Sensor base and manufacturing method thereof

Abstract

A sensor base includes a main body, and a battery receiving portion and a snap portion located on opposite sides of the main body, wherein the main body, the battery receiving portion, and the snap portion are an integrated structure; a sensor probe mounting portion and a transmitter conductive portion are provided on the main body; a battery and a conductive plate are also provided inside the sensor base, wherein the battery is located inside the battery receiving portion, and the conductive plate is located inside the battery receiving portion and the main body. The sensor base of the present invention encapsulates the battery and the conductive plate inside the sensor base, enabling the battery to be used as a consumable, thereby selecting a battery with a relatively small capacity and volume, reducing the volume of a dynamic blood glucose monitoring device, and eliminating the need for users to replace batteries, thereby enhancing the user experience; encapsulating the battery and the conductive plate simplifies the waterproof structure, enhances the waterproof performance level, and further reduces the volume of the dynamic blood glucose monitoring device.

Description

Technical Field

[0001] The present invention relates to the field of dynamic blood glucose monitoring sensors, and more particularly to a sensor base and a method for manufacturing the sensor base. Background Art

[0002] The dynamic blood glucose monitoring system (RGMS) is a new type of continuous dynamic blood glucose monitoring system that has been put into clinical use in recent years. It is connected to a probe similar to a needle, which is used to be inserted into the subcutaneous tissue. The diameter of the probe is very small, and the patient does not feel obvious pain or discomfort when inserted. The instrument receives an electrical signal reflecting blood sugar changes from the probe once at a certain interval, and converts the average value of the electrical signals collected multiple times into a blood sugar value and stores it. Hundreds of blood sugar values ​​can be recorded every day. The dynamic blood glucose monitor can also store the time of meals, exercise, medication, etc. at the same time. This means that patients no longer have to endure the pain of needle pricks every day, and it can provide daily blood sugar graphs, multi-day blood sugar graph fluctuation trend analysis and a summary of daily blood sugar data. It is a new breakthrough in blood sugar testing.

[0003] In order to reduce the cost of use for users, dynamic blood glucose monitoring devices generally use sensors as consumables and transmitters for continuous use. The sensor and transmitter are assembled and worn on the human body to transmit blood glucose data. However, the components of the sensor and transmitter make the dynamic blood glucose monitoring device larger in size and, in particular, thicker. When worn, it is easy for the sensor probe to collide with or rub against external objects, causing displacement of the sensor probe relative to the human tissue where it is worn. This can cause inflammation that affects the accuracy of blood glucose data at the very least, or even cause the entire sensor to fall off at the worst. Therefore, it is urgent to design a sensor base to reduce the size and thickness of the dynamic blood glucose monitoring device, thereby reducing the impact of physical factors on the accuracy of blood glucose monitoring data. Summary of the Invention

[0004] To address the shortcomings of the prior art, the present invention provides a sensor base. The sensor base of the present invention encapsulates a battery and a conductive plate within the sensor base, enabling the battery to be used as a consumable. This allows for the selection of batteries with relatively small capacity and volume, reducing the size of the continuous blood glucose monitoring device. Users no longer need to replace batteries, thus enhancing the user experience. Encapsulating the battery and conductive plate simplifies the waterproof structure, enhances the waterproof performance level, and further reduces the size of the continuous blood glucose monitoring device. The present invention also provides a method for manufacturing the sensor base, which uses a low-temperature protective shell injection molding process to prevent damage to the battery due to excessive temperatures, followed by a higher-temperature injection molding process to simplify the structure and enhance waterproof performance.

[0005] The specific technical solution of the present invention is as follows: a sensor base, including a main body, and a battery accommodating part and a snap-on part located on two opposite sides of the main body, wherein the main body, the battery accommodating part and the snap-on part are an integrated structure; a sensor probe mounting part and a transmitter conductive part are provided on the main body; a battery and a conductive plate are also provided inside the sensor base, wherein the battery is located inside the battery accommodating part, and the conductive plate is located inside the battery accommodating part and the main body.

