Methods of manufacturing devices for static and dynamic body measurements

Abstract

A method of fabricating a sensor for static and dynamic body measurements, comprising providing a first layer serving as a flexible support material; disposing a second layer on the first layer, the second layer serving as a sensing material; disposing a third layer on the second layer, the third layer comprising an insulating material; coupling the second layer and the third layer using a first electrode comprising a first conductive thread and a first non-conductive thread, the first conductive thread embedded in the second layer; and coupling the first layer and the second layer using a second electrode comprising a second conductive thread and a second non-conductive thread, the second conductive thread embedded in the second layer.

What is claimed is: 
     
       1. A method of fabricating a sensor for static and dynamic body measurements, comprising:
 providing a first layer serving as a flexible support material; 
 disposing a second layer on the first layer, the second layer serving as a first sensing material that is electrically conductive throughout the second layer; 
 disposing a third layer on the second layer, the third layer comprising an insulating material; 
 coupling the second layer and the third layer using a first electrode comprising a first conductive thread and a first non-conductive thread, the first conductive thread embedded in the second layer, wherein the first conductive thread and the first non-conductive thread are used together in a spool, sewing needle, top thread, bobbin, and/or combinations thereof to form the first electrode; and 
 coupling the first layer and the second layer using a second first electrode comprising a second first conductive thread and a second first non-conductive thread, the second conductive thread embedded in the second layer, wherein the second conductive thread and the second non-conductive thread are used together in a spool, sewing needle, top thread, bobbin, and/or combinations thereof to form the second electrode by penetrating the first layer or the second layer with one or both of the first conductive thread and the first non-conductive thread using one or more of a spool, sewing needle, top thread, or bobbin. 
 
     
     
       2. The method of  claim 1 , wherein the sensor is a first sensor, and wherein the method further comprises fabricating a second sensor spaced laterally from the first sensor along a common horizontal axis or a common vertical axis by steps comprising:
 disposing a fourth third layer on the first layer, the fourth third layer serving as a second sensing material; 
 disposing the third a fourth layer on the fourth third layer, the third fourth layer comprising the insulating material; 
 coupling the fourth layer and the third layer using a third second electrode comprising a third second conductive thread and a third second non-conductive thread, the third conductive thread embedded in the fourth layer; and 
 coupling the fourth third layer and the first layer using a fourth third electrode comprising a fourth third conductive thread, the fourth conductive thread embedded in the fourth layer wherein the first electrode and the third electrode are electrically connected. 
 
     
     
       3. The method of  claim 1 , further comprising:
 disposing an additional layer on the second layer, the additional layer comprising an insulating material; and 
 coupling the second layer and the additional layer using an additional electrode, 
 wherein the first electrode comprising the first conductive thread and the first non-conductive thread, and the second additional electrode comprising the second an additional conductive thread and the second an additional non-conductive thread, are couple coupled by the first layer and the second additional layer, 
 wherein the first conductive thread and the second conductive thread are embedded in the second layer, and 
 wherein the first non-conductive thread and the second non-conductive thread are embedded in the first layer. 
 
     
     
       4. The method of  claim 1 ,
 wherein the first electrode comprising the first conductive thread and the first non-conductive thread, and the second electrode comprising the second conductive thread and the second non-conductive thread are couple by the third layer and the second layer,   wherein the first conductive thread and the second conductive thread are embedded in the second layer, and   wherein the first non-conductive thread and the second non-conductive thread are embedded in the third layer.   
     
     
       5. The method of claim  1  2, further comprising:
 configuring, (i) a cross-sectional shape of the first second electrode or the second third electrode, or (ii) a spacing between two or more of the first second electrode and the second third electrode, or (iii) a thickness of the first sensing material, to alter one or more of a response time, an input dynamic range, an output dynamic range, and/or and a sensitivity of the sensor. 
 
     
     
       6. The method of  claim 1 , wherein the sensor is a first sensor, and wherein the first electrode (electrode  1 ) of the first sensor is connected with to a second sensor with an having a second electrode  2  by:
 bonding the first electrode  1  with the second electrode  2  with conductive epoxy, spray, paint, or a conductively doped adhesive material. 
 
