling the production of wireless nanosensor systems that can detect pathophysiological signals and transmit data wirelessly for remote monitoring.
Implementation Method 1
The direction/orientation of nanostructures and number of nanostructures deposited on the adhesive are both governed by an electrostatic field applied between activated nanostructure and the adhesive substrate on the roll
Implementation Method 2
deposition of vertically aligned nanostructures using electrostatic or pneumatic forces
Implementation Method 3
The direction/orientation of nanostructures and number of nanostructures deposited on the adhesive are both governed by an electrostatic field applied between activated nanostructure and the adhesive substrate on the roll, or through a pneumatic force imparted on the nanostructure material
Data Source
AI summary
A roll-to-roll printing process for large scale manufacturing of nanosensor systems for sensing pathophysiological signals is disclosed. The roll-to-roll manufacturing process may include three processes to improve the throughput and to reduce the cost in manufacturing: fabrication of textile based nanosensors, printing conductive tracks, and integration of electronics. The wireless nanosensor systems can be used in different monitoring applications. The fabric sheet printed and integrated with the customized components can be used in a variety of different applications. The electronics in the nanosensor systems connect to remote severs through adhoc networks or cloud networks with standard communication protocols or non-standard customized protocols for remote health monitoring.