Patent Description:
Conventionally, a biocompatible polymer board that is capable of being patched to the skin of a person or the like has been known.

For example, a biocompatible polymer board including a polymer layer that extends in a longitudinal direction and has flexibility and a module for data acquisition that is fixed to a one-side surface thereof has been proposed (ref: for example, Patent Document <NUM>).

Further related art may be found in <CIT> which describes a wireless disposable shock trauma monitoring device, in <CIT> which describes a non-invasive cardiac monitor and methods of using continuously recording cardiac data and in <CIT> which describes elastic movement sensors and calibration.

In the biocompatible polymer board of the above-described Patent Document <NUM>, the module for data acquisition extends long in the same direction as the longitudinal direction of the polymer layer. Thus, when the biocompatible polymer board of the above-described Patent Document <NUM> is patched to the skin of a person along the longitudinal direction of the polymer layer, deformation such as bending (or curving) along the longitudinal direction occurs in the polymer layer having flexibility. At this time, there is a disadvantage that a large stress is applied to the module for data acquisition caused by the deformation of the polymer layer, so that the module for data acquisition is damaged.

The present invention provides a patchable biosensor that is capable of suppressing damage to an electronic component when a substrate is patched to a surface of a living body.

The present invention is defined by appended independent claim <NUM>. The dependent claims describe optional features and distinct embodiments.

The present invention provides a patchable biosensor according to claim <NUM>.

When the substrate is patched to the surface of the living body along the longitudinal direction thereof, and the substrate is deformed along the longitudinal direction thereof, in the patchable biosensor, the longitudinal direction of the electronic component crosses that of the substrate, so that a stress applied to the electronic component can be reduced. Thus, when the substrate is patched to the surface of the living body, damage to the electronic component can be suppressed.

The longitudinal direction of the electronic component is perpendicular to the longitudinal direction of the substrate.

When the substrate is patched to the surface of the living body along the longitudinal direction thereof, and the substrate is deformed along the longitudinal direction thereof, in the patchable biosensor, the longitudinal direction of the electronic component is perpendicular to that of the substrate, so that the stress applied to the electronic component can be furthermore surely reduced. Thus, when the substrate is patched to the surface of the living body, the damage to the electronic component can be furthermore surely suppressed.

The patchable biosensor can further include a release sheet disposed on an other-side surface in the thickness direction of the substrate and for being peeled along the longitudinal direction of the substrate.

When the release sheet is peeled along the longitudinal direction of the substrate, the substrate is stretchable, so that deformation easily occurs.

As described above, however, in the patchable biosensor, the longitudinal direction of the electronic component crosses that of the substrate, so that when the release sheet is peeled from the substrate, the stress applied to the electronic component can be reduced.

There are at least two electronic components disposed next to each other along the longitudinal direction of the substrate.

At least the two electronic components disposed that are next to each other may be brought into contact with each other to be damaged caused by the above-described deformation along the longitudinal direction of the substrate.

In the patchable biosensor, however, the longitudinal direction of the electronic component crosses that of the substrate, so that the above-described occurrence of the contact is suppressed, and the damage to the electronic component can be suppressed.

A ratio (I/Tmax) of a gap I between the two electronic components in the longitudinal direction of the substrate to the maximum thickness Tmax of the electronic component is <NUM> or more.

The ratio (I/Tmax) of the gap I between the two electronic components in the longitudinal direction of the substrate to the maximum thickness Tmax of the electronic component is <NUM> or more, so that the contact of the two electronic components with each other is effectively suppressed, and the damage to the electronic component can be effectively suppressed.

The electronic component is at least one selected from the group consisting of an analog front end, a microcomputer, a memory, an interposer, and a chip.

In the patchable biosensor, at least one selected from the group consisting of the analog front end, the microcomputer, the memory, the interposer, and the chip is hard or fragile, and thus, the electronic component may be damaged when the stress is applied thereto.

As described above, however, in the patchable biosensor, the longitudinal direction of the electronic component crosses that of the substrate, so that the stress applied to the electronic component can be reduced.

Furthermore, the electronic component is at least one selected from the group consisting of the analog front end, the microcomputer, the memory, the interposer, and the chip, so that sensing performance of the patchable biosensor can be improved by the operation thereof.

The patchable biosensor can suppress damage to an electronic component when a substrate is patched to a surface of a living body.

A one embodiment of a patchable biosensor of the present invention is described with reference to <FIG>.

In <FIG>, as described later, each layer (for example, a pressure-sensitive adhesive layer <NUM>, a substrate layer <NUM>, or the like) included in an electronic component <NUM> is omitted so as to clearly show a shape when viewed from the side of the electronic component <NUM>.

As shown in <FIG> and <FIG>, a patchable biosensor <NUM> has a generally flat plate shape extending in a longitudinal direction. The patchable biosensor <NUM> includes a substrate <NUM> and the electronic component <NUM> that is disposed on a one-side surface in a thickness direction of the substrate <NUM>.

The substrate <NUM> is a patchable substrate including a circuit portion, and is also a substrate that is stretchable (flexible) and has pressure-sensitive adhesive properties, while having, for example, a circuit portion <NUM> (described later). The substrate <NUM> is a sheet that has a flat plate shape extending in the longitudinal direction and is excellently stretchable. To be specific, the substrate <NUM> has a belt shape extending in the longitudinal direction, and has a shape in which a central portion <NUM> in the longitudinal direction expands toward both outer sides in a short-length direction (direction perpendicular to the longitudinal direction and the thickness direction) (width direction).