[0006] Continuous glucose monitoring devices typically use a sensor as a consumable component, which is assembled with a transmitter and then worn on the body to transmit blood glucose data. The sensor and transmitter components make the continuous glucose monitoring device bulky and prone to collisions and friction with external objects. This can cause the sensor probe to shift relative to the tissue where it is worn. This can cause inflammation, affecting the accuracy of blood glucose data, or even cause the entire sensor to fall off. Therefore, reducing the size of continuous glucose monitoring devices, especially reducing thickness, to minimize the impact of contact with external objects is crucial. A battery is installed within the continuous glucose monitoring device for power, and battery size is the most significant factor affecting the size of the device. The battery and the conductive plate are encapsulated within the sensor base using methods such as injection molding. This has the following advantages: 1. Using the battery as a consumable component allows for the selection of a relatively small capacity battery, resulting in a smaller battery size, thus reducing the size of the continuous glucose monitoring device. 2. Encapsulating the battery and conductive plate simplifies the waterproof structure, enhances the waterproof performance, and further reduces the size of the continuous glucose monitoring device. 3. Using the battery as a consumable component eliminates the need for user replacement, making it more convenient to use.

[0007] As a preferred embodiment of the present invention, the sensor probe mounting portion is provided with at least one probe fixing groove, and the upper surface of the conductive plate is exposed at the bottom of the probe fixing groove.

[0008] Thus, the sensor probe is installed at the position of the probe fixing groove, and the sensor probe can be fixed by injecting solidifying glue into the probe fixing groove.

[0009] As a preferred embodiment of the present invention, the transmitter conducting portion is provided with a conducting groove and a conducting component installed in the conducting groove.

[0010] Therefore, the conductive groove is provided with contacts for the positive and negative poles of the battery, as well as connection contacts for the sensor probe, and contacts are also provided at the opposite position at the bottom of the transmitter. After the transmitter and the sensor base are snapped together, the battery powers the transmitter, and the transmitter powers the sensor probe after rectification by the circuit.

[0011] As a preferred embodiment of the present invention, a circular arc-shaped battery accommodating notch is provided on one side of the conductive plate, and the battery is installed in the battery accommodating notch.

[0012] Therefore, the battery is installed in the battery accommodating notch, which can reduce the thickness of the sensor base.

[0013] As a preferred embodiment of the present invention, the conductive plate is provided with battery conductive interfaces on both sides of the battery accommodating notch; the positive and negative poles of the battery are respectively welded with metal welding sheets, the thickness of the metal welding sheets does not exceed 0.5 mm, and after bending, they are connected to the two battery conductive interfaces for conduction.

[0014] Therefore, the battery can reduce the thickness of the sensor base through the metal welding sheet and the battery conductive interface.

[0015] As a preferred embodiment of the present invention, a probe conductive pad is provided on the conductive plate in the probe fixing groove, a probe conductive through-hole is provided in the middle of the probe conductive pad, a probe through-hole is provided at the bottom of the sensor probe mounting portion relative to the probe conductive through-hole, and the probe through-hole and the probe conductive through-hole are penetrated.

[0016] Thus, the sensor probe passes through the probe through-hole and the probe conductive through-hole, and is conductively connected to the probe conductive pad by welding or injecting conductive glue.

[0017] As a preferred embodiment of the present invention, the conductive plate is provided with a plurality of conductive contacts at the conductive groove, the battery conductive interface is connected to the conductive contacts through the wiring in the conductive plate, and the conductive pad is connected to the conductive contacts through the wiring in the conductive plate.

[0018] Therefore, the conductive plate is generally a PCB board, and all the conductive contacts are located in the conductive groove, which can facilitate conduction with the transmitter, and only the conductive groove needs to be waterproofed to improve the waterproof performance of the conductive part.

