Electronic Patch With Stepped Sensor Base For Wearable Comfort
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Solution Overview
Problem
Existing wearable electronic patches are not durable, stretchable, or comfortable due to rapid deterioration from body movements and laundering, limited fabric compatibility, and user discomfort caused by rigid layers, which hinders their effectiveness in monitoring physiological parameters.
Innovation Solution
An electronic patch design featuring a sensor pad with a stepped sensor base, an electrically conductive underlayer, a circuit layer, and elastic layers for flexibility, along with adhesive layers for durability and broad fabric compatibility, formed using silver and carbon pastes and printed using screen printing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If multiple rigid layers are used to provide sensor, computation, and communication functions, then device functionality is improved, but user comfort deteriorates due to discomfort when wearing
Solution Approach 1:
The patent replaces rigid layers with flexible elastic layers that can stretch and conform to body movements. The sensor base extends inwardly to define a stepped arrangement that maintains functionality while allowing flexibility. This resolves the contradiction by enabling the device to provide sensor, computation, and communication functions through flexible rather than rigid structures.
Solution Approach 2:
The sensor base extends inwardly from the sensor pad to define a stepped arrangement, adding a vertical dimension to the structure. This dimensional change allows the sensor to maintain contact with the skin while accommodating body movements, thus providing full functionality without compromising comfort.
2Reliability
If wearable conductive materials are used, then electrical conductivity is achieved, but durability deteriorates as they deteriorate rapidly with repeated elongations and laundering
Solution Approach 1:
The patent uses composite materials including silver paste for the sensor and carbon paste for the conductive underlayer. These materials are applied in a flexible matrix that maintains conductivity while withstanding repeated elongations and laundering. The combination of conductive materials with flexible substrates resolves the contradiction between maintaining electrical conductivity and achieving durability.
Solution Approach 2:
The patent changes the physical parameters of the conductive materials by using paste formulations that can be printed and cured to form flexible, durable conductive paths. The silver and carbon pastes are applied in specific patterns and cured to maintain conductivity while achieving wash resistance and stretchability.
3Measurement precision
If conventional wearable electronic patches are used, then basic sensing function is achieved, but adaptability deteriorates as they can only be applied to a limited range of fabric types
Solution Approach 1:
The patent creates a universal patch design with adhesive layers that can be applied to various fabric types including clothing, bandages, and other wearable items. The flexible construction and adhesive system allow the same sensor design to function on different substrates, achieving both precise physiological parameter detection and broad fabric compatibility.
4Extent of automation
If layered structure is used for sensor and circuit functions, then device functionality is improved, but reliability deteriorates as layers can break or delaminate under stress
Solution Approach 1:
The patent uses flexible elastic layers instead of rigid layered structures. The elastic layers can stretch and flex without breaking or delaminating, maintaining layer integrity while providing sensor and circuit functions. This resolves the contradiction by replacing brittle layered structures with flexible films that maintain both functionality and reliability.
Solution Approach 2:
The patent employs composite material structures where conductive pastes are applied over elastic layers, creating a integrated structure that prevents delamination. The combination of materials is designed to work together as a unified flexible structure rather than separate layers, improving reliability under stress.
Data Source
AI summary
Provided herein is an electronic patch for applying to a wearable item. The electronic patch includes a sensor comprising a sensor pad and a sensor base that together define a stepped arrangement, an electrically conductive underlayer disposed under the sensor base, a circuit layer disposed under the underlayer and electrically coupled to the sensor via the underlayer, a first elastic layer overlying the sensor base and arranged adjacent the sensor pad, and a second elastic layer disposed under the circuit layer. Also provided is a wearable item that includes the aforementioned electronic patch as well as methods of making said wearable item and electronic patch.