The substrate <NUM> includes the pressure-sensitive adhesive layer <NUM>, the substrate layer <NUM>, a wire layer <NUM>, a probe <NUM>, and a connecting portion <NUM>.

The pressure-sensitive adhesive layer <NUM> forms an other-side surface (pressure-sensitive adhesive surface) in the thickness direction of the substrate <NUM>. That is, the pressure-sensitive adhesive layer <NUM> is a layer that imparts the pressure-sensitive adhesive properties to the other-side surface in the thickness direction of the patchable biosensor <NUM> so as to patch the substrate <NUM> to a surface of a living body (a skin <NUM> or the like in <FIG>). The pressure-sensitive adhesive layer <NUM> forms the outer shape of the substrate <NUM>. The pressure-sensitive adhesive layer <NUM> has a flat plate shape extending in the longitudinal direction.

The pressure-sensitive adhesive layer <NUM> has two first opening portions <NUM> in both end portions in the longitudinal direction thereof. Each of the two first opening portions <NUM> has a generally ring shape when viewed from the top. The first opening portion <NUM> passes through the pressure-sensitive adhesive layer <NUM> in the thickness direction. The other-side surface in the thickness direction at the inside of the first opening portion <NUM> has an opening toward the other side in the thickness direction and has a first groove <NUM> corresponding to the probe <NUM>.

A material for the pressure-sensitive adhesive layer <NUM> is not particularly limited as long as it is, for example, a material having the pressure-sensitive adhesive properties. The pressure-sensitive adhesive layer <NUM> is also a stretchable material that is stretchable.

The substrate layer <NUM> forms the one-side surface in the thickness direction of the substrate <NUM>. The substrate layer <NUM>, along with the pressure-sensitive adhesive layer <NUM>, forms the outer shape (shape when projected in the thickness direction) of the substrate <NUM>. The shape when viewed from the top of the substrate layer <NUM> is the same as that when viewed from the top of the pressure-sensitive adhesive layer <NUM>. The substrate layer <NUM> is disposed on the entire one-side surface in the thickness direction of the pressure-sensitive adhesive layer <NUM>. The substrate layer <NUM> is a supporting layer that supports the pressure-sensitive adhesive layer <NUM>. The substrate layer <NUM> has a flat plate shape extending in the longitudinal direction.

The substrate layer <NUM> has a second groove <NUM> corresponding to the wire layer <NUM> (described later) on the one-side surface in the thickness direction thereof. The second groove <NUM> has the same pattern shape as that of the wire layer <NUM> when viewed from the top. The second groove <NUM> has an opening toward one side in the thickness direction.

The substrate layer <NUM> has a second opening portion <NUM> corresponding to the first opening portion <NUM>. The second opening portion <NUM> is communicated with the first opening portion <NUM> in the thickness direction. The second opening portion <NUM> has a generally ring shape when viewed from the top having the same shape and the same size as those of the first opening portion <NUM>.

An example of a material for the substrate layer <NUM> includes an insulator that is stretchable. Examples of the material include resins such as polyurethane resin.

The fracture elongation of the substrate layer <NUM> is, for example, <NUM>% or more, preferably <NUM>% or more, more preferably <NUM>% or more, and for example, <NUM>% or less. When the fracture elongation is the above-described lower limit or more, the material for the substrate layer <NUM> is excellently stretchable.

The wire layer <NUM> is, for example, embedded in the second groove <NUM>. To be more specific, the wire layer <NUM> is embedded in a one-side portion in the thickness direction of the substrate layer <NUM> so that the one-side surface in the thickness direction thereof is exposed from the substrate layer <NUM>. The one-side surface in the thickness direction of the wire layer <NUM>, along with the one-side surface in the thickness direction of the substrate layer <NUM> and the electronic component <NUM>, forms the one-side surface in the thickness direction of the substrate <NUM>.

The wire layer <NUM> has a wire pattern that connects the connecting portion <NUM> to the electronic component <NUM> (described later). The wire layer <NUM> includes a terminal for a component (not shown) to be used for electrical connection to the electronic component <NUM>.

A width (line width) of the wire layer <NUM> is set within a range that does not interrupt the stretchability of the substrate layer <NUM>, and is, for example, <NUM> or less, preferably <NUM> or less, and for example, <NUM> or more, preferably <NUM> or more.

Examples of a material for the wire layer <NUM> include conductors such as copper, nickel, and gold, and an alloy thereof. As the material for the wire layer <NUM>, preferably, copper is used.

As shown in <FIG>, the probe <NUM> is an electrode (bioelectrode) that senses an electrical signal, temperature, vibration, perspiration, and metabolite from a living body by being brought into contact with the skin <NUM> when the pressure-sensitive adhesive layer <NUM> is patched to the skin <NUM>. The probe <NUM> is embedded in the pressure-sensitive adhesive layer <NUM> so as to be exposed from the other-side surface in the thickness direction of the pressure-sensitive adhesive layer <NUM>. That is, the probe <NUM> is embedded in the first groove <NUM> in the pressure-sensitive adhesive layer <NUM> at the inside of the first opening portion <NUM>. The probe <NUM> is disposed on the other-side surface in the thickness direction of the pressure-sensitive adhesive layer <NUM> that forms the first groove <NUM>. The probe <NUM>, along with the pressure-sensitive adhesive layer <NUM>, forms the other-side surface in the thickness direction of the substrate <NUM>. The probe <NUM> has a net shape, preferably a generally grid shape (or a generally mesh shape) when viewed from the top. As shown in <FIG>, of the side surfaces of the probe <NUM>, the outer-side surface that is positioned at the outermost side forms a phantom circle going through those when viewed from the top. As a material for the probe <NUM>, the material illustrated in the wire layer <NUM> (to be specific, conductor) is used. A size of the outer shape of the probe <NUM> is set so that a phantom circle going through an outer-side surface <NUM> is overlapped with an inner peripheral surface defining the first opening portion <NUM> when viewed from the top.

