Electrorheological fluid structure having strain relief element and method of fabrication

A method comprising:

• positioning a first layer of polymeric material, a second layer of polymeric materials and a first patch so that:
• a first conductive trace forming a portion of a surface of the first layer at least partially coincides with a channel having a portion formed in the second layer, wherein the second layer includes a first surface and a second surface, and wherein the first conductive trace includes a first extension that:
• (i) branches away from a path of the channel, (ii) passes along the first surface of the second layer, and (iii) is exposed in an open space of a first access passage defined in part by the second layer,
• a portion of the surface of the first layer is in contact with a portion of the first surface of the second layer,
• the first patch is interposed between the surface of the first layer and the first surface of the second layer, and
• the first patch spans the channel and covers the first extension of the first conductive trace from the channel to the first access passage;
• and
• bonding the first layer, the second layer, and the first patch.