Wearable Electrode Manufacturing via Roll-to-Roll Diffusion Bonding
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Solution Overview
Problem
Current wearable electronics and human-machine interfaces lack efficient methods for detecting and applying electrical signals to the skin for various applications such as therapy, control, and sensory feedback, often resulting in limited functionality and comfort.
Innovation Solution
A wearable electronic device with a multilayered structure, including electrodes, insulation, and wiring layers, embedded in an encapsulating adhesive layer, which uses a roll-to-roll manufacturing process to create a flexible and conductive garment that can detect and apply electrical signals for haptic, auditory, and visual stimulation, enabling interaction between humans and machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for wearable electronics, then device functionality can be achieved, but manufacturing efficiency and productivity are limited
Solution Approach 1:
The patent combines multiple manufacturing operations (laminating, printing, bonding) into a single roll-to-roll process that simultaneously forms the multilayered structure with electrodes, insulation, and wiring layers, dramatically improving manufacturing efficiency while handling the complex structure
Solution Approach 2:
The patent changes the manufacturing parameters from batch processing to continuous roll-to-roll processing, adjusting temperature, pressure, and speed parameters to enable high-speed production of the multilayered wearable electronic structure
2Adaptability or versatility
If flexible materials are used for wearable electronics, then comfort and adaptability are improved, but electrical conductivity and signal detection capability may be compromised
Solution Approach 1:
The patent uses composite materials including flexible substrates with integrated conductive layers, combining the flexibility of polymer materials with the electrical conductivity of metal or conductive ink traces to maintain both comfort and signal reliability
Solution Approach 2:
The patent applies different material properties to different regions of the wearable device, with conductive materials strategically placed at electrode locations for signal detection while maintaining overall flexibility through flexible substrate materials in non-conductive regions
3Adaptability or versatility
If skin contact electrodes are used for detecting electrical signals, then therapeutic and control functionality is enabled, but skin irritation and comfort issues may arise
Solution Approach 1:
The patent introduces an adhesive intermediate layer between the conductive electrode and the skin surface, which acts as a mediator to improve electrical contact while reducing direct irritation to the skin, enabling functional capability without harmful effects
Solution Approach 2:
The patent changes the physical and chemical parameters of the electrode-skin interface by using hydrogel or adhesive materials with optimized conductivity and biocompatibility parameters, maintaining effective signal detection while minimizing skin irritation
4Productivity
If roll-to-roll manufacturing process is implemented, then manufacturing productivity is significantly improved, but manufacturing precision and quality control may be challenging
Solution Approach 1:
The patent replaces traditional mechanical alignment and bonding systems with heat-activated adhesive bonding in a roll-to-roll process, using thermal energy to activate adhesives and achieve precise bonding without complex mechanical alignment mechanisms, maintaining precision while enabling high-speed continuous manufacturing
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 device provides effective detection and application of electrical signals for therapeutic, control, and sensory feedback applications, enhancing user experience and functionality by providing immersive and interactive interfaces for entertainment, education, and rehabilitation.
Implementation Method 1
A diffusion bond is formed between the top surface of the print media layer and the elastic conductive ink
Implementation Method 2
An elastic conductive ink is deposited onto the print media layer
Implementation Method 3
An adhesive print media layer is provided
Data Source
AI summary
A method of making an electrode for a wearable electronic includes providing an adhesive print media layer. A surface treatment is performed to a top surface of the print media layer. An elastic conductive ink is deposited onto the print media layer. The elastic conductive ink comprises a conductive particulate disposed in a binder. A diffusion bond is formed between the top surface of the print media layer and the elastic conductive ink. The diffusion bond forming is facilitated by the surface treatment and even after the diffusion bond is formed, the top surface of the diffusion bonded electrode remains conductive.