As shown in <FIG> and <FIG>, the connecting portion <NUM> is provided corresponding to the second opening portion <NUM> and the first opening portion <NUM>, and has the same shape as that of those. The connecting portion <NUM> passes through (goes through) the substrate layer <NUM> and the pressure-sensitive adhesive layer <NUM> in the thickness direction, and fills the second opening portion <NUM> and the first opening portion <NUM>. As shown in <FIG>, the connecting portion <NUM> has an endless shape when viewed from the top along the outer-side surface <NUM> of the probe <NUM>. To be specific, the connecting portion <NUM> has a generally cylindrical shape in which an axis line thereof extends in the thickness direction (is along the phantom circle going through the outer-side surface <NUM>).

The inner-side surface of the connecting portion <NUM> is in contact with the outer-side surface <NUM> of the probe <NUM>. The connecting portion <NUM> pressure-sensitively adheres to the pressure-sensitive adhesive layer <NUM> at the outside of the first opening portion <NUM> and the pressure-sensitive adhesive layer <NUM> at the inside of the first opening portion <NUM>. The connecting portion <NUM> is in contact with the substrate layer <NUM> at the outside of the second opening portion <NUM> and the substrate layer <NUM> at the inside of the second opening portion <NUM>.

The one-side surface in the thickness direction of the connecting portion <NUM> is flush with the one-side surface in the thickness direction of the substrate layer <NUM>. The other-side surface in the thickness direction of the connecting portion <NUM> is flush with the other-side surface in the thickness direction of the pressure-sensitive adhesive layer <NUM>.

As shown in <FIG>, of the two connecting portions <NUM>, the connecting portion <NUM> that is positioned at one side in the longitudinal direction is continuous to one end portion in the longitudinal direction of the wire layer <NUM> that is positioned at one side in the longitudinal direction in one end portion in the thickness direction thereof. The connecting portion <NUM> that is positioned at the other side in the longitudinal direction is continuous to the other end edge in the longitudinal direction of the wire layer <NUM> that is positioned at the other side in the longitudinal direction in one end portion in the thickness direction thereof. That is, the connecting portion <NUM> is electrically connected to the wire layer <NUM>.

In this manner, the connecting portion <NUM> electrically connects the wire layer <NUM> to the probe <NUM>.

Examples of a material for the connecting portion <NUM> include metal and electrically conductive resin (including electrically conductive polymer). Preferably, an electrically conductive resin or the like is used.

The connecting portion <NUM> and the wire layer <NUM> configure the circuit portion <NUM> that electrically connects the probe <NUM> to the electronic component <NUM>. That is, the circuit portion <NUM> includes the wire layer <NUM> that is disposed on the one-side surface in the thickness direction of the substrate <NUM> and the connecting portion <NUM> that goes through the substrate <NUM> in the thickness direction. Preferably, the circuit portion <NUM> consists of only the wire layer <NUM> and the connecting portion <NUM>.

Examples of the electronic component <NUM> include logic ICs such as analog front end, microcomputer, and memory for being processed and memorized as an electrical signal from a living body obtained by the probe <NUM>; furthermore, transmitters such as communication IC for converting the electrical signal to an electric wave and wirelessly transmitting the electric wave to an external receiver; and furthermore, interposers.

As the electronic component <NUM>, the above-described illustrations are appropriately used alone or in combination of two or more.

The electronic component <NUM> is disposed in one portion in the short-length direction in the central portion <NUM> in the longitudinal direction of the substrate <NUM>. The plurality of (for example, three) electronic components <NUM> are disposed in alignment at spaced intervals to each other in the longitudinal direction of the substrate <NUM>. To be specific, the electronic component <NUM> includes a first component <NUM>, a second component <NUM>, and a third component <NUM>, and these are sequentially disposed from the other side toward one side in the longitudinal direction of the substrate <NUM>. For example, the first component <NUM> is the analog front end, the second component <NUM> is the memory, and the third component <NUM> is the communication IC.

Each of the plurality of electronic components <NUM> extends in a longitudinal direction LD of the electronic component <NUM>. The longitudinal direction LD of the electronic component <NUM> crosses the short-length direction of the substrate <NUM> and, to be specific, is perpendicular to the short-length direction of the substrate <NUM>. To be specific, each of the plurality of electronic components <NUM> has a generally rectangular shape when viewed from the top extending long along the short-length direction of the substrate <NUM>.

The plurality of electronic components <NUM> are overlapped with each other when projected in the longitudinal direction.

In the longitudinal directions LDs of the plurality of electronic components <NUM>, one end edges <NUM> at the side toward one end edge in the short-length direction of the substrate <NUM> (one end edges in the longitudinal direction) are positioned at the same position when projected in the longitudinal direction of the substrate <NUM>.

The electronic component <NUM> is disposed on the one-side surface in the thickness direction of the substrate <NUM>. To be specific, the electronic component <NUM> is in contact with the one-side surface in the thickness direction of the substrate layer <NUM>. The electronic component <NUM> has a generally rectangular flat plate shape when viewed from the cross-sectional view. A terminal (not shown) is provided on the other-side surface in the thickness direction of the electronic component <NUM>. The terminal (not shown) of the electronic component <NUM> is electrically connected to a terminal for a component (not shown) of the wire layer <NUM>.

