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Smart materials, dry textile sensors, and electronics integration in clothing, … — Nanowear Inc. (US20170354372A1)

Nanowear Inc. · Google Patents

Google Patents · Patents · License: Open Access

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vijayk.varadan

patent, google patents, intellectual property, US20170354372A1, Nanowear Inc., Vijay K. Varadan, en, 2017

ABSTRACT

Abstract

Sensors mounted on a textile include at least one of electrically conductive textile electrodes; single or multiple optically coupled infrared and red emitter and photodiode or photo transistor; and thin film or Resistive Temperature Detector (RTD). Textile electrodes, electrical connections, and electrical functionalization use at least one of nanoparticles, nanostructures, and mesostructures. Conductive thread, for electrical connections, may include a fiber core made from conductive materials such as but not limited to metals, alloys, and graphine structures, and a sheath of insulating materials such as but not limited to nylon, polyester, and cotton.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of U.S. application Ser. No. 13/657,854, filed Oct. 22, 2012, which is a continuation of U.S. application Ser. No. 13/415,698, filed Mar. 8, 2012, which claims the benefit of priority under 35 U.S.C. Â§119(e) of U.S. Provisional Patent Application No. 61/450,423, filed Mar. 8, 2011, the entire disclosures of which are hereby incorporated by reference.

This application is also a continuation-in-part of U.S. patent application Ser. No. 13/829,898, filed Mar. 14, 2013 which is a continuation-in-part of U.S. patent application Ser. No. 13/449,755 filed Apr. 18, 2012, the entire disclosures of which are hereby incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates to electronic and optical sensor technologies, and their packing to enable their integration into textile. These sensor capabilities will enable the use of textile for health monitoring, while operating in contact or in proximity of person's body.

BACKGROUND

Chronic disease management and in-hospital patient care are two major contributors to healthcare costs. The former consists of patients in need of repeated tests to assess disease progression or protocols for drug dosage adjustments. The latter consists of patients recovering from surgeries or in need for constant observation for diagnosis. They contribute to approximately 30% ($690 billion) and 20% ($460 billion) of the annual healthcare costs, respectively, in the United States of America. See, e.g., Tabibiazar R., Edelman S. V., âSilent Ischemia in People with Diabetes: A Condition That Must Be Heard,â Clinical Diabetes, Vol. 21 (1), 5-9 (2003), the disclosure of which is incorporated herein by reference.

Heart related ailments like coronary heart diseases, cardiovascular diseases, and strokes that are caused by clots or hypertension are the predominant causes of mortality in the US among both men and women. However, the number of deaths due to cardiac ailments in women has been consistently higher than in men since as early as 1985. In 2006, mortality due to all cardiac ailments among women was nearly 60% more than that due to all forms of cancer combined. This difference is also imminent in the case of postoperative survival among women after major cardiac surgeries like coronary bypass. At age 40 and older, 23 percent of women compared with 18 percent of men die within one year after a heart attack. This statistic has been related to the post-menopausal hormonal changes like the levels of estrogen in the blood. Estrogen has been known to have a prophylactic effect on the formation and growth of arterial plaques and clots, which can stifle the flow of blood through major blood vessels or stop it altogether. However, administration of Estrogen and Progestin has been shown to have minimal effect on the outcome of cardiovascular diseases in post-menopausal women.

Chronic diseases such as asymptomatic myocardial ischemia, a decrease in blood supply to the heart, appear as episodic events that do not leave any diagnostic evidence behind, making them all the more difficult to identify. Detection of Cardiac arrhythmias or irregular beats from continuous electroencephalogram (ECG) recordings is an important metric that physicians use to adjust medication for post myocardial infarction patients.

The major risk factors that have been reported to affect the cardiac health of women are smoking, inactivity, obesity, diabetes mellitus and hormonal changes resulting from menopause. Subtle changes in the cardiac activity manifested as irregular heartbeats, aberrational variations in the body's autonomous regulation of blood pressure and minor transient blockages in flow of blood to the heart, due to such chronic conditions or risk factors lead to fatal cardiac episodes. Thus, the best recourse is to engage in preventive measures involving continuous real-time monitoring to better track these physiological changes. Moreover, techniques like Electrocardiograph (ECG), blood pressure, heart rate variability analysis through time, frequency and wavelet domain analysis techniques have been successful in tracking the above-mentioned subtle changes.

