Large scale manufacturing of hybrid nanostructured textile sensors

Abstract

A process for the large scale manufacturing of vertically standing hybrid nanometer-scale structures of different geometries, including fractal architecture made of flexible materials, on a flexible substrate including textiles is disclosed. The nanometer-scale structures increase the surface area of the substrate. The nanometer-scale structures may be coated with materials that are sensitive to various physical parameters or chemicals such as but not limited to temperature, humidity, pressure, atmospheric pressure, 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 nanometer-scale structure and substrate with a material which can be used to sense physical parameters and chemicals as listed previously. An embodiment with nanometer-scale structures on a textile substrate coated with a conductive, malleable and bio-compatible sensing material for use as a biopotential measurement electrode is provided.

1 . (canceled) 
     
     
         2 . A nanostructured surface of 2-dimensional and 3-dimensional hybrid nanostructured articles made of one of the following:
 a. Short length multi-component yarn made with a combination of functionalized long chain polymers;   b. Short length multi-component fibers yarn with a combination of functionalized ceramic materials;   c. Short length multi-component metallic yarn made with a combination of functionalized metals;   d. Short length multi-component semiconductor nanofibrous articles made with a combination of functionalized semi-conductive materials; or   e. Short length multi-component yarn made with a combination of fibers from natural sources,   wherein the nanostructured surface is obtained by a deposition process comprising the following steps:   preparing the surface of a flexible or rigid substrate to achieve adhesion for a plurality of hybrid nanostructured articles;   depositing the plurality of said hybrid nanostructured articles;   providing electro/electromagnetic field to achieve random or fractal pattern of said plurality of hybrid nanostructured articles upon contacting the surface;   selective removal of a part or whole of deposited hybrid nanostructured article.   
     
     
         3 . The nanostructured surface of  claim 2 , wherein components of the multi-component hybrid nanostructured articles are selectively removed to modify its surface. 
     
     
         4 . The nanostructured surface of  claim 2 , wherein the deposited hybrid nanostructured articles are functionalized by electroless/electrolytic functionalization. 
     
     
         5 . A flow cell assembly for electroless/electrolytic coating of metallic or semi-conducting or piezo-electric or dielectric material on the hybrid nanostructured articles of  claim 2 . 
     
     
         6 . The hybrid nanostructured articles described in  claim 2  (a), wherein the deposited hybrid nanostructured article is coated with metallic material, using a flow cell assembly for electroless/electrolytic coating, for biopotential measurement applications. 
     
     
         7 . The hybrid nanostructured articles described in  claim 2  (a), wherein the deposited hybrid nanostructured article is coated with metallic material, using a flow cell assembly for electroless/electrolytic coating, for measurement and modulation of electromagnetic signals from non-biological sources. 
     
     
         8 . The hybrid nanostructured articles described in  claim 2  (a), (b), and (c), wherein the deposited hybrid nanostructured article is coated with metallic material, using a flow cell assembly for electroless/electrolytic coating, using a flow cell assembly for electroless/electrolytic coating, for applications comprising monitoring air quality, water quality, gas sensing, humidity and temperature sensing, and/or pollutant detection. 
     
     
         9 . The hybrid nanostructured articles described in  claim 2  (a), (b), (c) and (d), wherein the deposited hybrid nanostructured article is coated with metallic and semi-conducting material, using a flow cell assembly for electroless/electrolytic coating, for applications comprising temperature sensing, optical device, photovoltaic energy transduction, and/or thermal energy transduction. 
     
     
         10 . The hybrid nanostructured articles described in  claim 2  (a), wherein the deposited hybrid nanostructured article is coated with metallic and piezoelectric, using a flow cell assembly for electroless/electrolytic coating, for applications comprising motion sensing, acoustic transduction, noise dampening, and/or impact sensing. 
     
     
         11 . The hybrid nanostructured articles described in  claim 2  (e), wherein the deposited hybrid nanostructured article is coated with metallic material, using a flow cell assembly for electroless/electrolytic coating, for applications comprising humidity sensing, and/or structural defect detection. 
     
     
         12 . The nanostructured surface obtained by deposition of  claim 2 , wherein the short length multi-component yarn made with a combination of functionalized long chain polymers is selected from the group consisting of polyester, nylon, polypropylene, polybutylene, polylactic acid, poly-acrylonitrile, polycarbonate, polyurethane, polyolefin, polyimide and polyaramid, and wherein the short length multi-component yarn is melt blown or solution blown, or extruded and spun into fibers on spinneret. 
     
     
         13 . The nanostructured surface obtained by deposition of  claim 2 , wherein the short length multi-component fibers yarn with a combination of functionalized ceramic materials is selected from the group consisting of carbon fibers, carbon nanotube, graphite, silicates, borates, aluminates and metal oxide, and wherein the short length multi-component fibers yarn are made by sintering, sol gel, hydro-thermal process or extrusion. 
     
     
         14 . The nanostructured surface obtained by deposition of  claim 2 , wherein the short length multi-component metallic yarn made with a combination of functionalized metals is selected from the group consisting of silver, gold, platinum, titanium, iron, nickel, chromium, cobalt and aluminum and wherein the short length multi-component metallic yarn is made by extrusion, electrodeposition or vacuum thin film deposition. 
     
     
         15 . The nanostructured surface obtained by deposition of  claim 2 , wherein the short length multi-component semiconductor nanofibrous articles made with a combination of functionalized semi-conductive materials is selected from the group consisting of polypyrrole, polythiophenes, bismuth antimony telluride and gallium arsenide and wherein the short length multi-component semiconductor nanofibrous articles are made by extrusion, electrodeposition, vacuum thin film deposition or epitaxy. 
     
     
         16 . The nanostructured surface obtained by deposition of  claim 2 , wherein the short length multi-component yarn is made with a combination of fibers from natural sources selected from the group consisting of cotton, flacks, banana, jute and silk, and wherein the yarn is made by extrusion and spinning. 
     
     
         17 . The hybrid nanostructured articles of  claim 6 , wherein the biopotential measurement applications are selected from the group consisting of ECG, EEG, EOG, and EMG.