The electronic component <NUM> is, for example, hard compared to the pressure-sensitive adhesive layer <NUM> and the substrate layer <NUM>. Thus, an example of a material for the electronic component <NUM> includes a hard material. An example thereof includes a silicon-based inorganic material.

A length L in the longitudinal direction LD of the electronic component <NUM> is not particularly limited as long as it is above the above-described width W. A ratio (L/W) of the length L in the longitudinal direction to the width W is set so as to be <NUM> or more, and for example, <NUM> or less. The length L of the electronic component <NUM> signifies the length in the short-length direction of the substrate <NUM>.

A thickness T of the electronic component <NUM> is, for example, <NUM> or more, preferably <NUM> or more, and for example, <NUM> or less, preferably <NUM> or less.

The maximum thickness Tmax of the electronic components <NUM> that are next to each other is, for example, <NUM> or more, preferably <NUM> or more, and for example, <NUM> or less, preferably <NUM> or less. The maximum thickness Tmax signifies the thickness of the electronic component <NUM> that is thicker in a case where the two electronic components <NUM> each of which has a different thickness are next to each other.

A gap I between the electronic components <NUM> that are next to each other is, for example, <NUM> or more, preferably <NUM> or more, and for example, <NUM> or less, preferably <NUM> or less. The gap I corresponds to a distance in the short-length direction of the substrate <NUM> between the electronic components <NUM> that are next to each other.

A ratio (I/Tmax) of the gap I between the two electronic components <NUM> that are next to each other to the maximum thickness Tmax of the two electronic components <NUM> is <NUM> or more, preferably <NUM> or more, more preferably <NUM> or more, and for example, <NUM> or less.

When the above-described ratio (I/Tmax) is the above-described lower limit or more, the plurality of electronic components <NUM> can be disposed in saving space (at high density).

Meanwhile, when the above-described ratio (I/Tmax) is the above-described lower limit or more, in a case where the patchable biosensor <NUM> is patched to the skin <NUM>, contact of the two electronic components <NUM> with each other is effectively suppressed, and damage to the electronic component <NUM> can be effectively suppressed.

The width W of the electronic component <NUM> is a length of a direction perpendicular to the longitudinal direction LD of the electronic component <NUM>. The width W of the electronic component <NUM> corresponds to the length in the longitudinal direction of the substrate <NUM>, and to be specific, is, for example, <NUM> or less, preferably <NUM> or less, more preferably <NUM> or less, and for example, <NUM> or more. When the width W is the above-described upper limit or less, in a case where the substrate <NUM> is patched to the skin <NUM>, the damage at the time of applying the stress to the electronic component <NUM> can be effectively suppressed.

As shown in <FIG>, the patchable biosensor <NUM> includes a first release sheet <NUM> as one example of a release sheet. The first release sheet <NUM> forms the lowermost surface of the patchable biosensor <NUM>. The first release sheet <NUM> is disposed on the other-side surface in the thickness direction of the substrate <NUM>. The first release sheet <NUM> is a protecting sheet that covers the other-side surface in the thickness direction of the substrate <NUM> (pressure-sensitive adhesive surface of the pressure-sensitive adhesive layer <NUM>) to be protected from damage, dust, or the like. The first release sheet <NUM> is a peelable sheet that is peeled from the substrate <NUM> along the longitudinal direction of the substrate <NUM> at the time of the use of the patchable biosensor <NUM> (ref: <FIG>).

The first release sheet <NUM> has, for example, a generally flat plate shape extending in the longitudinal direction of the substrate <NUM>. Examples of a material for the first release sheet <NUM> include resins (polymers) such as polyester (polyethylene terephthalate or the like) and polyolefin (polypropylene or the like), and metals such as aluminum and stainless steel. As the material for the first release sheet <NUM>, in view of stretchability, preferably, a resin is used.

Next, a method for producing the patchable biosensor <NUM> is described with reference to <FIG>.

In this method, first, the substrate <NUM> is prepared in conformity with <FIG>.

To prepare the substrate <NUM>, first, as shown in <FIG>, the substrate layer <NUM> and the wire layer <NUM> are prepared. The substrate layer <NUM> and the wire layer <NUM> are prepared so that the wire layer <NUM> is embedded in the second groove <NUM> by the method described in, for example, <CIT> and <CIT>.

Next, as shown in <FIG>, the pressure-sensitive adhesive layer <NUM> is disposed on the other-side surface in the thickness direction of the substrate layer <NUM>. To dispose the pressure-sensitive adhesive layer <NUM>, for example, first, an application liquid containing the material for the pressure-sensitive adhesive layer <NUM> is prepared and subsequently, the application liquid is applied to the one-side surface in the thickness direction of the first release sheet <NUM> to be then dried by heating. In this manner, the pressure-sensitive adhesive layer <NUM> is disposed on the one-side surface in the thickness direction of the first release sheet <NUM>.

Next, the pressure-sensitive adhesive layer <NUM> is attached to the substrate layer <NUM> by, for example, laminator or the like. To be specific, the one-side surface in the thickness direction of the pressure-sensitive adhesive layer <NUM> is brought into contact with the other-side surface in the thickness direction of the substrate layer <NUM>.

At this point, each of the substrate layer <NUM> and the pressure-sensitive adhesive layer <NUM> does not have the second opening portion <NUM> and the first opening portion <NUM> (an opening portion <NUM>) (ref: <FIG>), respectively.

As shown in <FIG>, next, the opening portion <NUM> is formed in the substrate layer <NUM> and the pressure-sensitive adhesive layer <NUM>.

