Jig for assembling position sensors

Abstract

The jig 55 includes a base 90 and one or more movable blocks 77A, 77B, 77C, and 77D. The base 90 has a top surface 92 configured to receive a substrate 99 shaped as a flattened polyhedron having a plurality of facets 88A, 88B, 88C, 88D, and 88F. The one or more movable blocks 77A, 77B, 77C, and 77D are configured to move over the base 90 to fold a respective one of the facets 88A, 88B, 88C, 88D, 88E, and 88F and to hold the substrate 99 in the folded three-dimensional configuration.

Description

[Technical field]

[0001] The present invention relates generally to assembly tools, and more particularly to methods and systems for assembling position sensors. [Background technology]

[0002] Several electronic devices include foldable substrates that are assembled using a variety of techniques.

[0003] For example, US Patent Application Publication No. 2014 / 0090243 describes a method for manufacturing a device built on a flexible substrate using an in-situ folding assist device frame. The folding assist frame fits into a portion of the interior volume within the package so that one or more pivot members of the frame can be used as an in-situ bending jig to support and fold the planar flexible substrate into a desired three-dimensional configuration, instead of a conventional bending device. The frame can accommodate an arrangement of an unfolded or partially folded flexible circuit board, such as a folding assist feature such as a hinge incorporated in the frame that is attached to the flexible circuit board and closes around a pivot point to gently bend the circuit board into place, thus creating a three-dimensional folded circuit.

[0004] No. 5,434,362 describes a flexible circuit board assembly including a flexible substrate having first and second ends and an intermediate portion. Conductive metallized interconnect paths extend across the intermediate portion between the substrate ends. The first and second ends of the substrate are attached to the first and second ends of a stiffener plate. Summary of the Invention [Means for solving the problem]

[0005] Embodiments of the invention described herein provide a jig that includes a base and one or more moveable blocks. The base has an upper surface configured to receive a substrate shaped as a flattened polyhedron having a plurality of facets. The one or more moveable blocks are configured to move over the base to fold respective ones of the plurality of facets and to hold the substrate in the folded three-dimensional configuration.

[0006] In some embodiments, the base includes at least a track for moving at least one of the moveable blocks. In other embodiments, the substrate includes a bendable section between adjacent facets, and at least one of the moveable blocks is configured to bend the bendable section and secure one of the adjacent facets to a respective solid facet of the solid polyhedron. In yet other embodiments, the jig includes a fixture configured to secure at least one of the moveable blocks in a predetermined position on the base.

[0007] In one embodiment, the jig is secured to the base and includes a knob configured to secure at least one of the facets to a respective solid facet of the solid polyhedron. In another embodiment, the jig is configured to be secured to the base and includes a mechanical support portion having a bore, the knob configured to pass through the bore, and a distal end of the knob configured to be moved toward the solid polyhedron to secure at least one of the facets to the respective solid facet. In yet another embodiment, the mechanical support includes a bridge over the solid polyhedron, the bore being aligned with the respective solid facet when the bridge is secured to the base.

[0008] In some embodiments, the knob includes a screw and the bore includes a threaded bore configured to fit snugly over the screw. In other embodiments, the knob is configured to be rotated in opposite first and second directions, the distal end configured to move toward the solid polyhedron when the knob is rotated in the first direction and the distal end configured to move away from the solid polyhedron when the knob is rotated in the second direction. In yet other embodiments, the substrate comprises an upper facet, a lower facet, and one or more additional facets, the solid polyhedron is positioned on the lower facet, the one or more moveable blocks are configured to secure a respective one of the additional facets to a respective solid facet of the solid polyhedron, and the jig includes a knob configured to secure the upper facet to the upper solid facet of the solid polyhedron.

[0009] There is further provided, in accordance with an embodiment of the present invention, a method of assembly including placing a substrate shaped as a flattened polyhedron having a plurality of facets on an upper surface of a base, positioning a solid polyhedron on at least one of the facets, and moving one or more moveable blocks over the base for folding a respective one of the plurality of facets onto a respective solid facet of the solid polyhedron to hold the substrate in a folded three-dimensional configuration relative to the solid polyhedron.

[0010] In some embodiments, the method includes bonding adjacent edges of the folded facets together to encase the polyhedron with the substrate, hi other embodiments, bonding the adjacent edges includes using a bonding technique selected from the list consisting of: (a) welding, (b) soldering, (c) gluing, (d) stapling, and (e) clipping.

