Roll-to-roll printing process for manufacturing a wireless nanosensor
Inventors
Varadan, Vijay K. • Rai, Pratyush • Oh, Se Chang
Assignees
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Publication Number
US-10231623-B2
Publication Date
2019-03-19
Expiration Date
Abstract
A roll-to-roll printing process for large scale manufacturing of nanosensor systems for sensing pathophysiological signals is disclosed. The roll-to-roll manufacturing process may include three processes to improve the throughput and to reduce the cost in manufacturing: fabrication of textile based nanosensors, printing conductive tracks, and integration of electronics. The wireless nanosensor systems can be used in different monitoring applications. The fabric sheet printed and integrated with the customized components can be used in a variety of different applications. The electronics in the nanosensor systems connect to remote severs through adhoc networks or cloud networks with standard communication protocols or non-standard customized protocols for remote health monitoring.
Core Innovation
The invention relates to a roll-to-roll printing process for manufacturing a wireless nanosensor monitoring system using a continuously moving fabric roll. The process continuously unwinds a fabric from a fabric roll, prints an insulating base layer, prints a conductive track layer on top of the insulating base layer, and prints an insulating cover layer on top of the conductive track layer while the fabric is moving. At least one sensor is printed onto the fabric roll or onto another fabric and is connected to the conductive track layer to form a printed fabric.
The core workflow includes mounting and bonding electronics onto a surface of the fabric roll, and connecting the electronics to the conductive track layer to form a wireless monitoring system. The method continuously winds the printed fabric into a printed fabric roll during all the printing steps, connecting steps, and mounting step. This provides a continuous manufacturing approach for a printed wireless nanosensor monitoring system on fabric.
The invention further includes depositing at least one sensor using adhesive-defined deposition of vertically upright nanostructured fibers configured as sensors. The sensor deposition uses electrostatic flocking and/or pneumatic flocking to deposit vertically aligned nanostructures without templates or stoppage, integrating the sensor into the roll-to-roll printed stack.
An additional aspect describes integration of wireless communication and electronics connectivity as part of the manufactured printed fabric. The document describes wireless transmission with a remote/cloud architecture and alerting/emergency response protocol, as well as electronics connectors including a magnetic connector with a plug part and receptacle part using pogo pins and a PCB.
Claims Coverage
The partial content identifies one independent claim, clm-00001, directed to a continuous roll-to-roll printing process that manufactures a wireless nanosensor monitoring system on fabric while unwinding and rewinding during all steps. Dependent claims further refine sensor deposition and connection, sensor materials, and printed electronics materials.
Continuously roll-to-roll fabrication of a wireless nanosensor monitoring system on fabric
continuously unwinding a fabric from a fabric roll; printing an insulating base layer onto the fabric; printing a conductive track layer on top of the insulating base layer; printing an insulating cover layer on top of the conductive track layer; printing at least one sensor onto the fabric roll or onto another fabric; connecting the at least one sensor to the conductive track layer; mounting and bonding electronics onto a surface of the fabric roll; connecting the electronics to the conductive track layer to form the wireless monitoring system to form a printed fabric; and continuously winding the printed fabric into a printed fabric roll during all the printing steps, the connecting steps, and mounting step.
Printing-based sensor connection to the conductive track layer in a continuous process
printing at least one sensor onto the fabric roll or onto another fabric; and connecting the at least one sensor to the conductive track layer during the roll-to-roll manufacturing of the printed fabric.
Mounting and bonding electronics during roll-to-roll manufacture
mounting and bonding electronics onto a surface of the fabric roll; and connecting the electronics to the conductive track layer to form the wireless monitoring system while the fabric is continuously wound during all steps.
Electrostatic and/or pneumatic deposition of vertically aligned or standing sensor nanostructures
deposited vertically upright nanostructured fibers as sensors using adhesive-defined electrostatic flocking and/or pneumatic flocking to create a sensor connected to the conductive track layer.
Organic semiconductor electronics for wireless monitoring functions
performed using at least one organic semiconductor selected from pentacene, a pentacene-carbon nanotube composite, or poly-3hexylthiophene.
The claim coverage centers on a continuous roll-to-roll printing method that prints insulating and conductive layers, prints and connects at least one sensor to a conductive track layer, bonds electronics onto the fabric, and rewinds the printed fabric during all steps to form a wireless monitoring system. Refinements emphasize sensor deposition using adhesive-defined vertically aligned or standing nanostructures via electrostatic and/or pneumatic flocking, and specify organic semiconductor materials and insulating polymer options for the printed electronics stack.
Stated Advantages
Not explicitly described in patent.
Documented Applications
Not explicitly described in patent.
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