The opening portion <NUM> passes through the substrate layer <NUM> and the pressure-sensitive adhesive layer <NUM>. The opening portion <NUM> is a hole (through hole) in a generally circular shape when viewed from the top defined by an outer peripheral surface that defines the second opening portion <NUM> and the outer peripheral surface that defines the first opening portion <NUM>. The opening portion <NUM> has an opening toward one side in the thickness direction. Meanwhile, the lower end of the opening portion <NUM> is sealed by the first release sheet <NUM>.

To form the opening portion <NUM>, the pressure-sensitive adhesive layer <NUM> and the substrate layer <NUM> are, for example, subjected to punching and half etching.

Next, a probe member <NUM> is prepared to be fitted into the inside of the opening portion <NUM>.

To prepare the probe member <NUM>, first, as shown in <FIG>, a probe-including sheet <NUM> is prepared.

The probe-including sheet <NUM> includes a second release sheet <NUM>, a probe pattern <NUM> that is formed at one side in the thickness direction of the second release sheet <NUM>, the pressure-sensitive adhesive layer <NUM> that is formed at one side in the thickness direction of the second release sheet <NUM> and embeds the probe pattern <NUM>, and the substrate layer <NUM> that is disposed on the one-side surface in the thickness direction of the pressure-sensitive adhesive layer <NUM>.

The second release sheet <NUM> has the same structure as that of the above-described first release sheet <NUM>.

The probe pattern <NUM> has the same pattern shape as that of the probe <NUM>. A material for the probe pattern <NUM> is the same as that for the probe <NUM>. The probe pattern <NUM> has the plane area that is larger than the phantom circle going through the outer-side surface <NUM> of the probe <NUM>.

Each of the pressure-sensitive adhesive layer <NUM> and the substrate layer <NUM> in the probe-including sheet <NUM> has the same structure as that of the pressure-sensitive adhesive layer <NUM> and that of the substrate layer <NUM> described above.

The probe-including sheet <NUM> is prepared by the method described in, for example, <CIT> and <CIT>.

Next, as shown in <FIG>, a cutting line <NUM> in a generally circular shape when viewed from the top is formed in the probe pattern <NUM>, the pressure-sensitive adhesive layer <NUM>, and the substrate layer <NUM>. The cutting line <NUM> is formed by, for example, punching or the like. The cutting line <NUM> divides the probe pattern <NUM>, the pressure-sensitive adhesive layer <NUM>, and the substrate layer <NUM> at the inside and the outside thereof, and is not formed in the second release sheet <NUM>. The size of the cutting line <NUM> is the same as the inner size of the first opening portion <NUM> and the second opening portion <NUM>. That is, the cutting line <NUM> coincides with the phantom circle going through the outer-side surface <NUM>.

The probe member <NUM> is formed by forming of the cutting line <NUM>.

In the probe member <NUM>, the outer-side surface <NUM> of the probe <NUM> is flush with the outer-side surface of the pressure-sensitive adhesive layer <NUM>. In the probe member <NUM>, the outer-side surface <NUM> is exposed from the outer-side surface of the pressure-sensitive adhesive layer <NUM> outwardly in a radial direction.

Subsequently, as shown by an arrow of <FIG>, the probe member <NUM> is pulled up from the second release sheet <NUM>. To be specific, the other-side surface in the thickness direction of the probe member <NUM> is peeled from the second release sheet <NUM>.

Thereafter, as shown by the arrow of <FIG>, the probe member <NUM> is fitted into the inside of the opening portion <NUM>.

At this time, the pressure-sensitive adhesive layer <NUM>, the substrate layer <NUM>, and the probe <NUM> of the probe member <NUM> are spaced apart from the pressure-sensitive adhesive layer <NUM> and the substrate layer <NUM> around the opening portion <NUM>. That is, the probe member <NUM> is fitted into the inside of the opening portion <NUM> so as to form the second opening portion <NUM> and the first opening portion <NUM>.

Thereafter, as shown by <FIG>, the connecting portion <NUM> is provided at the inside of the second opening portion <NUM> and the first opening portion <NUM>.

To be specific, when the material for the connecting portion <NUM> is an electrically conductive resin composition, the electrically conductive resin composition (electrically conductive composition liquid) is poured into (or applied to) the second opening portion <NUM> and the first opening portion <NUM>. Thereafter, the electrically conductive resin composition (electrically conductive composition liquid) is heated and a solvent is removed, and a binder resin is cross-linked by a cross-linking agent.

In this manner, a laminate <NUM> for a biosensor including the substrate <NUM> and the first release sheet <NUM> is produced. The laminate <NUM> for a biosensor does not include the electronic component <NUM> (furthermore, a cell <NUM>), that is, the laminate <NUM> for a biosensor is not the patchable biosensor <NUM> and is an intermediate component for producing the patchable biosensor <NUM>.

As shown in <FIG>, thereafter, the plurality of electronic components <NUM> are mounted on the laminate <NUM> for a biosensor. To be specific, a terminal (not shown) of the electronic component <NUM> is brought into contact with a terminal for a component (not shown) in the wire layer <NUM>, and the other-side surface in the thickness direction of the electronic component <NUM> is brought into contact with the one-side surface in the thickness direction of the substrate layer <NUM>.

In this manner, the patchable biosensor <NUM> including the substrate <NUM>, the electronic component <NUM>, and the first release sheet <NUM> is produced.

The patchable biosensor <NUM> preferably consists of only the substrate <NUM>, the electronic component <NUM>, and the first release sheet <NUM>.