More generally, vigorous exercise and exertion is known to increase the risk of Sudden Cardiac Death (SCD) in both men and women, including youths as well as adults, with underlying cardiovascular diseases (CVD). Recently, SCDs have been reported with a high rate of occurrence among athletes in soccer, football and basketball. Prescreening athletes with 12-lead Electrocardiograms (ECG) has been a successful measure to identify individuals at high risk for SCDs and exclude them from participation. The total cost for such prescreening of athletes is estimated to be in the order of $10 B/year. The high risk of SCDs during training or exertion suggests that ECGs are of far greater value when acquired real-time during the actual training where abnormal cardiac electrophysiology can be tracked and identified before the onset of symptoms. The availability of such immediate diagnostic data would also significantly reduce the time taken to administer the appropriate resuscitation shock. What is needed is method for obtaining cardiovascular information in an unobtrusive manner so that participants in high-stress activities can be continuously monitored for abnormalities.

Cardiovascular diseases and neurological disorders form the majority of diseases that need constant or periodic medical attention. The concept of continuous health monitoring can be translated as point of care technology for preventive/corrective medicine and as metabolic rate estimation and regulation as a part of healthy lifestyle. Point of care technology aims at enabling diagnostics in hospice, at home or ambulatory (on the move).

Health monitoring textile is a type of wearable and ambient healthcare technology: an ensemble of non-invasive sensor systems, which operates in contact or in proximity of person's body. Resemblance to a conventional wearable item (apparel) or integrability in it increases the relevance of such a device. Wearable fabric based items like vests, socks, shorts, head bands, arm bands, wrist bands and caps, foot wear, and drapes like bed spreads/sheet and pillow covers can incorporate sensors for monitoring the health of an individual for diabetes, neurological, and cardiovascular monitoring.

Neurological disorders such as sleep disorders and sleep deprivation affect more than thirty million people, while another six million have moderate to severe sleep apnea in which breathing briefly stops. That is nearly one in five Americans, making sleep apnea as prevalent as asthma or diabetes. More than six million people have restless leg syndrome and periodic limb movement disorder which jolts them awake repeatedly. As many as twenty-five million people remain undiagnosed and untreated which will account for over $22 billion in unnecessary health care costs. Apart from physical factors such as obesity, studies have shown that the cumulative long-term effects of sleep loss and sleep disorders are associated with a wide range of serious health consequences and many life threatening illnesses including increased risk of hypertension, diabetes, depression, heart attack, impotence and stroke, to name a few. In addition, a significant percentage of severe traffic and industrial accidents may be caused by the involuntary human transition from wakefulness to sleep.

There are also apparent links between deficits in brain chemistry and obstructive sleep apnea (OSA) and REM sleep behavior disorder (RBD). Both are relatively common sleep problems that disturb the slumber and daytime behavior of millions of Americans. It has been reported that multiple system atrophy (MSA), a rare and fatal degenerative neurological disease, is almost always accompanied by severe sleep disorder. Patients with the fewest dopamine-producing neurons in the striatum of their brains had the worst RBD symptoms, talking and violent flailing during their sleep. People with OSA show tissue loss in brain regions that help store memory, thus linking OSA with memory loss and Alzheimer's disease. Obstructive sleep apnea, in which breathing temporarily stops during a person's sleep, often affects adults but goes undiagnosed in many cases. Its most notable symptoms are snoring and excessive daytime sleepiness, though it can also affect blood pressure, memory and even reaction-time while driving.

What is needed is a robust and nondisruptive monitoring bed sheets- and pillow cases-based system that addresses continuous biopotential measurements, which can analyze and record the required parameters while the patient is at home and sleeping in his or her own bed.

Textiles offer a durable platform for embedded sensor and communication systems, with the components like sensors and communication chip-sets stitched or woven into the fabric. Individual electronic components can be mounted on the textile and connected through electrical connects that have been built in or manufactured in the textile itself. The electronic functionality should be embedded while maintaining the textile properties of product like wearing comfort and durability. Manufacturing techniques used for such smart textiles have to be compatible with existing textile manufacturing techniques to minimize additional costs.

Physiological signals, such as but not limited to, Electrocardiogram (ECG), Pulse rate (and heart rate variability), blood pressure, Electroencephalography (EEG), electro-oculography (EOG) and electromyography (EMG), provide a comprehensive medical status of a person. In combination with wireless communication technology, they can be used for remote medical diagnosis or prognosis. Textile based dry electrodes with lower electrode-skin contact impedance for improved performance in bioelectric signal acquisition is important to achieve un-obstructive and long term health monitoring. This is not possible with conventional wet electrodes due to drying of the conductive gel over period of time that leads to loss of functionality and skin irritation. Un-obstructive blood pressure monitoring requires an alternative to the conventional inflatable cuff based sphygmomanometer. Also, such a setup is difficult to incorporate in textile and very energy intensive for mobile health monitoring.

