Technical Field

The present disclosure relates to a hygiene monitoring device comprising an electrode panel, and, in particular, a hygiene monitoring device comprising an electrode panel having a flex PCB panel. The present disclosure also relates to a method of manufacturing the same.

Background

A hygiene monitoring device may be used to monitor a hygienic state of a user. For example, a hygiene monitoring device may monitor a wetness level, a temperature and/or a concentration of a particular substance associated with the user. In certain known devices the hygiene monitoring device is attached to an article which is worn by the user such that the hygiene monitoring device may monitor a hygienic state of the article. In some devices, the hygiene monitoring device transmits information relating to the monitored hygienic state of the user, such as a soiling event. In other device, the hygiene monitoring device provides an alert such as a sound, to notify a detection of a soiling event.

Certain hygiene monitoring devices comprise an electrode panel with one or more electrodes, which is configured to be attached to the surface of the article or within the article. As such electrode strips may need to conform to the shape of the article, which may change depending on the movements of the user, the electrode strips may be flexible.

However, the known electrode panels are difficult to manufacture. In particular, the attachment of the electrodes to a substrate of the electrode panel proves to be a complicated and difficult step of manufacturing the hygiene monitoring device, and such a step is critical as it must allow the resulting device to maintain flexibility of the electrode panel and accuracy of measurements.

Accordingly, there is a need for a hygiene monitoring device which is easier to manufacture whilst maintaining flexibility of the electrode panel and accuracy of measurements.

Summary of the Disclosure

In a first aspect of the present invention, there is provided a hygiene monitoring device comprising an electrode panel, the electrode panel comprising: a flex PCB panel comprising at least one electrically conductive track disposed on a flexible substrate, the electrically conductive track defining a contact region; and a conductive elastomer electrode attached to the flex PCB panel at the contact region, the conductive elastomer electrode being attached to the flex PCB panel by an adhesive layer defining an opening therethrough, wherein the conductive elastomer electrode is electrically connected to the contact region by a conductive silicone connector extending between the conductive elastomer electrode and the contact region through the opening defined in the adhesive layer.

It has been found that by using a combination of a conductive elastomer electrode attached to the flexible substrate by an adhesive layer together with a conductive silicone connector extending through an opening of the adhesive layer allows for an easier-to-manufacture hygiene monitoring device which maintains flexibility of the panel and accuracy of measurements .

Hence, with such a configuration, a hygiene monitoring device is provided which is easier to manufacture whilst maintaining flexibility of the electrode panel and accuracy of measurements .

In one embodiment, the conductive elastomer electrode is a conductive silicone electrode.

In one embodiment, the conductive silicone electrode comprises silicone containing an electrically conductive filler .

In one embodiment, the conductive silicone electrode is a metal graphite filled silicone electrode.

In one embodiment, the conductive silicone electrode is a metal-filled silicone electrode.

In one embodiment, the conductive silicone connector comprises a conductive silicone sealant, preferably a silicone sealant comprising an electrically conductive filler .

In one embodiment, the conductive silicone sealant is curable .

In one embodiment, the conductive silicone sealant is a cured conductive silicone sealant.

In one embodiment, the conductive silicone sealant comprises or consists of Room-Temperature-Vulcanizing (RTV) silicone.

In one embodiment, the pressure sensitive adhesive is in form of an adhesive tape.

In one embodiment, the adhesive tape comprises or consists of a first adhesive layer contacting the conductive elastomer electrode, a second adhesive layer contacting the flexible substrate, and a carrier layer disposed between the first adhesive layer and the second adhesive layer. In one embodiment, the first adhesive layer and the second adhesive layer are formed from different materials.

In one embodiment, the first adhesive layer comprises or consists of a silicone-based adhesive.

In one embodiment, the second adhesive layer comprises or consists of an acrylic-based adhesive.

In one embodiment, the adhesive layer comprises or consists of a silicone-based adhesive.

In one embodiment, the adhesive layer comprises or consists of an acrylic-based adhesive.

In one embodiment, the adhesive layer is an insulating adhesive layer.

In one embodiment, the adhesive layer is a conductive adhesive layer. In such embodiments, the adhesive layer may contact the contact region thereby electrically connecting the adhesive layer to the contact region.

In one embodiment, the flexible substrate defines a recess which receives the adhesive layer and/or the conductive elastomer electrode.

