Stretchable Cover for Wearable Patch Components

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Solution Overview

Problem

Existing wearable patch devices for physiological monitoring face challenges in comfort, robustness, and safety due to concentrated retaining forces, limited flexibility, and complexity in mounting and dismounting components, which can lead to detachment and measurement errors, especially during physical activities.

Innovation Solution

A flexible and stretchable cover assembly that encloses electronic components, using clamping parts to apply compression forces for secure attachment while allowing for movement with the skin, reducing the risk of detachment and enhancing comfort and robustness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If components are mounted fixedly at specific positions determined by electrodes, then the components are securely retained, but the flexibility and stretchability of the patch device is limited

Engineering Contradiction:

Improvecomponent retentionVSAvoidflexibility and stretchability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patch device is divided into distinct functional layers: a flexible substrate layer that can stretch and adapt to skin, and a separate component carrier layer that houses the electronic components. This segmentation allows each layer to perform its specific function independently - the substrate provides flexibility while the component carrier provides stable mounting positions, resolving the contradiction between retention and flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A flexible intermediate layer or adhesive interface is introduced between the electrode-mounted substrate and the component carrier. This intermediary element can accommodate relative movement and deformation, allowing the component carrier to remain relatively stable while the substrate stretches and conforms to the skin surface, thus maintaining both component retention and overall flexibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If retaining forces are concentrated at specific mounting positions determined by electrodes, then the components are securely held, but the risk of detachment and skin stress increases

Engineering Contradiction:

Improvecomponent retentionVSAvoidskin stress and detachment risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The retention function is segmented from the electrode mounting positions. Instead of relying solely on electrode locations for component retention, a separate component carrier structure is introduced that distributes retention forces across multiple contact points or a larger surface area, reducing concentrated stress on the skin while maintaining secure component holding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The component retention mechanism is extended from a two-dimensional electrode plane to a three-dimensional structure with the component carrier rising above the substrate. This vertical dimension allows the component carrier to be retained by the cover structure rather than directly by skin-adhered electrodes, distributing forces more evenly and reducing skin stress.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If adhesive is used to connect electronics housing to the cover, then the printed circuit module is suspended above the adherent patch, but the flexibility of the cover is reduced

Engineering Contradiction:

Improvecomponent suspensionVSAvoidcover flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The cover is designed as a flexible shell or thin film structure that can enclose and retain the component carrier without requiring rigid adhesive bonding. The cover material itself provides the retention force through elastic deformation and friction, maintaining flexibility while achieving component suspension. The cover can stretch and conform to skin movements while keeping the electronics housing in position.

Inventive Principle:

Principle #30Flexible shells and thin films

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 improved comfort, robustness, and safety by distributing forces evenly, allowing for greater flexibility and compliance with skin movement, while simplifying the mounting and dismounting of components, thus enhancing the reliability of wearable patch devices.

Implementation Method 1

to apply a compression force to the component, thereby attaching the component to the inside of the cover

Methodology Applied

Scientific EffectCompression force: Compression

Implementation Method 2

the cover comprises at least one flexible and stretchable clamping part

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20240350060A1A Flexible and Stretchable Cover for Attaching a Component to a Patch

Publication Date: 2024.10.24 DATWYLER PHARMA PACKAGING BELGIUM

AI summary

The invention relates to the technical field of patches, more particularly to patches for attachment to the skin of a subject, for example in the medical, lifestyle, wellness or sports applications, etc. Specifically, it relates to the field of patch assemblies comprising components, such as for example sensors, electronics circuits, processors, data communication modules, batteries, etc. and/or any other suitable electronic components, also referred to as smart patches.