Shearable Electrode Layer for Wearable Patches
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Solution Overview
Problem
Conventional wearable patches face issues with comfort, durability, breathability, and adherence to curved surfaces due to rigid substrates, leading to discomfort, irritation, and inoperability during extended wear, especially when subjected to muscle movements and sweat buildup.
Innovation Solution
The development of highly compliant and flexible wearable patches with elastic layers, adhesive layers, and shearable electrode layers that can stretch and breathe, featuring a support substrate with openings for flexibility and a conductive via for signal transmission, along with flexible ribbons for connecting circuit modules, enabling durable and aesthetically appealing devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid polymer substrate is used in conventional wearable patches, then structural support and durability are improved, but breathability and comfort deteriorate due to sweat and moisture buildup
Solution Approach 1:
The patent employs a porous polymer substrate with controlled porosity (30-70% void volume) that allows sweat and moisture to pass through while maintaining structural support. The porous structure provides mechanical strength through the polymer matrix while the void spaces enable breathability and prevent moisture buildup against the skin.
Solution Approach 2:
The patent uses composite material structures combining rigid polymer substrates with flexible elastomeric layers. The rigid substrate provides structural support and durability, while the flexible elastomeric coating layer (5-50 micrometers thick) provides breathability and conformability to curved skin surfaces, resolving the contradiction between strength and comfort.
2Stability of the object's composition
If rigid polymer substrate is used in conventional wearable patches, then structural stability is improved, but adaptability to curved surfaces deteriorates
Solution Approach 1:
The patent applies a thin flexible elastomeric film layer (5-50 micrometers) over the rigid polymer substrate. This thin film allows the patch to conform to curved skin surfaces while the underlying rigid substrate maintains structural stability. The flexible layer acts as a compliant interface that adapts to body contours without compromising the structural integrity of the device.
3Measurement precision
If conventional electrodes are used for measuring human organ electrical activities, then measurement capability is achieved, but comfort and wearability deteriorate due to bulky design
Solution Approach 1:
The patent extracts the essential measurement function from bulky conventional electrodes and integrates it into a thin, flexible wearable patch. The electrode functionality is incorporated directly into the flexible substrate structure, eliminating the need for separate bulky electrode components while maintaining electrical signal measurement capability for ECG, EEG, and EMG applications.
Solution Approach 2:
The patent uses flexible thin film electrodes integrated into the wearable patch structure, replacing rigid conventional electrodes. These flexible electrodes maintain contact with the skin during body movements and provide accurate electrical signal measurement while being comfortable and unobtrusive for extended wear.
4Reliability
If conventional wearable patches are subjected to repeated elongations during body movements, then functionality is maintained initially, but durability deteriorates due to layer breakage and delamination
Solution Approach 1:
The patent incorporates dynamic stress-relief features including serpentine conductive traces and flexible hinge regions that allow the patch to deform elastically during body movements. These dynamic structures absorb repeated elongation stresses through controlled deformation, preventing permanent damage and delamination while maintaining electrical connectivity and functionality over extended wear periods.
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 solution provides long-lasting, comfortable, and robust wearable patches that can endure muscle movements and maintain constant contact with the skin, offering improved breathability and reliability in data collection while being aesthetically appealing.
Implementation Method 1
the support substrate includes a via that is conductively connected to the upper electrode layer and the lower electrode layer
Implementation Method 2
NFC uses passive energy that is collected through active electromagnetic coupling from the reader devices
Data Source
AI summary
A wearable patch capable of wireless communications includes an elastic layer, an adhesive layer under the elastic layer, and a shearable electrode layer that includes: a support substrate comprising one or more openings so positioned to allow the shearable electrode layer to be sheared and elongated, and breathable, an upper electrode layer on the support substrate, and a lower electrode layer under the support substrate. The support substrate can include a via that is conductively connected to the upper electrode layer and the lower electrode layer. The lower electrode can be in contact with a user's body and to pick up electric signals from the user's body.