SUMMARY

Printing processes can be used for making complex high resolution designs on a wide range of substrate, including textile. See, e.g., Sherman, R., âCould Printed Electronics Replace Traditional Electronics?â Printed Circuit Design & Fab, 27 (3), 38, 40, 42 (2010), the disclosure of which is incorporated herein by reference. Printing allows for direct pattern transfer of electronics with little or no waste of material and thus a cost effective alternative to photolithography techniques. Among the popular printing technologies, screen printing and gravure are well suited for mass produced electronics on textile because of their parallel printing technology and the substrate handling. See, e.g., Sheats, J., R., Biesty, D., Noel, J., Taylor, G., N., âPrinting technology for ubiquitous electronics,â Circuit World, 36 (2), 40-47 (2010); Kah, B., E., âPrinting methods for printed electronics,â 24th International Conference on Digital Printing Technologies. Digital Fabrication 2008, 15-20 (2008), the disclosures of which are incorporated herein by reference.

Parallel printing, as compared to serial printing technologies like ink jet printing, has a higher manufacturing throughput. Screen printing and gravure printing technologies do not deviate significantly from garment making techniques making them cost effective. These technologies will enable fabrication (over a large surface area) of electronics with varied functionality like:-sensor systems and flexible printed circuits for electrical connections between sensors and the embedded wireless telemetry systems.

The textile based healthcare applications and packaging technology described in accordance with embodiments of the present invention provide improved sensor performance and seamless integration of the sensor systems in the textile for un-obstructive health monitoring. The technologies use a novel combination of nanomaterials and textile fabric for sensor and packaging electronics, provided in a garment, bedsheets, pillow cases or arm bands.

According to various aspects of the disclosure, sensors mounted on a textile include at least one of electrically conductive textile electrodes; single or multiple optically coupled infrared and red emitter and photodiode or photo transistor; and thin film or Resistive Temperature Detector (RTD).

According to the disclosure, textile electrodes, electrical connections, and electrical functionalization use at least one of nanoparticles, nanostructures, and mesostructures. As used herein, electrical functionalization includes textile integrated sensors, electrical signal carrying lines, electrical connections, and analog and digital components.

In accordance with some aspects of the disclosure, conductive thread, for electrical connections, may include a fiber core made from nanoparticles and mesoparticles made of conductive materials such as but not limited to metals, alloys, and graphine structures, and a sheath of insulating materials such as but not limited to nylon, polyester, and cotton.

Also disclosed herein are embodiments of a wearable remote electrophysiological monitoring system which includes a fully wearable textile integrated real-time ECG acquisition system with wireless transmission of data for the continuous monitoring of football players during training and on the field during games. The system is applicable also to basketball players, soccer players and other athletes, as well as members of high-stress occupations such as military personnel, police, firefighters, and various other emergency responders.

To that end, the sensors required to pick up the necessary biological signals and constantly relay the signals need to be seamlessly integrated into everyday clothing such that no additional preparation or mounting of individual sensors is needed. The innovative âe-braâ described here is a foundation garment or a brassiere, designed with a multitude of sensor capabilities for cardiac and pulmonary health monitoring which are integrated into a fabric with improved performance. The end result is an autonomous garment that can collect and transmit vital health signals of the wearer.

The e-bra will also help non-critical users (i.e. those not acutely suffering from a condition such as heart or pulmonary diseases) for monitoring important metrics such as calories burned during a workout, to get an optimum workout by jogging or on a treadmill, and pacing their exercise. For instance, the wearer's heart rate should be at the proper intensity level for an extended period of time. If the heart rate gets too high, the wearer's activity can become counterproductive. If it is too low, the wearer is not getting optimal health benefits. This technology will thus monitor and provide the optimum workout needed for a given individual.

The e-bra system described here is a comfortable and wearable monitor for cardiovascular and pulmonary health for women. It has a basic structure of a foundation garment for woman's bosom that covers all or part of chest, shoulders, arms and upper back. Sensor components include biopotential electrodes like electrocardiogram (ECG) electrodes which are mounted on the garment, photoplethysmography channels which are worn as an arm band, piezoelectric acoustic sensors, temperature sensors, and piezoresistive respiration effort sensors.

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CROSS-REFERENCE TO RELATED APPLICATIONS

TECHNICAL FIELD

BACKGROUND

SUMMARY

This technology also provides additional benefits even if one is not a cardiovascular or pulmonary patient. For example, individuals could use the devices to report beneficial activities (exercising, taking medications, sleeping) and receive incentives from partners (doctors, insurance companies, social networks) with whom they share that information.

Thus, in one embodiment the invention provides a wearable remote electrophysiological monitoring system. The system includes a garment having at least one nanostructured, textile-integrated electrode attached thereto; a control module in electrical communication with the at least one nanostructured, textile-integrated sensor; and a remote computing system in communication with the control module.

