# Patent

## Title
Modular wearable sensor device

## Abstract

A wearable sensor and method for providing a wearable sensor are disclosed. In a first aspect, the wearable sensor comprises at least one power source and a first module coupled to the at least one power source. The first module includes a first outer shell and a first printed circuit board (PCB) within the first outer shell. The wearable sensor further comprises a second module coupled to the first module. The second module includes a second outer shell and a second PCB within the second outer shell. One of the first and second modules is disposable and the other of the first and second modules is reusable.

## Background
FIELD OF THE INVENTION
The present invention relates to wireless sensor devices, and more particularly, to a modular wearable sensor.
BACKGROUND
Sensor devices are used in a variety of applications including the health monitoring of users. In many of these health monitoring applications, a wireless sensor device is attached directly to the user's skin to measure certain data. This measured data can then be utilized for a variety of health related applications including but not limited to detecting whether the user has fallen, has suffered a heart attack, has difficulty breathing.
Utilizing these sensor devices, a user's health can be monitored continuously. However, due to the continuous nature of the monitoring, these sensor devices experience repeated use and high wear and tear. As a result, conventional sensor devices must often be replaced regularly to meet the high demands of monitoring a user's health around the clock. Due to the high replacement costs of these sensor devices, monitoring a user's health can become very costly.
These issues limit the usage of sensor devices to continuously measure a user's health. Therefore, there is a strong need for a cost-effective solution that overcomes the above issues by creating a decoupling sensor device that includes both a reusable and a disposable portion. The present invention addresses such a need.
SUMMARY OF THE INVENTION
A wearable sensor and method for providing a wearable sensor are disclosed. In a first aspect, the wearable sensor comprises at least one power source and a first module coupled to the at least one power source. The first module includes a first outer shell and a first printed circuit board (PCB) within the first outer shell. The wearable sensor further comprises a second module coupled to the first module. The second module includes a second outer shell and a second PCB within the second outer shell. One of the first and second modules is disposable and the other of the first and second modules is reusable.
In a second aspect, the method comprises providing at least one power source and coupling a first module to the at least one power source. The first module includes a first outer shell and a first printed circuit board (PCB) within the first outer shell. The method further comprises coupling a second module to the first module. The second module includes a second outer shell and a second PCB within the second outer shell. One of the first and second modules is disposable and the other of the first and second modules is reusable.



BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying figures illustrate several embodiments of the invention and, together with the description, serve to explain the principles of the invention. One of ordinary skill in the art will recognize that the particular embodiments illustrated in the figures are merely exemplary, and are not intended to limit the scope of the present invention.
FIG. 1 illustrates a modular wearable sensor in accordance with an embodiment.
FIG. 2 illustrates an external view of a disposable module in accordance with an embodiment.
FIG. 3 illustrates an exploded view of a disposable module in accordance with an embodiment.
FIG. 4 illustrates an external view of a reusable module in accordance with an embodiment.
FIG. 5 illustrates an exploded view of a reusable module in accordance with an embodiment.
FIG. 6 illustrates an exploded view of a reusable module with a transparent PCB in accordance with an embodiment.
FIG. 7 illustrates a view of the connection between the disposable module and the reusable module in accordance with an embodiment.



DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention relates to wireless sensor devices, and more particularly, to a modular wearable sensor. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiment and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiments shown but is to be accorded the widest scope consistent with the principles and features described herein.
A modular wearable sensor device provides a cost-effective health monitoring sensor device. By implementing a reusable module and a disposable module that each decouple from each other and each comprise varying components, the modular wearable sensor device can be utilized to more efficiently and continuously monitor a user's health. One of ordinary skill in the art readily recognizes that the shape and placement of the components of both the reusable module and the disposable module can vary and that would be within the spirit and scope of the present invention.
To describe the features of the present invention in more detail, refer now to the following description in conjunction with the accompanying Figures.
In one embodiment, the modular wearable sensor device is a wireless sensor device in a “patch” form factor that is attached to the user for health monitoring. One of ordinary skill in the art readily recognizes that a variety of wireless sensor devices and form factors can be utilized including but not limited to a wireless sensor device that looks like a band-aid and adheres to the user's body and that would be within the spirit and scope of the present invention.
FIG. 1 illustrates a modular wearable sensor 100 in accordance with an embodiment. The modular wearable sensor 100 includes a disposable module 102, a cover 104 coupled to the disposable module 102, and a reusable module 106 coupled to the disposable module 102. In one embodiment, after the reusable module 106 is coupled to the disposable module 102, the cover 104 is coupled to the disposable module 102 to enclose the reusable module 106 within the disposable module 102.
One of ordinary skill in the art readily recognizes that the cover 104 can be a variety of types of covers including but not limited to a flexible cover, a bendable cover, a stiff cover, and an elastic cover and that would be within the spirit and scope of the present invention. Additionally, one of ordinary skill in the art readily recognizes that the cover 104 can be coupled to the disposable module 102 utilizing a variety of coupling mechanism including but not limited to an adhesive and a clip and that would be within the spirit and scope of the present invention.
In one embodiment, the cover 104 is coupled to a top surface of the disposable module 102. One of ordinary skill in the art readily recognizes that the cover 104 can be coupled to a variety of surfaces of the disposable module 102 to allow varying coupling orientations of the reusable module 106 to the disposable module 102 including but not limited to a bottom surface and a side surface and that would be within the spirit and scope of the present invention.
In one embodiment, the disposable module 102 includes an outer shell unit that houses various components. The outer shell is soft, flexible, and stretchable to provide optimum wear comfort when attached to the body of a user. Additionally, the outer shell is waterproof and sealed so that a user can come in contact with water without having to detach the modular wearable sensor 100. The various components housed within the disposable module 102 can include but are not limited to a cover, foam layers, at least one power source, a flexible printed circuit board (PCB) including electrical components such as a connector, a small sensor, and a thermistor, electrode contacts to couple to electrodes, and an adhesive layer.
In one embodiment, the reusable module 106 includes an outer shell unit that houses various components including critical electronics. The outer shell is hard and rigid to protect the critical electronics. The various components including critical electronics housed within the reusable module 106 can include but are not limited to a connector, an antenna, a microcontroller, a sensor, a microelectromechanical system (MEMS), and a wireless transceiver. The reusable module 106 can be de-attached from the disposable module 102 via the connectors for re-use with another disposable module and/or wireless sensor device that includes a related connector.
One of ordinary skill in the art readily recognizes that the at least one power source can be a variety of device types including but not limited to a coin battery, a button battery, a flexible battery, and an energy harvesting unit and that would be within the spirit and scope of the present invention. Additionally, one of ordinary skill in the art readily recognizes that the various other components housed within both the disposable module 102 and the reusable module 106 can vary in device type and material and that would be within the spirit and scope of the present invention.
FIG. 2 illustrates an external view of a disposable module 200 in accordance with an embodiment. The disposable module 200 includes an outer shell 202. The outer shell 202 includes a top surface 204, a middle layer 206, and a bottom surface 208. In one embodiment, the outer shell 202 has a thickness variation across the top surface 204. One of ordinary skill in the art readily recognizes that the thickness variation across the top surface 204 can be a variety of thickness patterns including but not limited to a center portion of the top surface 204 being thicker than both end portions of the top surface 204 and that would be within the spirit and scope of the present invention.
FIG. 3 illustrates an exploded view of a disposable module 300 in accordance with an embodiment. The disposable module 300 includes a top cover layer 302, a top foam layer 304 coupled to the top cover layer 302, a flexible PCB 306 coupled to the top foam layer 304, a bottom foam layer 308 coupled to the flexible PCB 306, and at least two electrodes 310 coupled to the flexible PCB 306. The flexible PCB 306 enables the disposable module 300 to conform and to adhere to a user's movements. In the disposable module 300, the flexible PCB 306 includes an electrical component unit 312 including but not limited to a thermistor and a first connector unit 314 that enables the coupling of the disposable module 300 to the reusable module 106.
