Flexible wireless patch for physiological monitoring and methods of manufacturing the same

• US 9,597,034 B2
• Filed: 07/21/2015
• Issued: 03/21/2017
• Est. Priority Date: 05/24/2007
• Status: Active Grant

• Current Assignee: HMicro Inc.
• Original Assignee: HMicro Inc.
• Inventors: Beck, James C.
• Primary Examiner(s): LE, THIEN MINH
• Application Number:
  US14/805,389
• Publication Number:
  US 20150374294A1
• Time in Patent Office: 609 Days
• Field of Search: 235/492, 235/488, 235/487, 235/380, 235/493
• US Class Current: 1/1
• CPC Class Codes: A61B 2560/0214 of power generation or supply
• CPC Class Codes: A61B 2560/0412 Low-profile patch shaped housings
• CPC Class Codes: A61B 2562/125 characterised by the manufacture of electrodes
• CPC Class Codes: A61B 5/0002 Remote monitoring of patients using telemetry, e.g. transmission of vital signals via a communication network A61B5/07 takes precedence; transmission systems for measured values G08C; transmission H04B; transmission of digital information H04L; wireless communication networks H04W
• CPC Class Codes: A61B 5/0015 characterised by features of the telemetry system
• CPC Class Codes: A61B 5/24 Detecting, measuring or recording bioelectric or biomagnetic signals of the body or parts thereof
• CPC Class Codes: A61B 5/282 Holders for multiple electrodes for introduction into the body A61B5/287
• CPC Class Codes: A61B 5/6801 specially adapted to be attached to or worn on the body surface
• CPC Class Codes: A61B 5/6833 Adhesive patches
• CPC Class Codes: A61B 5/6841 by using templates
• CPC Class Codes: A61B 5/7203 for noise prevention, reduction or removal
• CPC Class Codes: H01P 11/00 Apparatus or processes specially adapted for manufacturing waveguides or resonators, lines, or other devices of the waveguide type
• CPC Class Codes: Y10T 29/49016 Antenna or wave energy "plumbing" making
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

Provided herein is an integrated wireless patch comprising a contact layer, an electronics layer, and a battery layer. The contact layer is a substrate having gel cutouts. The electronics layer can be folded into contact with the contact layer. The battery layer can be folded into contact with the electronic layer. Further provided herein is a method of manufacturing a wireless integrated patch comprising folding a substrate comprising at least one cutout, at least one contact disk in communication with a surface of a patient through the cutout, and battery terminals, wherein the at least one cutout, the at least on contact, and the battery terminals are adaptable to be located in different layers after the substrate is folded.

Claims

1. An integrated wireless patch comprising different layers, the patch comprising:

a contact layer comprising a substrate configured to come into contact with a surface of a user, wherein the contact layer comprises one or more cutouts configured to provide flexibility and reduce strain between the contact layer and the surface of the user;

a battery layer disposed over the contact layer, wherein the battery layer comprises a battery;

an electronic layer disposed above the contact layer and adjacent to the battery layer, wherein the electronic layer comprises at least one contact pad configured to sense an electrical signal from the surface of the user; and

an adhesive spacer adaptable to be located adjacent to the contact layer and the electronic layer, wherein the adhesive spacer is configured to prevent signal leakage from the at least one contact pad.

2. The patch of claim 1 wherein the battery layer comprises battery terminal tabs.

3. The patch of claim 1 wherein the patch is adaptable to be assembled by positioning the electronic layer between the contact layer and the battery layer.

4. The patch of claim 1 wherein the contact layer comprises an electrode gel configured to facilitate communication between the surface of the user and the at least one contact pad.

5. The patch of claim 1 wherein the one or more cutouts are one or more spiral cutouts.

6. The patch of claim 1 further comprising at least one antenna powered by the battery.

7. The patch of claim 1 further comprising at least one application-specific integrated circuit on the electronic layer.

8. The patch of claim 1 wherein the adhesive spacer is configured to add thickness to the patch, thereby protecting components on the electronics layer.

9. The patch of claim 1 wherein the electronic layer comprises conducting traces that relay the signal from the user sensed by the contact pads to an application-specific integrated circuit on the electronic layer.

10. The patch of claim 1 wherein each of the different layers are configured to be stacked above or below a different layer.

11. The patch of claim 1 wherein each of the different layers comprise a similar shape or size.

12. The patch of claim 1 wherein a center of each of the different layers substantially align.

13. The patch of claim 1 wherein prevention of signal leakage improves a quality of the signal sensed from each of the contact pad.

14. An integrated wireless patch comprising different layers, the patch comprising:

a contact layer comprising a substrate, wherein the contact layer is configured to come into contact with a surface of a user, wherein the contact layer comprises one or more cutouts configured to provide flexibility and reduce strain between the contact layer and the surface of the user, and wherein the contact layer comprises an electrode gel configured to facilitate communication between the surface of the user and the at least one contact pad;

a battery layer disposed over the contact layer, wherein the battery layer comprises a battery; and

an electronic layer disposed above the contact layer and adjacent to the battery layer, wherein the electronic layer comprises at least one contact pad configured to sense an electrical signal from the surface of the user,

wherein each of the different layers are configured to be stacked above or below a different layer.

15. The patch of claim 14 wherein the battery layer comprises battery terminal tabs.

16. The patch of claim 14 wherein the patch is adaptable to be assembled by positioning the electronic layer between the contact layer and the battery layer.

17. The patch of claim 14 wherein the one or more cutouts are one or more spiral cutouts.

18. The patch of claim 14 further comprising at least one antenna powered by the battery.

19. The patch of claim 14 further comprising at least one application-specific integrated circuit on the electronic layer.

20. The patch of claim 14 wherein the electronic layer comprises conducting traces that relay the signal from the user sensed by the contact pads to an application-specific integrated circuit on the electronic layer.

21. The patch of claim 14 wherein each of the different layers comprise a similar shape or size.

22. The patch of claim 14 wherein a center of each of the different layers are substantially aligned.