In another embodiment, the invention provides a system for cardiac monitoring of an individual. The system includes a garment having a plurality of nanostructured textile electrodes integrated therein, the electrodes arranged on the garment to record data for an ECG of the individual; a first controller electrically coupled to the plurality of electrodes, the controller including a wireless transmitter, the first controller being configured to collect the recorded data for the ECG from the plurality of electrodes and to cause the wireless transmitter to wirelessly transmit the recorded data; and a wireless receiving station including a wireless receiver and a second controller, the second controller configured to cause the wireless receiver to receive the recorded data transmitted by the wireless transmitter, analyze the recorded data for the ECG, analyze the recorded data, identify an abnormality in the ECG, and generate an alert if an abnormality in the ECG is identified.

In yet another embodiment, the invention provides a system for cardiac monitoring of a group of individuals including a plurality of wearable monitoring units. Each wearable monitoring unit includes a garment having a plurality of nanostructured textile electrodes integrated therein, the electrodes being arranged on the garment to record data for an ECG of the individual; a first controller electrically coupled to the plurality of electrodes, the controller including a wireless transmitter, the first controller being configured to collect the recorded data for the ECG from the plurality of electrodes and to cause the wireless transmitter to wirelessly transmit the recorded data. The system also includes at least one wireless receiving station including a wireless receiver and a second controller, the second controller configured to cause the wireless receiver to receive the recorded data transmitted by the wireless transmitter and to analyze the recorded data for the ECG, the second controller further configured to analyze the recorded data, identify an abnormality in the ECG, and generate an alert if an abnormality in the ECG is identified.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention can become more fully understood from the detailed description given herein below and the accompanying drawings, given by way of illustration only and thus not intended to be limitative of the present invention:

FIG. 1 illustrates a design of an exemplary arm band for brachial artery plethysomography in accordance with various aspects of the disclosure;

FIG. 2 illustrates an exemplary mechanism for adjusting the relative positions of the sensors according to various aspects of the disclosure;

FIG. 3 illustrates an exemplary packaging technology for the sensors in accordance with various aspects of the disclosure;

FIG. 4 is a graph showing the signal from an exemplary 3-Lead ECG dry textile electrodes system with

leads

1 , 2 , and 3 plotted simultaneously;

FIG. 5 is a graph of a leading electrocardiograph (lead 2 ) and lagging brachial artery pulse data acquired on the same time line for measurement of pulse transit time;

FIG. 6 is a graph showing calibration curves for systolic and diastolic blood pressures versus pulse transit time;

FIG. 7 is a graph illustrating a Resistive Temperature Detector based temperature sensor calibration curve; and

FIG. 8 is a graph of brain rhythm such as Alpha, Beta, Theta and Delta waves from a textile sensor in pillow cases and bed sheets

FIG. 9( a ) shows lead placement for a twelve-lead ECG with derived limb leads.

FIG. 9( b ) illustrates the placement of electrodes on the frontal side of the garment in which the electrodes have been placed according to the medical specifications for the limb leads, precordial leads, chest lead, and ground lead.

FIG. 9( c ) illustrates the mounting of an electrode on elastic backing using stitching.

FIG. 10 illustrates the back electrode site and the elastic backings provided in the brassiere platform where the elastic backings facilitate the ECG electrodes maintaining contact with the skin.

FIG. 11 shows the position for the acoustic sensor(s), respiration effort sensor and temperature sensor(s).

FIG. 12 shows the back side of a complete brassiere system, with an extended left arm sleeve that can be detached, with the inset showing a photoplethysmography module.

FIG. 13( a ) shows a scanning electron image of gold nanowires such as those used in embodiments of the nanostructure-based electrodes.

FIG. 13( b ) shows gold nanostructure-containing electrodes mounted on a standard snap-on button.

FIG. 13( c ) shows conductive fabric incorporating a textile electrode which includes nanostructures.

FIG. 14 shows a block diagram of an embodiment of the system.

FIG. 15 shows nanostructures projecting from a fiber.

FIG. 16 shows statistics on cardiac related mortalities in females as compared to females in the United States: 1976-2006.

FIG. 17( a ) shows placement of electrodes for ECG lead 2 .

FIG. 17( b ) shows an ECG waveform with characteristic P wave, QRS complex, and T and U waves.

FIG. 19 shows an e-bra worn by a test subject, the control module, and the smartphone display interface.

FIG. 19( a ) shows the electrode positions on the e-bra.

FIG. 19( b ) shows data acquired from subject 1 .

FIG. 19( c ) shows data acquired from subject 2 .

FIG. 20 shows R-R interval determination from an ECG.

FIG. 21( a ) shows a plot of the RR interval series against beat number.

FIG. 21( b ) shows a plot of the AR PSD computed from the RRI series for the standing case.

FIG. 22( a ) shows a plot of the RR interval series against beat number.

FIG. 22( b ) shows a plot of the AR PSD computed from the RRI series for the standing case.