In one embodiment, conductive elastomer electrode is planar, and, optionally, rectangular, such as rectangular with rounded edges. Using such rounded edges may prevent peeling at the edges.

In one embodiment, the electrode panel is in the shape of an elongate strip.

In one embodiment, the electrode panel is configured to be removably attachable to a wearable hygiene article. In one embodiment, at least two conductive elastomer electrodes are arranged spaced apart along the flex PCB panel. Each of the conductive elastomer electrodes may be of the type described herein, and may be attached to the flex PCB panel in the manner described anywhere herein.

In one embodiment, the hygiene monitoring device is configured to monitor wetness level, a temperature, a concentration of a particular substance (liquid or gas) associated with the user, movement and/or temperature. In one embodiment, the hygiene monitoring device comprises a biosensor .

In one embodiment, the hygiene monitoring device is removably attachable to a wearable hygiene article. In one embodiment, the hygiene monitoring device comprises a mechanical fastening component, such as a hook material patch, that may removably attach to a corresponding loop material on the wearable hygiene article, or vice versa. In one embodiment, the hygiene monitoring device comprises an adhesive fastener component, such as a pressure sensitive adhesive, that may removably attach to a corresponding tape landing zone on the wearable hygiene article.

In one embodiment, the hygiene monitoring device is reusable.

In one embodiment, the wearable hygiene article is a disposable adsorbent article, such as a diaper or incontinent shield .

In one embodiment, the hygiene monitoring device is configured to be removably attached to a hygiene product, preferably a disposable hygiene product.

In one embodiment, the electrode panel is configured to be realisably attached to a surface of a wearable article. In a second aspect of the present disclosure, there is provided a method of producing a hygiene monitoring device comprising an electrode panel, the method comprising: providing a flex PCB panel comprising at least one electrically conducive track disposed on a flexible substrate, the electrically conductive track defining a contact region; and attaching a conductive elastomer electrode to the flex PCB panel at the contact region, the conductive elastomer electrode being attached to the flex PCB panel by an adhesive layer defining an opening therethrough, wherein the conductive elastomer electrode is electrically connected to the contact region by a conductive silicone connector extending between the conductive elastomer electrode and the contact region through the opening defined in the adhesive layer.

With such a method, a hygiene monitoring device may be manufactured more easily whilst maintaining flexibility of the electrode panel and accuracy of measurements.

In one implementation, the attaching comprises disposing the adhesive layer on the flexible substrate, and then subsequently disposing the conductive elastomer electrode on the adhesive layer.

In one implementation, between the steps of disposing the adhesive layer on the flexible substrate and disposing the conductive elastomer electrode on the adhesive layer, the conductive silicone connector is deposited in the opening of the adhesive layer.

In one implementation, the attaching comprises disposing the adhesive layer on the conductive elastomer electrode, and then subsequently disposing the flexible substrate on the adhesive layer. In one implementation, between the steps of disposing the adhesive layer on the conductive elastomer electrode and disposing the flexible substrate on the adhesive layer, the conductive silicone connector is deposited in the opening of the adhesive layer.

In such implementations, the adhesive layer disposed on the conductive elastomer electrode may be placed on top of the flexible substrate.

In one implementation, the conductive silicone connector is curable, and wherein after the step of attaching the conductive elastomer electrode to the flex PCB panel, the conductive silicone connector cures. In such implementations, the conductive silicone connector may partly cure before the step of attaching the conductive elastomer electrode to the flex PCB panel.

Brief Description of the Drawings

Figures 1 and 2 show a hygiene monitoring device for monitoring a hygienic state of a user; and

Figures 3 to 5 show certain steps in the manufacture of the hygiene monitoring device.

Detailed Description

Figure 1 shows a hygiene monitoring device 10 for monitoring a hygienic state of a user. The hygiene monitoring device 10 may be removably attached to wearable article of a user so that it may monitor the hygienic state of the article.

The hygiene monitoring device 10 comprises a housing 11 and an electrode panel 12 in the form of a strip. The electrode panel 12 extends on both sides of the housing 11. In other embodiments, the electrode panel 12 may extend on only one side of the housing 11.

The hygiene monitoring device comprises a monitoring unit (not shown) provided to the electrode panel 12 which is configured to receive information (e.g. in the form of electrical signals) from the electrode panel 12 about the hygienic state of the article. In this embodiment, the monitoring unit is disposed in the housing 11.

