Large scale manufacturing of hybrid nanostructured textile sensors

• US 10,131,993 B2
• Filed: 02/06/2017
• Issued: 11/20/2018
• Est. Priority Date: 01/16/2015
• Status: Active Grant

• Current Assignee: Nanowear Inc.
• Original Assignee: Nanowear Inc.
• Inventors: Varadan, Vijay K., Rai, Pratyush, Oh, Se Chang
• Primary Examiner(s): Talbot, Brian K
• Application Number:
  US15/425,302
• Publication Number:
  US 20170226643A1
• Time in Patent Office: 652 Days
• Field of Search: 427 58
• CPC Class Codes: B05D 1/04 involving the use of an electrostatic field B05D1/025 and B05D1/14 take precedence
• CPC Class Codes: B05D 1/14 Flocking
• CPC Class Codes: B05D 1/16 Flocking otherwise than by spraying
• CPC Class Codes: B82Y 15/00 Nanotechnology for interacting, sensing or actuating, e.g. quantum dots as markers in protein assays or molecular motors
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: C23C 18/1635 Composition of the substrate
• CPC Class Codes: C23C 18/1641 Organic substrates, e.g. resin, plastic
• CPC Class Codes: C23C 18/1692 Heat-treatment
• CPC Class Codes: C23C 18/2086 with use of organic or inorganic compounds other than metals, first
• CPC Class Codes: C23C 18/31 Coating with metals
• CPC Class Codes: D01D 4/00 Spinnerette packs; Cleaning thereof D01D5/0069, D01D5/24, D01D5/253, D01D5/28 take precedence
• CPC Class Codes: D06N 1/00 Linoleum , e.g. linoxyn, polymerised or oxidised resin
• CPC Class Codes: D06N 2209/041 Conductive
• CPC Class Codes: D06N 3/0059 Organic ingredients with special effects, e.g. oil- or water-repellent, antimicrobial, flame-resistant, magnetic, bactericidal, odour-influencing agents; perfumes D06N3/0065 takes precedence
• CPC Class Codes: D06N 3/0061 Organic fillers or organic fibrous fillers, e.g. ground leather waste, wood bark, cork powder, vegetable flour; Other organic compounding ingredients; Post-treatment with organic compounds
• CPC Class Codes: D06N 7/0097 Web coated with fibres, e.g. flocked
• CPC Class Codes: H05K 3/12 using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns
• CPC Class Codes: H05K 3/4661 Adding a circuit layer by direct wet plating, e.g. electroless plating; insulating materials adapted therefor other insulating materials H05K3/387

Abstract

A process for the large-scale manufacturing vertically standing hybrid nanometer scale structures of different geometries including fractal architecture of nanostructure within a nano/micro structures made of flexible materials, on a flexible substrate including textiles is disclosed. The structures increase the surface area of the substrate. The structures maybe coated with materials that are sensitive to various physical parameters or chemicals such as but not limited to humidity, pressure, atmospheric pressure, and electromagnetic signals originating from biological or non-biological sources, volatile gases and pH. The increased surface area achieved through the disclosed process is intended to improve the sensitivity of the sensors formed by coating of the structure and substrate with a material which can be used to sense physical parameters and chemicals as listed previously. An embodiment with the structures on a textile substrate coated with a conductive, malleable and bio-compatible sensing material for use as a biopotential measurement electrode is provided.

Claims

1. A method for manufacturing of hybrid nanostructured textile sensors comprising:

embedding polymer nanofibers into a matrix polymer to form a yarn;

dissolving the matrix polymer to expose the polymer nanofibers; and

coating the polymer nanofibers with a film.

2. The method as recited in claim 1 wherein the yarn is a micro denier yarn.

3. The method as recited in claim 1 wherein the micro denier yarn has a helical structure.

4. The method as recited in claim 1 wherein the polymer nanofibers are vertically standing structures.

5. The method as recited in claim 1 wherein the polymer nanofibers are helical structures.

6. The method as recited in claim 1 further comprising the step of:

imparting an electrostatic charge to the yarn prior to the dissolving the matrix polymer.

7. The method as recited in claim 1 wherein the polymer nanofibers are made of a polymer material selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate and polybutylene terephthalate.

8. The method as recited in claim 1 wherein the polymer nanofibers are made of a polyester.

9. The method as recited in claim 6 wherein the step of imparting further includes performing an electrostatic and/or pneumatic assisted deposition process using a high strength electrostatic field of 2 kV/cm-10 kV/cm.

10. The method as recited in claim 1 wherein the polymer nanofibers are made of a polyurethane.

11. The method as recited in claim 1 wherein the matrix polymer is made of a material selected from the group consisting of polystyrene, polyvinyl alcohol, ethylene vinyl alcohol, polyacrylamide and poly lactic acid.

12. The method as recited in claim 1 wherein the matrix polymer is made of a polyethylene terephthalate modified with sulfonated isocyanate.

13. Themethod as recited in claim 1 wherein the film is a conductive material selected from the group consisting of silver, gold, platinum, polyaniline, polypyrrole and poly(3,4-ethylenedioxythiophene).

14. The method as recited in claim 1 wherein the film is a metal oxide film.

15. The method as recited in claim 1 wherein the film is a piezoelectric material film.

16. The method of claim 1, further comprising

receiving a fabric piece in a printing press,

printing an adhesive film in a pattern of array of specific shapes on the fabric;

and

electrostatic force assisted deposition of the film coated nano-fibers onto the adhesive film on the fabric in a vertically upright position.