FIG. 23 shows the sequence of processes and steps followed by the cloud server when an emergency abnormal condition reflected by abnormal health data is detected.

FIG. 24 shows the sequence of processes and steps followed on the mobile device in response to an emergency message sent by the cloud server.

FIG. 25 shows a schematic of the overall implementation of the football player monitoring system.

FIG. 26 ( a - d ) shows components of a wireless ECG monitoring garment system, wherein FIG. 26( a ) shows a compression base layer garment with sensor electrodes and printed traces; FIG. 26( b ) shows protective shoulder pads with snap on connection cables to connect sensors to a wireless module; FIG. 26( c ) shows a wireless module with a 5-channel amplifier and an XBee ZigBee module; and FIG. 26( d ) shows a wireless communication module placed in a pocket on the interior of the shoulder pad.

FIG. 27 shows a schematic of the wireless module.

FIG. 28( a ) shows a schematic of a 3-stage amplifier for use with embodiments of a wireless ECG monitoring garment system.

FIG. 28( b ) shows a schematic of a Wilson Central Terminal (WCT) generation circuit.

FIG. 29( a ) shows ECG signals acquired using the system having Lead I and I 1 , precordial leads V 1 , V 2 and V 5 .

FIG. 29( b ) shows Lead III and augmented limb leads derived from signals in FIG. 29( a ) .

FIG. 30 shows SEM images of polyaniline (A), MWCNTs (B) and polyaniline coated MWCNTs (C).

FIG. 31 shows SEM photographs of (A) thiol functionalized polymer capped silver nanoparticle and (B) pure silver nanoparticle.

FIG. 32 shows a schematic diagram of the deposition of Ag/CNT and SEM image of the deposition of Ag/CNT.

FIG. 33 shows a photo of core and core and shell particles (A) and SEM images of core particle (B) and core and shell type (C) and SEM images of functionalized CNTs/Core and shell particles based ink (D).

FIG. 34 illustrates a nanoprinting process.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

An electrode design for electrophysiological sensing (ECG, EEG, etc.) is developed as a electrically functionalized piece of fabric mounted on a spring mechanism. The electrode fabric is dyed with conductive ink, or enmeshed/decorated with conductive nanoparticles. The electrode surfaces have been engineered to have nanoscale and mesoscale free standing conductive structures. This is done to increase the effective surface area of the electrodes. Electrode surface area, which is in contact with the skin, is important to the signal quality. The signal measured is electric potential across the load resistance between the two electrodes that can be conceived as the impedance due to body bulk, skin and electrodes. Large electrode surface area results in low skin-electrode contact resistance. The free standing structures are deposited on the above mentioned conductive fabric by flocking electrically conductive fibers. Another technique is printing the electrodes with nanocomposite ink, which will have nanostructures on the surface of the printed thick film for increase surface area. Printed electrode for Electrocardiography (ECG, EEG etc.) is a technology based on the fabric itself. The electrodes system printed on the textile serves for multi-lead ECG signal acquisition, when the electrode surface is in contact with person's skin. The composition of the ink will be described in more detail below.

FIGS. 1 and 2 illustrate the design of an arm band 1000 for brachial artery plethysomography. The arm band 1000 includes a multichannel infra-red emitter- detector system 1001 which includes optically coupled infrared emitters 1 . 1 and photodiode detectors 2 . 1 arranged in arrays and connected to a breakout plug that can be connected to the primary circuit on the textile. Blood pressure measurement system is an opto-electronic system, plethysmograph (PPG) that monitors the blood flow in the brachial artery in the left arm. The multichannel infra red emitter- detector system 1001 on the arm band 1000 is placed on the left on the axis of the brachial artery (inside part of the left arm) to detect change in blood flow of the brachial artery. The system is used in combination with the ECG measurement to estimate the time it takes for the pulse, pulse transit time (PTT) to move from the aortic valve to the PPG site. The PTT is an index for estimation of arterial blood pressure (ABP). The PPG system uses infrared reflectance by the blood for monitoring the blood flow volume. Positions for the emitter arrays 1 (including emitters 1 . 1 ) and the detector array 2 (including detectors 2 . 1 ) are important to get the optimum reflectance signature.

FIG. 2 illustrates the mechanism for adjusting the relative positions of the sensors (emitters 1 . 1 and detectors 2 . 1 ). The sensors positions can be changed by sliding the emitter arrays 1 on a spin and securing them by hock and loop to accommodate for different arm diameters. The size of the arm varies from person to person. To address this issue, provision for adjusting the array spacing has been provided. The emitters 1 . 1 and detectors 2 . 1 are surface mounted devices (SMDs). They have been soldered on to a flexible printed circuit 3 with flat flexible connections running between components. This is to enable packaging of the components in a textile based arm band. The components are arranged in three arrays. Array in the middle is stationary, while the flanking arrays can move on two spines 4 . The system uses hook and loop arrangement 11 to secure the arrays in position. The band system has been designed as a detachable component of the textile health monitoring system. A flat flexible connection port 6 is provided on the band for connection to ancilliary or master circuit for power supply and signal relay. The use of flexible printed circuit is to enable packaging of the components in a textile based arm band 7 with a buckle 8 , and hock and loop 9 for strapping around the arm.