[0011] The invention will be more fully understood from consideration of the following detailed description taken in conjunction with the drawings, in which: [Brief description of the drawings]

[0012] [Figure 1] 1 is a schematic, pictorial illustration of an ear, nose and throat (ENT) procedure using an ENT system, according to one embodiment of the present invention; [Diagram 2] 1 is a schematic, pictorial diagram of a jig for assembling a three-axis position sensor (TAPS), in accordance with one embodiment of the present invention; [Diagram 3] 1 is a schematic, pictorial representation of a TAPS bendable substrate, according to one embodiment of the present invention. [Figure 4] 1 is a schematic, pictorial view of a jig base and block for assembling TAPS, in accordance with one embodiment of the present invention; [Diagram 5] 3 is a flow chart that generally illustrates a method of manufacturing a TAPS using the jig of FIG. 2, in accordance with one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Overview DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments of the present invention described below provide methods and apparatus for improving the manufacturability of position sensors used in magnetic position tracking systems for medical applications.

[0014] In some embodiments, the 3-axis position sensor (TAPS) includes a ferrite cube, also referred to herein as a solid cube or cube, that is wrapped with a bendable substrate, such as a flexible printed circuit board (PCB) having multiple bendable facets. Wrapping the solid cube with the PCB involves folding the PCB facets onto respective facets of the solid cube and bonding between the edges of the PCB facets to secure the PCB facets to the facets of the solid cube. Such complex and time-consuming operations may be performed manually (e.g., by an operator) or using one or more robots.

[0015] In some embodiments, a jig for assembling TAPS is provided. The jig includes a base having a top surface and four tracks patterned into the base. The base is configured to receive a PCB shaped as a flattened cube having six facets, also referred to herein as facets 1-6. During the assembly process, the cube is placed onto the first facet of the PCB.

[0016] In some embodiments, the jig comprises four moveable blocks configured to move along respective four tracks of the base to fold the second, third, fourth, and fifth facets of the PCB onto the four solid facets of the cube, respectively, The base and each block have a bore, and the jig comprises four pins for fixing each of the four blocks in place on the base to hold the PCB in a folded three-dimensional configuration against the solid facets of the cube.

[0017] In some embodiments, the jig comprises a fixture having a bridge secured to a base and a knob configured to move through a bore in the bridge to secure the sixth PCB facet to the cube.

[0018] In some embodiments, when the block and fixture are secured to the base, the jig is configured to secure all of the PCB facets to their respective cube facets. In such embodiments, the operator's hands are free to join (e.g., weld, solder, or glue) the edges of adjacent PCB facets to complete the PCB wrapping of the cube.

[0019] The disclosed techniques improve assembly quality and reduce production costs of devices or components encased in foldable substrates.

[0020] System Description 1 is a schematic pictorial diagram of an ear, nose and throat (ENT) procedure using an ENT system 20, according to one embodiment of the present invention. In some embodiments, the ENT procedure is a balloon sinuplasty procedure in which a balloon (not shown) is inserted into a clogged ostium of a sinus 48 and inflated to open the ostium and allow normal flow and drainage of mucus from the sinus through the nasal cavity 26 of the patient 22. In other embodiments, the ENT procedure may include any other diagnostic or therapeutic procedure performed in the patient's ENT. In such an embodiment, the ENT system 20 includes a medical catheter, which in this example is an ENT tool 28, configured to perform one or more types of ENT procedures on one or more sinuses 48 of the patient 22.

[0021] In some embodiments, the ENT tool 28 comprises a rotatable hollow tube (referred to herein as tube 52) that is inserted by the physician 24 into a cavity, such as the aforementioned nasal cavity 26, of the patient 22. The ENT tool 28 further comprises a handheld device 30 coupled to a proximal end of the tube 52, the handheld device 30 being configured to assist the physician 24 in performing the ENT procedure on the head 41 of the patient 22.

[0022] In one embodiment, system 20 further comprises a magnetic position tracking system configured to track the position of one or more position sensors in head 41. The magnetic position tracking system comprises a magnetic field generator 44 and a position sensor 57 that generates a position signal in response to sensing an external magnetic field generated by magnetic field generator 44, thereby enabling processor 34 (described in more detail below) to estimate the position of position sensor 57 within head 41 of patient 22.