In one embodiment, the bottom foam layer 310 is a double adhesive layer so that it adheres to the flexible PCB 306 and to a user at the same time. One of ordinary skill in the art readily recognizes that the at least two electrodes 310 can measure a variety of health related values including but not limited to ECG and respiratory rates and that would be within the spirit and scope of the present invention.
In one embodiment, the top cover layer 302 and the top foam layer 304 each have an opening to allow for the insertion and coupling of the reusable module 106. The opening of the top cover layer 302 is covered by an adjustable cover 316 to protect the reusable module 106 once inserted and coupled to the first connector unit 314. One of ordinary skill in the art readily recognizes that each of the openings of the top cover layer 302 and the top foam layer 304 can be similarly shaped or different as long as they are shaped in accordance with the shape of the reusable module 106 and that would be within the spirit and scope of the present invention.
In one embodiment, the top foam layer 304 has another opening for the insertion and coupling of a battery 318. The battery 318 is coupled to the flexible PCB 306 to power both the electrical component unit 312 of the flexible PCB 306 and the reusable module 106 through the connector unit 314. In another embodiment, a waterproof and breathable battery cover is utilized to protect the battery 318. One of ordinary skill in the art readily recognizes that the disposable module 300 can include a variety of power sources including but not limited to a single battery and multiple batteries and that would be within the spirit and scope of the present invention.
In one embodiment, the flexible PCB 306 and the bottom foam layer 308 each have two openings to allow for the coupling of the at least two electrodes 310 to the electrode contacts of the flexible PCB 306. In one embodiment, the at least two electrodes 310 are made of an electrolyte, including but not limited to an electrolytic medium or gel (hydrogel), and an electrochemical electrode, including but not limited to a metallic electrode. One of ordinary skill in the art readily recognizes that each of the two openings of the flexible PCB 306 and the bottom foam layer 308 can be similarly shaped or different as long as they are shaped in accordance with the shape of the at least two electrodes 310 and that would be within the spirit and scope of the present invention.
FIG. 4 illustrates an external view of a reusable module 400 in accordance with an embodiment. The reusable module 400 includes an outer shell 402 and a connector opening 404 coupled to the outer shell 402. The outer shell 402 includes a top surface 406, a middle layer 408 that houses electrical components, and a bottom surface. In one embodiment, the outer shell 402 is comprised of a hard material to protect the electrical components housed within.
FIG. 5 illustrates an exploded view of a reusable module 500 in accordance with an embodiment. The reusable module 500 includes a top cover layer 502, a bottom cover layer 506 coupled to the top cover layer 502, a PCB 504 coupled between the top cover layer 502 and the bottom cover layer 506, and a connector opening 508 coupled to both the top cover layer 502 and the bottom cover layer 506. The PCB 504 includes an electrical component unit 510 and a second connector unit 512 coupled to the electrical component unit 510 for further monitoring and processing of information collected by the at least two electrodes 310. FIG. 6 illustrates a transparent view 600 of the PCB of the reusable module 500. In the transparent view 600, the PCB 504′ is transparent so that components coupled on both sides of the PCB 504′ are visible.
The first connector unit 314 of the flexible PCB 306 couples to the second connector unit 512 of the reusable module 500 to provide connectivity between the at least two electrodes 310 and the reusable module 500. The coupling between the first connector unit 314 and the second connector unit 512 enables the modular wearable sensor 100 to monitor health related values of the user for either a continuous period or predetermined time period. FIG. 7 illustrates a view of the connection 700 between the disposable module and the reusable module in accordance with an embodiment. The second connector unit of the reusable module 500′ can be coupled to the first connector unit 314° of the flexible FOB 306′ to connect the at least two electrodes 310′ to the reusable module 500′.
One of ordinary skill in the art readily recognizes that the first connector unit 314 of the flexible PCB 306 within the disposable module 300 and the second connector unit 512 of the PCB 504 within the reusable module 500 can be a variety connector types including but not limited to Secure Digital (SD) card connectors, miniSD card connectors, microSD card connectors, flash memory card connectors, and custom designed connectors and that would be within the spirit and scope of the present invention.
One of ordinary skill in the art readily recognizes that the flexible PCB 306 of the disposable module 300 can include similar electrical components as the PCB 504 of the reusable module 500 and that would be within the spirit and scope of the present invention. In this embodiment, the modular wearable sensor 100 would include only the disposable module 300 that is capable of monitoring health related values of the user, rendering the modular wearable sensor 100 entirely disposable.
As above described, the modular wearable sensor and method provide for a cost-efficient health monitoring device that includes at least one reusable module and at least one disposable module that are capable of decoupling from each other to enable the continuous monitoring of a user. By implementing similar connector units within both the disposable module and the reusable module of the modular wearable sensor, the reusable module can be decoupled from the disposable module. Complex and costly electrical components for the health monitoring and processing of a user's data can be housed within the reusable module portion so that when the disposable module is discarded, higher monitoring costs do not result.
Although the present invention has been described in accordance with the embodiments shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiments and those variations would be within the spirit and scope of the present invention. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims.