FIG. 3 illustrates the packaging technology for the sensors. The textile based electric connection lines for the sensors are linked to the break out pins of a socket. The figure depicts the socket with thread as well as printed lines on fabric. The corresponding plug is mounted on the electronics for wireless communication and power supply. A similar concept is used for connecting the arm band electronics to the master circuit. Printed electrical connects, on the textile fabric, can function like a flexible textile based printed circuit film. This will act as a system to facilitate packaging of the sensor systems, and amplifier-transmitter electronics in the textile. ( FIG. 3 ) The connect lines or conductive traces 12 use nanomaterial composite based inks. The binder itself can serve as printing ink, so that the conductive traces can be insulated by an overlay of traces made with binder only. The ink formulation uses modified acrylic, epoxy or resin binders with conductive nano particles and nanostructures dispersed in it. The nanocomposite based conductive patterns provide electrical properties similar to conductive metal wires or strips, while being able conform with the flexibility of textile. Binder's adhesion properties allow for printing on nylon, cotton, lycra, spandex, neoprene or other elastomeric fabric or film. The binder possesses high elasticity; therefore, it will protect the traces from disruption due to stretching of the fabric or film.

Textile based connections for packaging of sensor and wireless electronics in textiles, can be accomplished with conductive threads 13 . The textile health monitoring system also uses conductive threads made of conductive fiber core and an insulation sheath. Conductive fiber core can be made of nano fibers or meso fibers made of metals like silver, copper, titanium; alloys like stainless steel, nickel-cromium; and graphine structures like carbon nanotubes. The sheath can be made of nylon, polyester, and cotton. These threads are compatible with machine weaving. In addition to being compatible with textile platform, the printed connections and conductive threads are resistant to triboelectric effect. This prevents build up of static charge, which occurs when wearing textile products. Thus, signal artifacts due to static charge build up are avoided.

The printed connections and conductive thread connections are required to be able to connect to the electronics for wireless communication and power supply. While these components are not made on textile substrate, their electronic connects do not readily interface with the textile based connects. The textile health monitoring system uses a special electronic connector assembly ( FIG. 3 ), which houses a socket 14 with break out pins attached to corresponding textile connects 15 with rivets, crimps or silver epoxy. The socket is compatible to the plug 16 on the electronic module for wireless communication and power supply.

In various embodiments, the invention includes a wearable remote electrophysiological monitoring system 20 ( FIG. 14 ). The system 100 may include a garment 200 having at least one nanostructured, textile-integrated electrode 205 attached thereto, a control module 300 in electrical communication with the at least one nanostructured, textile-integrated electrode 205 , and a remote computing system 400 in communication with the control module 300 ( FIG. 14 ).

The system may also include a plurality of physiological sensors such as a photoplethysmography sensor 210 , an acoustic sensor 215 , a temperature sensor 220 , and a strain sensor 225 ( FIG. 14 ). The acoustic sensor 215 may be attached to the garment 200 to collect acoustic signals from a heart of a wearer of the garment 200 . The temperature sensor 220 may include a resistive temperature detector, a thermistor, and an infrared photodiode detector. The strain sensor 225 may include a piezoresistive respiration effort sensor to monitor breathing of a wearer of the garment 200 . The various physiological sensors may be electrically connected to the control module 300 by silver-coated thread, conducted traces, nanocomposite inks, or other techniques described herein. Each group of electrodes or sensors may have an amplifier module associated therewith, for example attached to the garment 200 in the vicinity of the electrodes or sensors or incorporated into the control module 300 .

The remote computing system 400 may communicate with the control module 300 using radio-frequency communications, for example using short-range communications such as Bluetooth; a local area network (e.g. wi-fi); satellite; or cellular communications technology. The remote computing system 400 may also communicate with the control module 300 using other forms of communications such as infrared light or microwaves. In some embodiments, the remote computing system 400 may communicate with the control module 300 using a wire-based connection or a combination of wired and wireless modalities.

The nanostructured, textile-integrated electrodes 205 may be made of a hierarchically-organized nanostructure sheet with vertically standing nanowires/filaments. The electrodes 205 are generally incorporated in the fabric of the garment 200 with an elastic backing for concomitant contact with the skin.