[0019] As a preferred embodiment of the present invention, the conductive component includes conductive silicone and an elastic seal, and a plurality of the conductive silicones are respectively arranged at relative positions of the conductive contacts. The elastic seal is filled in the conductive groove and the top is higher than the conductive groove notch. After the conductive silicone body passes through the elastic seal, the elastic seal is exposed at the top.

[0020] Thus, the bottom of the conductive silicone is in conduction with the conducting contact, and the top is in conduction with the contact on the emitter after being snap-fitted to the emitter, and the elastic seal is squeezed by the contact surface of the emitter to form a seal.

[0021] As a preferred embodiment of the present invention, the bottom area of ​​the conductive silicone is larger than the top area, and the elastic sealing member has a through hole with the same cross-section as the conductive silicone.

[0022] Therefore, the bottom area of ​​the conductive silicone is larger than the top area, so that it will not fall out from the bottom to the top after being installed in the elastic seal, and the conductive silicone can be prevented from falling during transportation and disassembly; the conductive silicone can be a structure with a "convex" vertical cross-section, and the elastic seal is insulating rubber, and the bottom is bonded to the bottom of the conductive groove by glue, thereby ensuring that the elastic seal and the conductive silicone are installed in the conductive groove and will not fall off.

[0023] A method for manufacturing a sensor base, comprising the following manufacturing steps:

[0024] Step A, welding the metal welding sheet and the battery;

[0025] Step B, installing the battery and the metal welding sheet assembly at the battery receiving notch of the conductive plate;

[0026] Step C, welding the other end of the metal welding piece to the battery conductive interface of the conductive plate;

[0027] Step D: injection molding the entire assembly of the conductive plate, the battery, and the metal welding sheet at a temperature of 130° C. to 150° C., with the temperature above 100° C. lasting no longer than 8 seconds during the injection molding process, and with an injection molding thickness of 0.3 mm to 0.6 mm;

[0028] Step E: injecting the component after the first injection molding again at an injection molding temperature of 150° C. to 250° C.

[0029] In step A, the welding temperature between the metal welding sheet and the battery does not exceed 200°C, and the duration of the temperature above 150°C during the welding process does not exceed 5 seconds, thereby ensuring that the battery will not be damaged due to excessive temperature; steps B and C require the use of a positioning mechanism to position the conductive plate and the battery to ensure that the relative positions have high consistency after welding as a whole; the injection molding process in step D ensures that the temperature is within the range that will not damage the battery, and a 0.3mm-0.6mm protective layer is first injected to ensure that the temperature of the molding injection in step E will not affect the battery.

[0030] In summary, the present invention has the following beneficial effects:

[0031] The sensor base of the present invention encapsulates the battery and conductive plate within the sensor base, allowing the battery to be used as a consumable. This allows for the selection of batteries with relatively small capacity and volume, reducing the size of the continuous blood glucose monitoring device. Users no longer need to replace batteries, thus enhancing the user experience. Encapsulating the battery and conductive plate simplifies the waterproof structure, enhances the waterproof performance level, and further reduces the size of the continuous blood glucose monitoring device. The present invention also provides a manufacturing method for the sensor base, which uses a low-temperature protective shell injection molding process to prevent battery damage due to excessive temperatures, followed by a higher-temperature injection molding process, simplifying the structure and enhancing waterproof performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a three-dimensional diagram of the sensor base of the present invention without the conductive component installed;

[0033] Figure 2 A three-dimensional diagram of the sensor base of the present invention with the conductive assembly installed;

[0034] Figure 3 A cross-sectional view of the sensor base of the present invention with the conductive assembly installed;

[0035] Figure 4 This is a front view of a perspective view of the sensor base battery and the conductive plate welding assembly of the present invention;

[0036] Figure 5 This is a back view of the three-dimensional diagram of the sensor base battery and the conductive plate welding assembly of the present invention;

[0037] Figure 6 This is a structural diagram of a sensor base according to an embodiment of the present invention, in which the conductive component is separated;

[0038] In the figure, 1-main body, 11-sensor probe mounting part, 111-probe fixing groove, 112-probe through-hole, 12-emitter conduction part, 121-conduction groove, 122-conduction component, 1221-conductive silicone, 1222-elastic sealing part, 2-battery accommodating part, 3-snapping part, 4-battery, 41-metal welding piece, 5-conduction plate, 51-battery accommodating notch, 52-battery conduction interface, 53-probe conductive pad, 531-probe conduction through-hole, 54-conduction contact. DETAILED DESCRIPTION

[0039] The present invention will be further described below through specific embodiments with reference to the accompanying drawings.