In some embodiments, the hygiene monitoring device 10 further comprises a transmitter (not shown) which is configured to transmit data to an external device, such as a centralised server (not shown) . The hygiene monitoring device 10 is configured to transmit information relating to the monitored hygienic state of the article. In some embodiments, the hygiene monitoring device 10 may be configured to sound an alarm/alert when a particular hygienic state of the article is detected.

As shown in Figure 2, the electrode panel 12 of the hygiene monitoring device 10 comprises four conductive elastomer electrodes 12a-12d which are spaced apart along the longitudinal length of the electrode panel 12. The hygiene monitoring device 10 is configured such that the conductive elastomer electrodes 12a-12d may be brought into contact with the wearable article such that they may measure the hygienic state of the article, for example, by measurement of wetness level of the article, presence of particular chemical compounds/compositions and/or pH levels. The operation of such electrodes will be known to a person skilled in the art and, for example, may include the operation disclosed in WO 2016/090492, the contents of which are hereby incorporated by reference to the extent permitted by law.

As described below in relation to Figures 3 to 5, the electrode panel 12 is flexible so that it may confirm to the wearable article. In particular, the electrode panel 12 comprises a flex PCB panel having a flexible substrate 13 with electrically conductive tracks disposed thereon for electrically coupling to the conductive elastomer electrodes 12a-12d. For ease of illustration, Figures 3 to 5 only show one conductive elastomer electrode 12a and its corresponding track 14. However, as will be readily understood, similar features are present for each of the remaining conductive elastomer electrodes 12b-12d and corresponding tracks.

Figures 3 to 5 show certain steps in the manufacture of the hygiene monitoring device 10. As noted above, for simplicity, the method of manufacture is described only in relation to the first conductive elastomer electrode 12a, but, as will be readily understood, similar steps and procedures may be followed for each of the remaining conductive elastomer electrodes 12b-12d.

Furthermore, Figures 3 to 5 show the housing 11 attached to the flexible substrate 13, purely for aiding in the explanation of the steps. As will be readily appreciated, any or all of these steps may occur without the housing 11 being attached .

As shown in Figure 3, the flexible substrate 13 is provided with track 14 disposed thereon. The flexible substrate 13 provided with track 14 disposed thereon may be provided by commonly-known methods in the art, for example, as described in W02017/108109, the contents of which are hereby incorporated by reference to the extent permitted by law. For example, the flex-PCB may comprise a substrate layer of a electrically insulating polymeric material such as polyethylene terephthalate, polyimide, polyethylene naphtalate, polyetherimide or ethylene vinyl acetate, with electrically conductive tracks disposed thereon. The electrically conductive tracks may be from electrically conductive materials such as metals, metal alloys, electrically conductive polymers or electrically conductive oxides, as known to the person skilled in the art. The flex- PCB may further comprise an additional electrically insulating cover layer disposed on top of at least part the electrically conductive tracks, while providing openings in the cover layer to enable electrical contact to be established through the openings. The track 14 comprises a straight portion 14a and a contact region 14b. In the embodiment shown, the contact region 14b is disposed at an end of the straight portion 14a. However, as would be understood by the skilled person, the contact region 14b may be disposed anywhere along the length of the straight portion 14a. Furthermore, in alternative embodiments, the straight portion 14a may instead be any track portion of any shape, for example, a shape including one or more bends.

Once the hygiene monitoring device 10 is assembled (see Figure 5) , the track 14 allows for electrical communication between the conductive elastomer electrode 12a and the monitoring unit (not shown) in the housing 11. To this end, the track 14 may take any form so long as it has a contact region 14b configured to electrically connect to the conductive elastomer electrode 12a.

In the configuration shown in Figure 4, an adhesive layer 15 has been disposed on the flexible substrate 14. As can be seen, the adhesive layer 15 defines an opening 15a therethrough. The opening 15a is positioned such that the contact region 14b of the track 14 is within the opening 15a.