Next, the usage of the patchable biosensor <NUM> is described with reference to <FIG>.

To use the patchable biosensor <NUM>, first, as shown by a phantom line of <FIG>, the cell <NUM> is mounted on the patchable biosensor <NUM>.

The cell <NUM> has a generally flat plate (box) shape extending in a plane direction. The cell <NUM> has a terminal (not shown) that is provided on the other-side surface in the thickness direction thereof.

To mount the cell <NUM> on the patchable biosensor <NUM>, a terminal (not shown) of the cell <NUM> is electrically connected to a terminal for a cell (not shown) of the wire layer <NUM>. At this time, the other-side surface in the thickness direction of the cell <NUM> is brought into contact with the one-side surface in the thickness direction of the substrate layer <NUM>.

Next, the first release sheet <NUM> (ref: the arrow and the phantom line of <FIG>) is peeled from the substrate <NUM>, and the substrate <NUM> is patched to the skin <NUM>.

As shown by the phantom line and the arrow of <FIG>, for example, first, one end edge in the longitudinal direction of the first release sheet <NUM> (portion facing one end edge in the longitudinal direction of the substrate <NUM> in the first release sheet <NUM>) is peeled from the substrate <NUM>, and as shown in <FIG>, while holding the one end edge, the one-side portion in the longitudinal direction of the first release sheet <NUM> is peeled from the one-side portion in the longitudinal direction of the substrate <NUM>. In this manner, the one-side portion in the longitudinal direction of the other-side surface (pressure-sensitive adhesive surface) in the thickness direction of the substrate <NUM> is exposed toward the other side in the thickness direction.

Subsequently, as shown in <FIG>, the other-side surface (pressure-sensitive adhesive surface) in the thickness direction of the substrate <NUM> pressure-sensitively adheres to the surface of the skin <NUM>.

Thereafter, as shown by the arrow of <FIG>, and <FIG>, an other-side portion in the longitudinal direction of the first release sheet <NUM> is peeled from the other-side portion in the longitudinal direction of the substrate <NUM>, and the other-side portion in the longitudinal direction of the substrate <NUM> is exposed. Immediately after this, the portion pressure-sensitively adheres to the surface of the skin <NUM>. In this manner, the first release sheet <NUM> is removed from the patchable biosensor <NUM>, and at the same time, the entire other-side surface (pressure-sensitive adhesive surface) in the thickness direction of the substrate <NUM> is patched to the surface of the skin <NUM>.

Thereafter, a living body is sensed by the probe <NUM>, the circuit portion <NUM> (the connecting portion <NUM> and the wire layer <NUM>), and the electronic component <NUM>.

To be specific, the probe <NUM> senses as the electrical signal from the living body, and the electrical signal sensed by the probe <NUM> is input into the electronic component <NUM> via the connecting portion <NUM> and the wire layer <NUM>. The electronic component <NUM> processes the electrical signal and memorizes it as information based on an electric power supplied from the cell <NUM>. Furthermore, if necessary, the electrical signal is converted into an electric wave to be wirelessly transmitted to an external receiver.

To be more specific, the operation of the first component <NUM>, the second component <NUM>, and the third component <NUM> in the electronic component <NUM> is described in the following. When the patchable biosensor <NUM> is a patchable electrocardiograph (described later), a potential change of the heart obtained by the probe <NUM> is converted into digital data in the first component <NUM> that is the analog front end, and records the potential change of the heart in the second component <NUM> that is the memory. As one example, the second component <NUM> records the potential change of the heart of <NUM> bit and the data rate of <NUM>. Also, the third component <NUM> that is the communication IC wirelessly transmits the signal obtained by the probe <NUM> to the outside.

After the above-described operation (that is, after the sensing of the living body by the patchable biosensor <NUM>), the patchable biosensor <NUM> is removed from the skin <NUM>, and the recorded data is taken out from the second component <NUM> to be analyzed. Thereafter, the second component <NUM> (furthermore, the first component <NUM> and the third component <NUM> as needed) is reused.

As shown in <FIG> and <FIG>, in Comparative Example <NUM> in which the longitudinal direction LD of the electronic component <NUM> is along the longitudinal direction of the substrate <NUM>, when the substrate <NUM> is attempted to be patched to the skin <NUM> along the longitudinal direction thereof, the substrate <NUM> is deformed along the longitudinal direction thereof, and in this way, a large stress F is applied to the above-described electronic component <NUM>. Thus, as shown in <FIG>, the damage (crack or the like) to the electronic component <NUM> occurs by the stress F.

In the patchable biosensor <NUM>, however, as shown in <FIG>, when the substrate <NUM> is patched to the skin <NUM> along the longitudinal direction thereof, and the substrate <NUM> is deformed along the longitudinal direction thereof, the longitudinal direction LD of the electronic component <NUM> crosses the longitudinal direction of the substrate <NUM>, so that the stress applied to the electronic component <NUM> can be reduced. Thus, when the substrate <NUM> is patched to the skin <NUM>, the damage to the electronic component <NUM> caused by the above-described stress can be suppressed.

Furthermore, the longitudinal direction LD of the electronic component <NUM> is perpendicular to the longitudinal direction of the substrate <NUM>, so that the stress applied to the electronic component <NUM> can be furthermore surely reduced.

As shown in <FIG>, when the first release sheet <NUM> is peeled along the longitudinal direction of the substate <NUM>, the substrate <NUM> is stretchable, so that the deformation easily occurs.