     
     
       7. The method of  claim 1 , wherein the sensor is a first sensor, and wherein the first electrode (electrode  1 ) of the first sensor is connected with to a second sensor with an having a second electrode  2  by:
 terminating the first electrode  1  with a conductive terminal attached to one or more of a conductive wire, thread, and material, and/or combinations thereof, that is used to overlap with the second electrode  2 . 
 
     
     
       8. The method of  claim 1 , wherein the sensor is a first sensor, and wherein the first electrode (electrode  1 ) of the first sensor is connected with to a second sensor with an having a second electrode  2  by:
 terminating both the first electrode  1  and the second electrode  2  with a conductive terminal such that is the first electrode and the second electrode are connected together physically, magnetically, and/or combinations thereof or both physically and magnetically. 
 
     
     
       9. The method of  claim 1 , wherein the sensor is a first sensor, and wherein the first electrode (electrode  1 ) of the first sensor is connected with to a second sensor with an having a second electrode  2  by:
 overlapping the ends of the first electrode  1  of the first sensor with the second electrode  2  of the second sensor using a third conductive material to overlap the ends of the first electrode  1  with the second electrode  2 . 
 
     
     
       10. The method of  claim 9 , wherein the overlap of the first electrode  1  and the second electrode  2  is achieved using one or more of manual connection techniques, mechanical connection techniques, electrical connection techniques, computerized connection techniques, embroidery stitches, and threading, and/or combinations thereof. 
     
     
       11. The method of  claim 9 , wherein the overlap of the first electrode  1  and the second electrode  2  is achieved by using one or more of resins, sprays, paints, or epoxies, and/or combinations thereof to bond the first electrode  1  with and the second electrode  2  with a conductively doped adhesive. 
     
     
       12. The method of  claim 9 , wherein the overlap of the first electrode  1  and the second electrode  2  is achieved by using one or more of a conductive terminal, and a magnetic terminal, and/or combinations thereof. 
     
     
       13. The method of  claim 1 , wherein the first electrode comprises:
 at least one conductive thread, wherein the at least one conductive thread is one or more ply per conductive thread, and   at least one non-conductive thread, wherein the at least one non-conductive thread is one or more ply per non-conductive thread,   wherein the at least one conductive thread and the at least one non-conductive thread are interlaced when embedded in a given layer,   wherein the at least one conductive thread or the at least one non-conductive thread are separately exposed on a front or a back of the given layer, or exposed on a same side of the given layer, and   wherein the at least one conductive thread or the at least one non-conductive thread is patterned to a shape or an area of a corresponding conductive or non-conductive layer.   
     
     
       14. The method of  claim 1 , wherein the first or the second conductive thread comprises a dopant selected from the group consisting of one or more of a group I element, a group II element, a transition metal, a group III element, a group IV element, a group V element, a group VI element, and a group VII element, and combinations thereof. 
     
     
       15. The method of claim  1  2, wherein a tension between the first or the second conductive thread and the first or the second non-conductive thread is configured to alter one or more of a tensile strength, a stability, a texture, an elasticity, and/or and a friability of the first electrode or the second electrode. 
     
     
       16. The method of claim  1  2, wherein altering an exposed length between the non-conductive to and conductive segments within the sensing material in coupled layer(s) is configured to alter alters one or more of a conductivity and/or and a sensitivity of the first electrode or the second electrode. 
     
     
       17. The method of claim  1  2, wherein one or more of (i) a dopant, (ii) a ply count, and/or and (iii) a thread pattern density, is configured to alter one or more of a conductivity and/or and a sensitivity of the first electrode or the second electrode. 
     
     
       18. The method of  claim 1 , wherein one or more of the first layer, the second layer, the third layer, and the first electrode, and/or the second electrode can be further fabricated or modified is disposed, coupled, or formed using one or more of electrospinning/spraying , electrospraying, and spray painting, and combinations thereof. 
     