[0040] like Figure 1 、 Figure 2 、 Figure 3A sensor base includes a main body 1, and a battery accommodating portion 2 and a snap portion 3 located on two opposite sides of the main body 1. The main body 1, the battery accommodating portion 2 and the snap portion 3 are an integrated structure; the main body 1 is provided with a sensor probe mounting portion 11 and a transmitter conductive portion 12; a battery 4 and a conductive plate 5 are also provided inside the sensor base, the battery 4 is located inside the battery accommodating portion 2, and the conductive plate 5 is located inside the battery accommodating portion 2 and the main body 1.

[0041] Continuous glucose monitoring devices typically use a sensor as a consumable component, which is assembled with a transmitter and then worn on the body to transmit blood glucose data. However, the sensor and transmitter components make the CGM device bulky and susceptible to collisions and friction with external objects. This can cause the sensor probe to shift relative to the tissue where it is worn. This can cause inflammation, potentially affecting the accuracy of blood glucose data, or even cause the entire sensor to fall off. Therefore, reducing the size of CGM devices, particularly their thickness, to mitigate the effects of contact with external objects is crucial. CGM devices are powered by a battery, and battery size is the most significant factor affecting their size. Encapsulating the battery 4 and conductive plate 5 within the sensor base using methods such as injection molding offers the following advantages: 1. Using the battery 4 as a consumable component allows for the selection of a relatively small capacity battery, resulting in a smaller battery size, thus reducing the size of the CGM device. 2. Encapsulating the battery 4 and conductive plate 5 simplifies the waterproof structure, enhancing the waterproof performance and further reducing the size of the CGM device. 3. Using the battery 4 as a consumable component eliminates the need for user replacement, making it more convenient to use.

[0042] like Figure 1 、 Figure 2 、 Figure 3 The sensor probe mounting portion 11 is provided with at least one probe fixing groove 111 , and the upper surface of the conductive plate 5 is exposed at the bottom of the probe fixing groove 111 .

[0043] Thus, the sensor probe is installed at the probe fixing groove 111 , and the sensor probe can be fixed by injecting solidifying glue into the probe fixing groove 111 .

[0044] like Figure 1 、 Figure 2 、 Figure 3 The emitter conductive portion 12 is provided with a conductive groove 121 and a conductive component 122 installed in the conductive groove 121 .

[0045] Therefore, contacts for the positive and negative poles of the battery 4 and connection contacts for the sensor probe are provided in the conduction groove 121, and contacts are also provided at the opposite position at the bottom of the transmitter. After the transmitter and the sensor base are snapped together and connected, the battery 4 supplies power to the transmitter, and the transmitter supplies power to the sensor probe after rectification by the circuit.

[0046] like Figure 4 、 Figure 5 A circular arc-shaped battery receiving notch 51 is provided on one side of the conducting plate 5 , and the battery 4 is installed at the battery receiving notch 51 .

[0047] Thus, the battery 4 is installed in the battery receiving notch 51 , which can reduce the thickness of the sensor base.

[0048] like Figure 4 、 Figure 5 The conductive plate 5 is provided with battery conductive interfaces 52 on both sides of the battery accommodating notch 51; the positive and negative poles of the battery 4 are respectively welded with metal welding pieces 41, the thickness of the metal welding pieces 41 does not exceed 0.5 mm, and after bending, they are connected to the two battery conductive interfaces 52 for conduction.

[0049] Therefore, the battery 4 can reduce the thickness of the sensor base through the metal welding piece 41 and the battery conductive interface 52.