As described above, however, in the patchable biosensor <NUM>, the longitudinal direction LD of the electronic component <NUM> crosses the longitudinal direction of the substrate <NUM>, so that when the first release sheet <NUM> is peeled from the substrate <NUM>, the stress applied to the electronic component <NUM> can be reduced. Thus, when the substrate <NUM> is patched to the skin <NUM>, the damage to the electronic component <NUM> can be furthermore surely suppressed.

As shown in <FIG> and <FIG>, there may be a case where the plurality of electronic components <NUM> having the longitudinal directions LDs along the longitudinal direction of the substrate <NUM> and disposed next to each other in the longitudinal direction of the substrate <NUM> are brought into contact with each other by the above-described deformation along the longitudinal direction of the substrate <NUM>, and are damaged caused by the contact (Comparative Example <NUM>). To be specific, the damage caused by the contact of the first component <NUM> with the second component <NUM>, and the contact of the second component <NUM> with the third component <NUM> is assumed.

In the patchable biosensor <NUM>, however, as shown in <FIG>, the longitudinal direction LD of the electronic component <NUM> crosses the longitudinal direction of the substrate <NUM>, so that the above-described occurrence of the contact is suppressed, and the damage to the electronic component <NUM> can be suppressed.

In the patchable biosensor <NUM>, when the ratio (I/Tmax) of the gap I between the two electronic components <NUM> to the maximum thickness Tmax of the electronic component <NUM> is <NUM> or more, the contact of the two electronic components <NUM> that are next to each other with each other is effectively suppressed, and the damage to the electronic component <NUM> can be effectively suppressed.

In the patchable biosensor <NUM>, at least one selected from the group consisting of the analog front end, the microcomputer, the memory, the interposer, and the chip is hard or fragile, and thus, the electronic component <NUM> may be damaged when the stress is applied thereto.

As described above, however, in the patchable biosensor <NUM>, the longitudinal direction LD of the electronic component <NUM> crosses the longitudinal direction of the substrate <NUM>, so that the stress applied to the electronic component <NUM> can be reduced.

Furthermore, the electronic component <NUM> includes the first component <NUM> that is the analog front end, the second component <NUM> that is the memory, and the third component <NUM> that is the communication IC, so that sensing performance of the patchable biosensor <NUM> can be improved by the above-described operation in the electronic component <NUM>.

The patchable biosensor <NUM> is not particularly limited as long as it is, for example, a device that is capable of monitoring a state of a living body by sensing an electrical signal from the living body. To be specific, examples of the patchable biosensor <NUM> include patchable electrocardiograph, patchable electroencephalograph, patchable hemomanometer, patchable pulsimeter, patchable electromyograph, patchable thermometer, and patchable accelerometer. These devices may be an individual device, or a plurality of these may be installed in one device.

The patchable biosensor <NUM> is preferably used as a patchable electrocardiograph. In the patchable electrocardiograph, the probe <NUM> senses an action potential of the heart as the electrical signal.

The living body includes a human body and a living being other than the human body. Preferably, a human body is used.

In the modified examples, the same reference numerals are provided for members and steps corresponding to each of those in the one embodiment, and their detailed description is omitted. Furthermore, in the modified examples, the same function and effect as that of the one embodiment can be achieved unless otherwise specified.

As shown in <FIG>, the patchable biosensor <NUM> can also include (only) the substrate <NUM> and the electronic component <NUM> without including the first release sheet <NUM>.

As shown in <FIG>, preferably, the patchable biosensor <NUM> includes the first release sheet <NUM>, the substrate <NUM>, and the electronic component <NUM>. The pressure-sensitive adhesive surface of the substrate <NUM> can be protected from the damage, the dust, or the like by the first release sheet <NUM>. Meanwhile, as shown in <FIG>, when the first release sheet <NUM> is peeled from the substrate <NUM> along the longitudinal direction of the substrate <NUM>, the deformation of the substrate <NUM> easily occurs.

As described above, however, in the patchable biosensor <NUM>, the longitudinal direction LD of the electronic component <NUM> crosses the longitudinal direction of the substrate <NUM>, so that when the first release sheet <NUM> is peeled from the substrate <NUM>, the stress applied to the electronic component <NUM> can be reduced.

The longitudinal direction LD of the electronic component <NUM> may cross the longitudinal direction of the substrate <NUM>. That is, though not shown, the longitudinal direction LD of the electronic component <NUM> is not perpendicular to the longitudinal direction of the substrate <NUM>, and may cross the longitudinal direction of the substrate <NUM>. To be specific, as shown in <FIG>, the longitudinal directions LDs of the plurality of electronic components <NUM> incline with respect to the longitudinal direction of the substrate <NUM>. An angle made between the longitudinal direction LD of the electronic component <NUM> and the longitudinal direction of the substrate <NUM> is, for example, above <NUM> degree, furthermore <NUM> degrees or more, and for example, below <NUM> degrees, furthermore, below <NUM> degrees.

Furthermore, the longitudinal direction LD that crosses (is perpendicular to) the longitudinal direction of the substrate <NUM> may be included in the electronic component <NUM>. For example, of the plurality of electronic components <NUM>, one may have the longitudinal direction LD that crosses (is perpendicular to) the longitudinal direction of the substrate <NUM>, and another may also have the longitudinal direction LD along the longitudinal direction of the substrate <NUM>.

To be specific, of the plurality of electronic components <NUM>, for example, the longitudinal directions LDs of the one or more electronic components <NUM> cross (are perpendicular to) the longitudinal direction of the substrate <NUM>, preferably, the longitudinal directions LDs of a half or more of the electronic components <NUM> cross (are perpendicular to) the longitudinal direction of the substrate <NUM>, more preferably, the longitudinal directions LDs of <NUM>% or more of the electronic components <NUM> cross (are perpendicular to) the longitudinal direction of the substrate <NUM>, further more preferably, the longitudinal directions LDs of all of the electronic components <NUM> cross (are perpendicular to) the longitudinal direction of the substrate <NUM>.

