Flexible Textile Sensor with Embedded Conductor for Comfortable Heart Rate Monitoring
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Solution Overview
Problem
Traditional heart-rate monitoring bands are uncomfortable due to their thickness and reduced breathability, and previous solutions using textile materials face issues with electrode placement, signal transmission conductor positioning, and mechanical stress, leading to unreliable and uncomfortable physiological signal measurement.
Innovation Solution
A flexible sensor construction with a moisture-permeable textile substrate, where the signal transmission conductor is embedded on the inner surface and protected by insulating layers, ensuring reliable signal transmission without direct skin interference and maintaining comfort and breathability, using a multi-layer structure with a substrate, insulating layers, and a conductor layer to prevent moisture and mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional plastic heart rate bands are used, then signal transmission is reliable, but the product is thick and uncomfortable against the skin
Solution Approach 1:
The patent replaces traditional thick plastic bands with thin flexible textile substrates that conform to the skin surface. The sensor elements are integrated directly into the textile layers, allowing the band to be thin and comfortable while maintaining functional performance.
Solution Approach 2:
The patent uses composite textile structures combining different fiber layers with conductive elements. The multi-layer textile construction provides both comfort against the skin and reliable signal transmission pathways through the integrated conductive threads and patterns.
2Reliability
If conductors are placed on the surface of textile material, then electrical contact with electrodes is achieved, but breathability is reduced and discomfort occurs
Solution Approach 1:
The patent moves conductive elements from the outer surface dimension to the inner structure dimension of the textile. Conductive threads are embedded within the textile layers rather than placed on the surface, allowing breathability to be maintained while electrical contact is established through the textile's internal conductive pathways.
Solution Approach 2:
The patent uses moisture-retaining layers and conductive fiber intermediaries to bridge the gap between skin contact and electrical signal transmission. These intermediary layers maintain electrical connectivity while preserving the textile's breathability and comfort properties.
3Strength
If electrodes are moulded through textile material, then secure attachment is achieved, but conductors remain loose and vulnerable to mechanical stress
Solution Approach 1:
The patent merges the conductor attachment process with the electrode formation process. Conductive threads are integrated into the electrode structures during the same manufacturing step, ensuring both secure attachment and protected conductor pathways without separate attachment steps that could leave conductors vulnerable.
4Strength
If thermo-compression is used to attach conductors to textile, then secure attachment is achieved, but interference signals connect from skin through fabric
Solution Approach 1:
The patent applies different properties to different locations within the textile structure. Insulating coatings or barrier layers are applied locally at specific positions where skin contact occurs, preventing interference signals from reaching conductors through the fabric while maintaining conductor attachment strength in other areas.
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 a durable, comfortable, and breathable heart-rate monitoring system that combines flexibility with reliable signal transmission, protecting the conductor from stress and interference, and allowing the use of unstretchable materials, enhancing the manufacturing and user experience.
Implementation Method 1
The outer layer is a flexible and moisture-permeable substrate, which has an outer surface (first surface) and an inner surface (second surface) opposite to this
Implementation Method 2
A signal transmission conductor is arranged in a watertight manner on the inner surface of the substrate, so that interference signals cannot connect directly from the skin through the substrate
Implementation Method 3
A signal transmission conductor is arranged in a watertight manner on the inner surface of the substrate... An electrode, with a signalling surface facing in the same direction as the outer surface of the flexible substrate, is in turn connected electrically to the transmission conductor
Data Source
AI summary
An article of wearing apparel provided with a sensor for measuring a physiological signal, and a method for manufacturing the wearing apparel provided with a sensor. The wearing apparel includes a flexible substrate and the sensor includes at least one electrode, which has a signalling surface, and which faces in the same direction as the first surface of the flexible substrate. In addition, the sensor includes a signal transmission conductor, which is connected electrically to the electrode. The signal transmission conductor is attached in a watertight manner to the second surface of the substrate. The wearing apparel is comfortable to the user, and sensor in the wearing apparel is reliable, economical to manufacture, and waterproof.