[0050] like Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 A probe conductive pad 53 is provided on the conductive plate 5 in the probe fixing groove 111, a probe conductive through-hole 531 is provided in the middle of the probe conductive pad 53, a probe through-hole 112 is provided at the bottom of the sensor probe mounting portion 11 at a position opposite to the probe conductive through-hole 531, and the probe through-hole 112 and the probe conductive through-hole 531 are opposite to each other.

[0051] Thus, the sensor probe passes through the probe through-hole 112 and the probe conductive through-hole 531 and is conductively connected to the probe conductive pad 53 by welding or injecting conductive glue.

[0052] like Figure 1 、 Figure 4 The conductive plate 5 is provided with a plurality of conductive contacts 54 at the conductive groove 121 , the battery conductive interface 52 is connected to the conductive contacts 54 through the wiring in the conductive plate 5 , and the conductive pad 53 is connected to the conductive contacts 54 through the wiring in the conductive plate 5 .

[0053] Therefore, the conducting board 5 is generally a PCB board, and the conducting contacts 54 are all located in the conducting groove 121 to facilitate conduction with the transmitter, and only the conducting groove 121 needs to be waterproofed to improve the waterproof performance of the conductive part.

[0054] like Figure 2 、 Figure 3 、 Figure 6The conductive component 122 includes a conductive silicone rubber 1221 and an elastic seal 1222. Multiple conductive silicone rubbers 1221 are respectively arranged at positions relative to the conductive contacts 54. The elastic seal 1222 is filled in the conductive groove 121 and the top is higher than the notch of the conductive groove 121. After the main body of the conductive silicone rubber 1221 passes through the elastic seal 1222, the elastic seal 1222 is exposed at the top.

[0055] Thus, the bottom of the conductive silicone 1221 is connected to the conductive contact 54, and the top is connected to the contact on the emitter after being snapped into connection with the emitter, and the elastic seal 1222 is squeezed by the contact surface of the emitter to form a seal.

[0056] like Figure 3 、 Figure 6 The bottom area of ​​the conductive silicone 1221 is larger than the top area, and the elastic sealing member 1222 has a perforation with the same cross-section as the conductive silicone 1221 .

[0057] Therefore, the bottom area of ​​the conductive silicone 1221 is larger than the top area, so that it will not fall out from the bottom to the top after being installed in the elastic seal 1222, and the conductive silicone 1221 can be prevented from falling during transportation and disassembly; the conductive silicone 1221 can be a structure with a "convex" vertical cross-section, and the elastic seal 1222 is insulating rubber, and the bottom is bonded to the bottom of the conductive groove 121 by adhesive, thereby ensuring that the elastic seal 1222 and the conductive silicone 1221 are installed in the conductive groove 121 and will not fall off.

[0058] A method for manufacturing a sensor base, comprising the following manufacturing steps:

[0059] Step A: welding the metal welding sheet 41 to the battery 4;

[0060] Step B: Install the battery 4 and the metal welding piece 41 assembly in the battery receiving notch 51 of the conductive plate 5;

[0061] Step C: Weld the other end of the metal welding piece 41 to the battery conductive interface 52 of the conductive plate 5;

[0062] Step D: Injection mold the entire assembly of the conducting plate 5, the battery 4, and the metal welding piece 41 at a temperature of 130°C to 150°C, with the temperature above 100°C for no more than 8 seconds during the injection molding process, and the injection molding thickness is 0.3mm-0.6mm;

[0063] Step E: injecting the component after the first injection molding again at an injection molding temperature of 150° C. to 250° C.

[0064] In step A, the welding temperature between the metal welding sheet 41 and the battery 4 does not exceed 200°C, and the duration of the temperature above 150°C during the welding process does not exceed 5 seconds, thereby ensuring that the battery 4 will not be damaged due to excessive temperature; steps B and C require the use of a positioning mechanism to position the conductive plate 5 and the battery 4 to ensure that the relative positions have high consistency after welding as a whole; the injection molding process of step D ensures that the temperature is within the range that will not damage the battery 4, and first injects a layer of 0.3mm-0.6mm protective layer to ensure that the temperature of the molding injection in step E will not affect the battery 4.