The nanostructured, textile-integrated electrodes 205 include nanostructures 207 attached to and projecting from electrically- conductive fibers 209 that may be incorporated into a portion of fabric. The nanostructures 207 may project from the fiber 209 to varying lengths ranging from 0.01-10 micrometers, and in one embodiment project from the fiber 209 less than one micrometer. The portion of fabric may then be attached to or otherwise incorporated into the garment 200 and placed into electrical communication with the control module 300 .

The nanostructures 207 projecting from the fiber 209 may have different shapes and form factors and may include one-dimensional nanostructures 207 a, two-dimensional nanostructures 207 b, and/or three-dimensional nanostructures 207 c ( FIG. 15 ). The one-dimensional structures 207 a may include approximately linear structures such as wires or tubes. The two-dimensional structures 207 b may include shapes such as bumps or bubbles. The three-dimensional structures 207 c may include shapes such as helices. The helices are particularly suitable as they have a large surface area available for making contact with a wearer's skin. In some embodiments in which helical structures are employed, a particular handedness of the helices (e.g. left-handed or right-handed) may produce better results such as improved conductivity. The fiber 209 from which the nanostructures 207 project is typically electrically conductive, which may be achieved by using a fiber 209 that is coated with an electrically conductive material (e.g. silver) or by using a fiber 209 that is blended or intertwined with an electrically conductive material (e.g. silver). The nanostructures 207 may be fabricated from a number of different materials such as gold, silver, steel, or textiles. In one embodiment, a piece of fabric having fibers with nanostructures thereon can have a density of between 10,000 and 100,000 nanostructures per square centimeter of fabric.

In various embodiments, the nanostructured, textile-integrated electrodes 205 are used as dry contact sensors, i.e. sensors that do not require a conductive gel or other substance to be used with the <figure-callout id="205"

CLAIMS

Claims ( 33 )

What is claimed is:

1 . A wearable remote electrophysiological monitoring system, comprising:

a garment having at least one dry contact sensor, the dry contact sensor including at least one nanostructured, textile-integrated electrode attached thereto, the nanostructured, textile-integrated electrode including a piece of fabric having between 10,000 and 100,000 nanostructures per square centimeter of fabric, the fabric including electrically conductive fibers, said nanostructures having vertically standing nanowires, the vertically standing nanowires projecting from the fibers to varying lengths of between 0.01 and 10 micrometers, the nanowires arranged to make contact with the wearer's skin, wherein the vertically standing nanowires are vertically standing when viewed relative to the fabric when the fabric is in a horizontal plane, wherein the conductive fibers include textile fibers blended or coated with metal, the textile fibers being selected from the group consisting of nylon, silk, polyester, modified celluloses, polymers, cotton, lycra, and spandex; a control module in electrical communication with the at least one nanostructured, textile-integrated electrode; and a remote computing system in communication with the control module.

2 . The wearable remote electrophysiological monitoring system of claim 1 , wherein the dry contact sensor is electrically connected to the control module by silver-coated thread.

3 . The wearable remote electrophysiological monitoring system of claim 1 wherein the dry contact sensor is electrically coupled to the plurality of nanostructured textile electrodes by printed conductive tracks comprising a flexible nanocomposite trace which includes silver nanoparticles and an elastic acrylic based binder.

4 . The wearable remote electrophysiological monitoring system of claim 1 , wherein the remote computing system communicates with the control module using radio-frequency communications.

5 . The wearable remote electrophysiological monitoring system of claim 1 , wherein each of the plurality of nanostructures projects from the fiber less than one micrometer.

6 . The wearable remote electrophysiological monitoring system of claim 1 , wherein at least one of the plurality of nanostructures comprises a one-dimensional nanostructure.

7 . The wearable remote electrophysiological monitoring system of claim 6 , wherein the one-dimensional nanostructure comprises a wire or a tube.

8 . The wearable remote electrophysiological monitoring system of claim 1 , wherein at least one of the plurality of nanostructures comprises a bump.

9 . The wearable remote electrophysiological monitoring system of claim 1 , wherein at least one of the plurality of nanostructures comprises a three-dimensional nanostructure.

10 . The wearable remote electrophysiological monitoring system of claim 9 , wherein the three-dimensional nanostructure comprises a helical nanostructure.

11 . The wearable remote electrophysiological monitoring system of claim 1 , wherein the vertically standing nanowires comprise carbon nanotubes coated with a conductive polymer.

12 . The wearable remote electrophysiological monitoring system of claim 1 , wherein the conductive polymer is polyaniline.

13 . The wearable remote electrophysiological monitoring system of claim 1 , wherein the dry contact sensor is electrically connected to the control module by a conductive trace formed from nanocomposite ink, the nanocomposite ink comprises carbon nanotubes coated with a conductive polymer.