In certain embodiment, the adhesive layer 15 may be a pressure sensitive adhesive in form of an adhesive tape. For example the adhesive tape may be a double sided adhesive tape, i.e. with a first and second layer of adhesive material on each side of a carrier layer, the first and second layer of adhesive material may be the same or different. It may be advantageous that the first and second adhesive materials are different, for example in order to provide good adhesion to on the one hand, and by means of the first adhesive layer, between the tape and the conductive elastomeric electrode, and on the other hand, and by means of the second adhesive layer, between the tape and the flex-PCB panel. Such double sided adhesive tapes are commercially available, for example from 3M (MN, US) under as 9699 Silicone / Acrylic Double Coated Tape.

The opening 15a has been illustrated to have a greater size than the contact region 14b, but, as will be readily appreciated, the opening 15a may be of any size so long as the contact region 14b of the track 14 is within the opening 15a (i.e. exposed once the adhesive layer 15 is deposited on the flexible substrate 13) . For example, the size of the opening 15a may correspond to the size of the contact region 14b, or, in alternative embodiments, the opening 15a may be smaller than the contact region 14b.

Once the adhesive layer 15 is disposed on the flexible substrate 13, a conductive silicone connecter (not shown) may be disposed within the opening 15a such that it contacts the contact region 14b.

Thereafter, as shown in Figure 5, the conductive elastomer electrode 12a may be placed on the adhesive layer 15 such that the elastomer electrode 12a is attached to the flexible substrate of the flexible PCB panel at the contact region 14b.

In certain embodiments, the conductive elastomer electrode 12a is a conductive silicone electrode.

In this configuration, the conductive elastomer electrode 12a is electrically connected to the contact region 14b via the conductive silicone connector which extends between the conductive elastomer electrode 12a and the contact region 14b and through the opening 15a defined in the adhesive layer 15. Silicone materials, such as the material of the conductive silicone electrode and the conductive silicone connector, may be made conductive by including conductive filler material in the silicone, as is well known in the art. Examples of conductive filler materials include metal particles, such as silver, gold, nickel and copper, as well as metal covered graphite particles, such as nickel graphite. Electrically conductive silicone materials are commercially available, for example from Silicone Solutions (OH, US) and Stockwell Elatomerics (PA, US) .

Accordingly, in the configuration shown in Figure 5, the conductive elastomer electrode 12a is in electrical communication with the contact region 14b of the track which in turn allows for electrical communication between the conductive elastomer electrode 12a and the monitoring unit (not shown) disposed within the housing 11.

As noted above, similar steps as described in relation to Figures 4 and 5 may be followed for each of the remaining conductive elastomer electrodes 12b-12d and their respective tracks (not shown) .

Although the above explanation is considered to fully clarify how the present disclosure may straightforwardly be put into effect by those skilled in the art, it is to be regarded as purely exemplary.

For example, even though the conductive elastomer electrode 12a and the corresponding adhesive layer 15 are shown to have the same outer perimeter shape, it is contemplated that the shape of the conductive elastomer electrodes may not correspond to the shape of the adhesive layers. For example, in certain embodiments, the conductive elastomer electrode extends beyond the adhesive layer. In the above embodiments, the hygiene monitoring device 10 comprises a housing 11 which has a monitoring unit therein. However, in alternative embodiments, the hygiene monitoring device may not comprise any distinct housing. In such embodiments, the monitoring unit may be provided on the electrode panel itself, for example, as part of the flex PCB panel .

In the above embodiments, the electrode panel 12 is shown as an elongate strip. However, in alternative embodiments, the electrode panel may not be an elongate strip in any particular direction. For example, the electrode panel may be in the form of a square or a circle.

In the above embodiment, the electrode panel 12 comprises four conductive elastomer electrodes 12a-12d. In alterative embodiments, the electrode panel 12 can include any number of electrodes, including a single electrode, two electrodes, three electrodes or five electrodes. In the case where the electrode strip includes a single electrode, a second electrode may be provided on the housing 11.

All of the above are fully in the scope of the disclosure, and are considered to form the basis for alternative embodiments in which one or more combinations of the above described features are applied, without limitation to the specific combinations disclosed above.

In light of this, there will be many alternatives which implement the teaching of the present disclosure. It is expected that one skilled in the art will be able to modify and adapt the above disclosure to suit their own circumstances within the scope of the present disclosure, while retaining some or all technical effects of the same, either disclosed or derivable from the above, in light his common general knowledge in this art. All such equivalent modifications or adaptations fall within the scope of the present invention as defined by the appended claims.