[0065] The embodiments described above are merely descriptions of preferred embodiments of the present invention and are not intended to limit the concept and scope of the present invention. Any modifications and improvements to the technical solution of the present invention made by a person of ordinary skill in the art without departing from the design concept of the present invention shall fall within the scope of protection of the present invention. The technical content for which protection is sought in the present invention is fully set forth in the claims.

Claims

1. A method for manufacturing a sensor base, characterized in that: The sensor comprises a main body (1), a battery receiving portion (2) and a buckle portion (3) located on two opposite sides of the main body (1), wherein the main body (1), the battery receiving portion (2) and the buckle portion (3) are an integrated structure; a sensor probe mounting portion (11) and a transmitter conducting portion (12) are provided on the main body (1); a battery (4) and a conducting plate (5) are further provided inside the sensor base, wherein the battery (4) is located inside the battery receiving portion (2), and the conducting plate (5) is located inside the battery receiving portion (2) and the main body (1); The sensor probe mounting portion (11) is provided with at least one probe fixing groove (111), and the upper surface of the conductive plate (5) is exposed at the bottom of the probe fixing groove (111); The transmitter conducting portion (12) is provided with a conducting slot (121) and a conducting component (122) installed in the conducting slot (121); A circular arc-shaped battery accommodating notch (51) is provided on one side of the conduction plate (5), and the battery (4) is installed in the battery accommodating notch (51); The conduction plate (5) is provided with battery conduction interfaces (52) on both sides of the battery receiving notch (51); the positive and negative electrodes of the battery (4) are respectively welded with metal welding sheets (41), the thickness of the metal welding sheets (41) does not exceed 0.5 mm, and after being bent, they are connected to the two battery conduction interfaces (52) for conduction; A probe conductive pad (53) is provided on the conductive plate (5) at a position inside the probe fixing groove (111), a probe conductive through-hole (531) is provided in the middle of the probe conductive pad (53), a probe through-hole (112) is provided at a position opposite to the probe conductive through-hole (531) at the bottom of the sensor probe mounting portion (11), and the probe through-hole (112) and the probe conductive through-hole (531) are interpenetrating. The conducting plate (5) is provided with a plurality of conducting contacts (54) at the conducting groove (121); the battery conducting interface (52) is connected to the conducting contacts (54) through wiring in the conducting plate (5) for conduction; and the conductive pad (53) is connected to the conducting contacts (54) through wiring in the conducting plate (5) for conduction; The conducting component (122) comprises a conductive silicone rubber (1221) and an elastic sealing member (1222), wherein a plurality of the conductive silicone rubbers (1221) are respectively arranged at positions relative to the conducting contacts (54), the elastic sealing member (1222) is filled in the conducting groove (121) and the top thereof is higher than the notch of the conducting groove (121), and the conductive silicone rubber (1221) body passes through the elastic sealing member (1222) and the top thereof is exposed to the elastic sealing member (1222); The bottom area of ​​the conductive silicone rubber (1221) is larger than the top area, and the elastic sealing member (1222) has a through hole with the same cross-section as the conductive silicone rubber (1221); The manufacturing steps include: Step A, welding the metal welding sheet (41) and the battery (4); Step B, installing the battery (4) and the metal welding sheet (41) assembly at the battery receiving notch (51) of the conductive plate (5); Step C, welding the other end of the metal welding sheet (41) to the battery conduction interface (52) of the conduction plate (5); Step D: injection molding the entire assembly of the conductive plate (5), the battery (4) and the metal welding sheet (41), with the injection molding temperature being 130° C. to 150° C., the temperature being above 100° C. for no more than 8 seconds during the injection molding process, and the injection molding thickness being 0.3 mm to 0.6 mm; Step E: injecting the component after the first injection molding again at an injection molding temperature of 150° C. to 250° C.

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