## Claims

1. A wearable sensor, wherein the wearable sensor is attachable to a user, the wearable sensor comprising:
at least one power source;
a first module coupled to the at least one power source, wherein the first module includes a first outer shell and a first printed circuit board (PCB) within the first outer shell, wherein the first outer shell comprises a first top cover, a top foam layer coupled to the first top cover, and a bottom foam layer coupled to the first PCB, further wherein the top foam layer includes a first opening for housing the at least one power source and a second opening for housing a second module, wherein the bottom foam layer is a double adhesive layer that adheres to both the first PCB and the user, wherein the bottom foam layer includes at least two openings to house at least two electrodes for monitoring of the user; and
the second module coupled to the first module via the second opening, wherein the second module includes a second outer shell and a second PCB within the second outer shell, further wherein the first module is disposable and the second module is reusable.

2. The wearable sensor of claim 1, wherein the first PCB is coupled between the top foam layer and the bottom foam layer.

3. The wearable sensor of claim 2, wherein the second outer shell comprises a second top cover, a bottom cover coupled to the second top cover, and a connector opening coupled to the bottom cover, further wherein the second PCB is coupled between the second top cover and the bottom cover.

4. The wearable sensor of claim 3, wherein the first PCB comprises a first connector coupled to a stiffener.

5. The wearable sensor of claim 4, wherein the first PCB comprises a first electrical component that is selected from the group consisting of a small sensor and a thermistor.

6. The wearable sensor of claim 5, wherein the second PCB comprises a second electrical component that is selected from the group consisting of a second connector, an antenna, a microcontroller, a microelectromechanical system (MEMS), and a wireless transceiver.

7. The wearable sensor of claim 6, further comprising the second connector, wherein the second connector is coupled to the first connector via the second opening of the top foam layer.

8. The wearable sensor of claim 7, wherein the first connector is selected from the group consisting of a standard MicroSD card form factor and a custom designed card form factor.

9. The wearable sensor of claim 2, wherein the second outer shell is selected from the group consisting of two horizontally coupled pieces and a conformal coating form.

10. The wearable sensor of claim 2, wherein the at least one power source is selected from the group consisting of a rechargeable battery, a coin battery, a button battery, a flexible battery, an energy harvesting unit, and a solar cell, further wherein the at least one power source is coupled to the first module via the first PCB.

11. The wearable sensor of claim 2, wherein a center portion of the first top cover is thicker than peripheral portions of the first top cover.

12. The wearable sensor of claim 2, wherein the bottom foam layer comprises a hydrogel layer that includes an adhesive.

13. The wearable sensor of claim 1, wherein the first PCB is selected from the group consisting of a soft PCB, a flexible PCB, and a stretchable PCB to provide wear comfort.

14. A method for providing a wearable sensor, wherein the wearable sensor is attachable to a user, the method comprising:
providing at least one power source;
coupling a first module to the at least one power source, wherein the first module includes a first outer shell and a first printed circuit board (PCB) within the first outer shell, wherein the first outer shell comprises a first top cover, a top foam layer coupled to the first top cover, and a bottom foam layer coupled to the first PCB, further wherein the top foam layer includes a first opening for housing the at least one power source and a second opening for housing a second module, wherein the bottom foam layer is a double adhesive layer that adheres to both the first PCB and the user;
providing least two openings within the bottom foam layer;
housing at least two electrodes within the at least two openings, wherein the at least two electrodes are utilized to monitor the user; and
coupling the second module to the first module via the second opening, wherein the second module includes a second outer shell and a second PCB within the second outer shell, further wherein the first module is disposable and the second module is reusable.

15. The method of claim 14, further comprising:
coupling the first PCB between the top foam layer and the bottom foam layer.

16. The method of claim 15, further comprising:
providing a second top cover and a bottom cover within the second outer shell, wherein the bottom cover includes a connector opening;
coupling the bottom cover to the second top cover; and
coupling the second PCB between the second top cover and the bottom cover.

17. The method of claim 16, further comprising:
providing a stiffener and a first connector within the first PCB; and
coupling the stiffener to the first connector.

18. The method of claim 17, further comprising:
providing an electrical component within the second PCB, wherein the electrical component is selected from the group consisting of a second connector, an antenna, a microcontroller, a microelectromechanical system (MEMS), and a wireless transceiver.

19. The method of claim 18, further comprising:
providing the second connector, and
coupling
the second connector to the first connector via the second opening of the top foam layer.