14 . The wearable remote electrophysiological monitoring system of claim 1 , wherein the conductive polymer is polyaniline.

15 . The wearable remote electrophysiological monitoring system of claim 13 , wherein the nanocomposite ink has a resistance value of less than 1 mÎ©/sq.

16 . The wearable remote electrophysiological monitoring system of claim 13 , wherein the carbon nanotubes are coated with conductive nanoparticles.

17 . The wearable remote electrophysiological monitoring system of claim 16 , wherein the conductive nanoparticles are silver nanoparticles and the conductive polymer is polyaniline.

18 . The wearable remote electrophysiological monitoring system of claim 13 , wherein the conducted polymer coated carbon nanotubes are suspended in an organic binder.

19 . The wearable remote electrophysiological monitoring system of claim 11 , wherein the carbon nanotubes are coated with conductive nanoparticles.

20 . The wearable remote electrophysiological monitoring system of claim 19 , wherein the conductive nanoparticles are silver nanoparticles and the conductive polymer is polyaniline.

21 . The wearable remote electrophysiological monitoring system of claim 1 , wherein the vertically standing nanowires are vertically standing conductive fibers adhered to the fabric via flocking.

22 . The wearable remote electrophysiological monitoring system of claim 21 , wherein the fabric has been leveled to a roughness below 100 nm by successively coating and curing the fabric with polymers having different viscosities.

23 . The wearable remote electrophysiological monitoring system of claim 1 , wherein the dry contact sensor is electrically connected to the control module by a conductive thread, the conductive thread comprising a conductive fiber core and an insulation sheath, the conductive fiber core including nanofibers or mesofibers made of a metal or a graphine structure.

24 . The wearable remote electrophysiological monitoring system of claim 1 , wherein the vertically standing nanowires are comprised of polymer nanofibers coated with a conductive material.

25 . The wearable remote electrophysiological monitoring system of claim 24 , wherein the polymer nanofibers are made of a material selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, polyester, polyurethane, polystyrene, polyvinyl alcohol, ethylene vinyl alcohol, polyacrylamide or poly lactic acid.

26 . The wearable remote electrophysiological monitoring system of claim 24 , wherein the polymer nanofibers are made of a polyethylene terephthalate modified with sulfonated isocyanate.

27 . The wearable remote electrophysiological monitoring system of claim 24 , wherein the conductive material is selected from the group consisting of silver, gold, platinum, polyaniline, polypyrrole, poly(3,4-ethylenedioxythiophene), titanium oxide, iron oxide, and zinc oxide.

28 . The wearable remote electrophysiological monitoring system of claim 24 , wherein the nanostructures are formed by nano-imprinting by applying a nanocomposite ink to a fabric in a pattern, and forming vertically standing nanowires from the nanocomposite ink molded with an etched drum.

29 . A wearable remote electrophysiological monitoring system, comprising:

a garment having at least one dry contact sensor, the dry contact sensor including at least one nanostructured, textile-integrated electrode attached thereto, the nanostructured, textile-integrated electrode including a piece of fabric having between 10,000 and 100,000 nanostructures per square centimeter of fabric, the fabric including electrically conductive fibers, said nanostructures having vertically standing nanowires, the vertically standing nanowires projecting from the fibers to varying lengths of between 0.01 and 10 micrometers, the nanowires arranged to make contact with the wearer's skin, wherein the vertically standing nanowires are vertically standing when viewed relative to the fabric when the fabric is in a horizontal plane, wherein the conductive fibers include textile fibers blended or coated with metal, wherein the vertically standing nanowires are comprised of polymer nanofibers coated with a conductive material; a control module in electrical communication with the at least one nanostructured, textile-integrated electrode; and a remote computing system in communication with the control module.

30 . The wearable remote electrophysiological monitoring system of claim 29 , wherein the dry contact sensor is electrically connected to the control module by a conductive thread, the conductive thread comprising a conductive fiber core and an insulation sheath, the conductive fiber core including nanofibers or mesofibers made of a metal or a graphine structure.

31 . The wearable remote electrophysiological monitoring system of claim 29 , wherein the polymer nanofibers are made of a material selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, polyester, polyurethane, polystyrene, polyvinyl alcohol, ethylene vinyl alcohol, polyacrylamide or poly lactic acid.

32 . The wearable remote electrophysiological monitoring system of claim 29 , wherein the conductive material is selected from the group consisting of silver, gold, platinum, polyaniline, polypyrrole, poly(3,4-ethylenedioxythiophene), titanium oxide, iron oxide, and zinc oxide.

33 . The wearable remote electrophysiological monitoring system of claim 29 , wherein the nanostructures are formed by nano-imprinting by applying a nanocomposite ink to a fabric in a pattern, and forming vertically standing nanowires from the nanocomposite ink molded with an etched drum.

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