HEALTH-MONITOR PATCH
A health-monitor patch comprising at least one physiological sensor and digital processor is configured to be adhered to the skin of a subject. A health-monitor patch may further include an accelerometer and may detect cardiac waveforms, activity performed by the subject, and a body orientation of the subject. A health-monitor patch may be disposable, in some embodiments, and used for outpatient monitoring. Aspects of noise cancellation and reel-to-reel manufacturing are also described.
1 . A monitor for a subject, comprising:
circuitry configured to receive a signal and process the signal to monitor at least one characteristic of the subject; and
a flexible polymer casing extending around the circuitry to form a waterproof enclosure for the circuitry, wherein the flexible polymer casing is infused with a conductive material at at least one location to form at least one infused electrode that extends from an exterior of the flexible polymer casing to an interior of the flexible polymer casing, and wherein the at least one infused electrode is coupled to the circuitry so as to allow the signal to pass from outside the flexible polymer casing to the circuitry.
2 . The monitor of claim 1 , wherein the flexible polymer comprises silicone.
3 . The monitor of claim 2 , wherein the conductive material comprises carbon.
4 . The monitor of claim 1 , wherein the conductive material comprises carbon.
5 . The monitor of claim 1 , wherein the at least one infused electrode comprises first and second spaced-apart infused electrodes and the circuitry is configured to process a signal from the first and second infused electrodes to monitor a cardiac characteristic of the subject.
6 . The monitor of claim 5 , wherein the first and second infused electrodes are disposed on a same side of the flexible polymer casing.
7 . The monitor of claim 6 , further comprising an electrode strip attachable to the side of the polymer casing on which the first and second infused electrodes are disposed, the electrode strip comprising monitor electrodes configured and arranged to establish conductive paths between the first and second infused electrodes and respective first and second locations on a surface of the skin of the subject.
8 . The monitor of claim 7 , wherein the electrode strip comprises an adhesive layer disposed on each of two sides so that one side may be releasably adhered to the side of the polymer casing on which the first and second infused electrodes are disposed and the other side may be releasably adhered to the skin of the subject.
9 . The monitor of claim 1 , wherein the circuitry comprises a digital processor and a battery.
10 . A method for making a monitor for a subject, comprising:
providing circuitry configured to receive a signal and process the signal to monitor at least one characteristic of the subject;
forming a flexible polymer casing extending around the circuitry to form a waterproof enclosure for the circuitry;
infusing the flexible polymer casing with a conductive material at at least one location to form at least one infused electrode that extends from an exterior of the flexible polymer casing to an interior of the flexible polymer casing; and
coupling the at least one infused electrode to the circuitry so as to allow the signal to pass from outside the flexible polymer casing to the circuitry.
11 . The method of claim 10 , wherein forming the flexible polymer comprises molding silicone.
12 . The method of claim 11 , wherein the conductive material comprises carbon.
13 . The method of claim 10 , wherein the conductive material comprises carbon.
14 . The method of claim 10 , wherein the at least one infused electrode comprises first and second spaced-apart electrodes and the circuitry is configured to process a signal from the first and second electrodes to monitor a cardiac characteristic of the subject.
15 . The method of claim 10 , wherein the acts of forming and infusing the flexible polymer casing comprise a multi-step injection process in which a polymer infused with the conductive material is injected at the at least one surface location, and an insulating polymer is injected to form at least a portion of a remainder of the casing.
16 . The method of claim 15 , wherein the polymer infused with the conductive material is at least partially uncured when contacted by the insulating polymer.
17 . A monitor for a subject, comprising:
circuitry configured to receive a signal from at least one electrode and process the signal to monitor at least one characteristic of the subject; and
a flexible waterproof enclosure for the circuitry that is infused with a conductive material at at least one location to form at least one infused electrode that extends from an exterior of the flexible waterproof enclosure to an interior of the flexible waterproof enclosure, and wherein the at least one infused electrode is coupled to the circuitry so as to allow the signal to pass from outside the flexible waterproof enclosure to the circuitry.
18 . The monitor of claim 17 , wherein the at least one infused electrode comprises first and second spaced-apart infused electrodes and the circuitry is configured to process a signal from the first and second infused electrodes to monitor a cardiac characteristic of the subject.
19 . The monitor of claim 18 , wherein the first and second infused electrodes are disposed on a same side of the waterproof enclosure.
20 . The monitor of claim 19 , further comprising an electrode strip attachable to the side of the waterproof enclosure on which the first and second infused electrodes are disposed, the electrode strip comprising monitor electrodes configured and arranged to establish conductive paths between the first and second infused electrodes and respective first and second locations on a surface of the skin of the subject.