The arrangement of the plurality of electronic components <NUM> is not limited to the description above, and for example, the arrangement shown in <FIG> can be also used.

For example, as shown in <FIG>, in the modified example, the plurality of electronic components <NUM> (the first component <NUM>, the second component <NUM>, and the third component <NUM>) are disposed at spaced intervals to each other in the short-length direction of the substrate <NUM>.

As shown in <FIG>, the plurality of electronic components <NUM> are disposed in the central portion in the short-length direction of the substrate <NUM>. Each of both end edges in the short-length direction of the substrate <NUM> extends linearly along the longitudinal direction of the substrate <NUM> over the central portion <NUM> in the longitudinal direction and both end portions in the longitudinal direction.

As shown in <FIG>, the plurality of electronic components <NUM> are disposed in alignment at spaced intervals to each other in both directions of the longitudinal direction and the short-length direction of the substrate <NUM>. To be specific, in the modified example shown in <FIG>, the electronic component <NUM> includes the first component <NUM>, the second component <NUM>, and the third component <NUM> that are disposed at spaced intervals to each other in the longitudinal direction, and a fourth component <NUM> and a fifth component <NUM> that are disposed at spaced intervals to each other at both sides in the short-length direction of the second component <NUM>.

In the modified example shown in <FIG>, the first component <NUM> and the second component <NUM> are disposed at spaced intervals to each other in the longitudinal direction of the substrate <NUM>, and the third component <NUM> and the fourth component <NUM> are disposed at spaced intervals to each other in the longitudinal direction of the substrate <NUM>. Each of the third component <NUM> and the fourth component <NUM> is disposed to face each of the first component <NUM> and the second component <NUM> at spaced intervals thereto at the other side in the short-length direction.

As shown in <FIG>, in the modified example, the plurality of electronic components <NUM> are displaced from each other. For example, in the modified example shown in <FIG>, when projected in the longitudinal direction of the substrate <NUM>, the first component <NUM> and the third component <NUM> are displaced from the second component <NUM> and the fourth component <NUM>, and are not overlapped with them.

In the modified example shown in <FIG>, when projected in the longitudinal direction of the substrate <NUM>, a portion of the first component <NUM> (the other-side portion in the longitudinal direction LD of the electronic component <NUM>) is overlapped with the second component <NUM>, and a remaining portion of the first component <NUM> (one-side portion in the longitudinal direction LD of the electronic component <NUM>) is not overlapped with the second component <NUM>. Also, when projected in the longitudinal direction of the substrate <NUM>, a portion of the second component <NUM> (the other-side portion in the longitudinal direction LD of the electronic component <NUM>) is overlapped with the third component <NUM>, and a remaining portion of the second component <NUM> (one-side portion in the longitudinal direction LD of the electronic component <NUM>) is not overlapped with the third component <NUM>.

Furthermore, as shown in <FIG>, when projected in the longitudinal direction of the substrate <NUM>, the first component <NUM>, the second component <NUM>, the third component <NUM>, and the fourth component <NUM> are sequentially disposed from one side toward the other side in the short-length direction of the substrate <NUM>, and when projected in the short-length direction of the substrate <NUM>, the first component <NUM>, the second component <NUM>, the third component <NUM>, and the fourth component <NUM> are sequentially disposed from the other side toward one side in the longitudinal direction of the substrate <NUM>.

Of the modified examples of <FIG>, preferably, the modified examples of <FIG> are used, more preferably, the modified examples of <FIG> are used.

In the modified examples of <FIG>, when projected in the longitudinal direction of the substrate <NUM>, a portion that is not overlapped with each other exists, so that the contact of at least the above-described portions with each other caused by the deformation when the substrate <NUM> is patched to the skin <NUM> can be effectively suppressed.

In the modified examples of <FIG>, when projected in the longitudinal direction of the substrate <NUM>, a portion that is overlapped with each other does not exist, so that the contact of the electronic components <NUM> with each other can be prevented.

While the illustrative examples are provided in the above description, such is for illustrative purpose only and it is not to be construed as limiting the scope of the present invention.

Claim 1:
A patchable biosensor (<NUM>) comprising:
a substrate (<NUM>) extending in a longitudinal direction (LD) and being stretchable for being patched to a surface of a living body and
electronic components (<NUM>) disposed on a one-side surface in a thickness direction of the substrate (<NUM>) and extending in the longitudinal direction, wherein
the longitudinal direction of the electronic components (<NUM>) is perpendicular to the longitudinal direction of the substrate (<NUM>),
the electronic components (<NUM>) include at least two electronic components disposed next to each other along the longitudinal direction of the substrate (<NUM>),
a ratio I/Tmax of a gap I between the two electronic components in the longitudinal direction of the substrate (<NUM>) to the maximum thickness Tmax of the electronic components (<NUM>) is <NUM> or more, characterised in that
a ratio L/W of the length L in the longitudinal direction of the electronic components (<NUM>) to the width W of the electronic components (<NUM>) is set so as to be <NUM> or more,
wherein the length L of the electronic components (<NUM>) signifies the length in the short-length direction of the substrate (<NUM>) and
the width W of the electronic components (<NUM>) is a length of a direction perpendicular to the longitudinal direction (LD) of the electronic components (<NUM>).