     
       19. A method of fabricating a sensor, comprising:
 providing a first layer serving as a flexible support material; 
 disposing a second layer on the first layer, the second layer serving as a sensing material that is electrically conductive throughout the second layer; and  
 disposing a third layer on the second layer, the third layer comprising an insulating material; 
 coupling the second layer and the third layer using a first electrode comprising a first conductive thread and a first non-conductive thread, the first conductive thread embedded in the second layer; and 
 coupling the first layer and the second layer using a second first electrode comprising a second first conductive thread and a second first non-conductive thread, the second conductive thread embedded in the second layer, by penetrating the first layer or the second layer with one or both of the first conductive thread and the first non-conductive thread using one or more of a spool, sewing needle, top thread, or bobbin,  
 wherein altering an exposed length between non-conductive to and conductive segments of the first electrode or the second electrode within the sensing material in coupled layer(s) is adapted to alter alters a conductivity and/or, a sensitivity, or both a conductivity and a sensitivity, of the first electrode or the second electrode. 
 
     
     
       20. The method of  claim 19 , further comprising:
 wherein the first conductive thread and the first non-conductive thread are used together in a spool, sewing needle, top thread, bobbin, and/or combinations thereof to form the first electrode, and 
 wherein the second conductive thread and the second non-conductive thread are used together in a spool, sewing needle, top thread, bobbin, and/or combinations thereof to form the second electrode forming the first electrode by combining the first conductive thread and the first non-conductive thread using one or more of a spool, sewing needle, top thread, or bobbin. 
 
     
     
       21. The method of claim 1, further comprising:
 disposing an additional layer on the second layer, the additional layer comprising an insulating material; and   coupling the second layer and the additional layer using an additional electrode,   wherein the first layer and the additional layer are one piece of a material folded onto each other with the second layer disposed between the first layer and the additional layer.   
     
     
       22. The method of claim 1, further comprising:
 folding a portion of the first layer to place the first electrode in a three-dimensional space relative to a plane defined by the portion of the first layer.   
     
     
       23. The method of claim 1, wherein disposing the second layer on the first layer comprises arranging the second layer in a pattern that compresses or expands as the flexible support material is stretched, pressed, or bent. 
     
     
       24. The method of claim 1, wherein the sensor is a first sensor, and wherein the method further comprises fabricating one or more additional sensors on the first layer in a pattern configured to measure electric field tomography or electric impedance tomography. 
     
     
       25. The method of claim 1, wherein the sensor is a first sensor, and wherein the method further comprises fabricating one or more additional sensors in different topologies and arrangements using at least one of vinyl cutting techniques, embroidery of conductive fabrics or thin-sheet conductive metals, physical or vapor deposition, atomic layer deposition, spin coating, sputtering, spraying, or 3D printing. 
     
     
       26. A method of fabricating a device, comprising:
 providing a first layer serving as a flexible support material;   disposing a second layer on the first layer, the second layer serving as a first sensing material;   coupling the first layer and the second layer using a first electrode comprising a first conductive thread, the first conductive thread embedded on a first side of the second layer;   embedding a second conductive thread on a second side of the second layer as a second electrode;   disposing a third layer on the first layer, the third layer serving as a second sensing material; and   coupling the first layer and the third layer using a third electrode comprising a third conductive thread, the third conductive thread embedded in the third layer,   wherein the first electrode and the third electrode are electrically connected.   
     
     
       27. The method of claim 26, further comprising:
 providing a fourth layer on the third layer, the fourth layer comprising an insulating material;   coupling the third layer and the fourth layer using the third electrode;   providing a fifth layer on the fourth layer, the fifth layer serving as a third sensing material;   coupling the fourth layer and the fifth layer using a fourth electrode comprising a fourth conductive thread, the fourth conductive thread embedded on a third side of the fifth layer; and   embedding a fifth conductive thread on a fourth side of the fifth layer as a fifth electrode,   wherein the third electrode and the fourth electrode are electrically connected.   
     
     
       28. The method of claim 27, further comprising:
 embedding a sixth conductive thread on the third layer as a sixth electrode.   
     
     
       29. A device having at least one sensor, the device comprising:
 a first sensor, comprising:
 a first layer serving as a flexible support material; 
 a second layer adjacent to the first layer, the second layer serving as a first sensing material; and 
 a third layer adjacent to the second layer, the third layer comprising an insulating material, 
 wherein the second layer and the third layer are coupled using a first electrode comprising a first conductive thread and a first non-conductive thread, the first electrode being embedded into the third layer, and 
 wherein the first layer and the second layer are further coupled using a second electrode comprising a second conductive thread and a second non-conductive thread, the second electrode being embedded into the first layer.