[0023] This method of location sensing has been implemented in a variety of medical applications, for example in the CARTO™ system manufactured by Biosense Webster Inc. (Irvine, Calif.), and is described in detail in U.S. Pat. Nos. 5,391,199, 6,690,963, 6,484,118, 6,239,724, 6,618,612, and 6,332,089, WO 96 / 05768, and U.S. Patent Application Publication Nos. 2002 / 0065455(A1), 2003 / 0120150(A1), and 2004 / 0068178(A1), the disclosures of all of which are incorporated herein by reference.

[0024] In some embodiments, system 20 further comprises a localization pad 40 comprising magnetic field generators 44 fixed on a frame 46. In the exemplary configuration shown in FIG. 1 , pad 40 comprises five magnetic field generators 44, but may alternatively comprise any other suitable number of magnetic field generators 44. Pad 40 further comprises a pillow (not shown) positioned under head 41 of patient 22 such that magnetic field generators 44 are located at fixed, known positions external to head 41.

[0025] In some embodiments, the system 20 comprises a console 33 comprising a memory 49 and a drive circuit 42 configured to drive a magnetic field generator 44 with a suitable signal via a cable 37 to generate a magnetic field within a predetermined working volume in the space surrounding the head 41.

[0026] In some embodiments, the console 33 includes a processor 34, which is typically a general-purpose computer with suitable front-end and interface circuitry for receiving signals from the ENT tool 28 to which the one or more magnetic sensors 57 are coupled via cable 32, and for controlling the other components of the system 20 described herein.

[0027] In some embodiments, the processor 34 is configured to estimate a position of each position sensor 57. Based on the estimated position of each sensor in the coordinate system of the magnetic position tracking system, the processor 34 is configured to derive the position, orientation, and radius of curvature of the distal end assembly 77.

[0028] In the context of the scope of the present invention, the terms “flexion” and “deflection” are used interchangeably and refer to the steering of one or more segments of the ENT tool 28 .

[0029] In some embodiments, the processor 34 is configured to receive one or more anatomical images via an interface (not shown), such as computed tomography (CT) images depicting respective segmented two-dimensional (2D) slices of the head 41, acquired using an external CT system (not shown). The term "segmentation" refers to displaying the different types of tissue identified within each slice by measuring the respective attenuation of the tissues in the CT system.

[0030] The console 33 further comprises an input device 39 for controlling the operation of the system 20, and a user display 36 configured to display data (e.g., images) received from the processor 34 and / or to display inputs inserted by the physician 24 or a user of the input device 39.

[0031] In some embodiments, the processor 34 is configured to select one or a modal slice from within a CT image, such as the anatomical image 35, and display the selected slice on the user display 36. In the example of FIG. 1, the anatomical image 35 illustrates an anterior cross-sectional view of one or more paranasal sinuses 48 of the patient 22.

[0032] In some embodiments, the processor 34 is configured to be aligned between the coordinate system of the CT system and the coordinate system of the magnetic position tracking system and to overlay the position of the distal end assembly 77 onto the anatomical image 35.

[0033] In some cases, the head 41 of the patient 22 may be unnecessarily moved during an ENT procedure. The unwanted movement may result in a misalignment between the coordinate system of the CT system and the coordinate system of the magnetic position tracking system. In some embodiments, the system 20 includes a position tracking assembly (PTA) 70 that is coupled to the forehead of the patient 22 or to any suitable position on the head 41.

[0034] Reference is now made to inset 56, which illustrates PTA 70. In some embodiments, PTA 70 includes a three-axis position sensor (TAPS) 11 coupled to console 33 via cable 54 and configured to generate a position signal in response to sensing an external magnetic field generated by magnetic field generator 44.

[0035] In some embodiments, the processor 34 is configured to align the TAPS 11 to the coordinate system of the position tracking system (e.g., prior to an ENT procedure). Note that the head 41 is considered a rigid object, and thus, when the ENT tool 28 is positioned on the head 41 without moving, the distance between the position sensor 57 and the TAPS 11 remains constant.

[0036] In some embodiments, in response to the aforementioned undesired movement of head 41, processor 34 is configured to use the position signal of TAPS 11 to correct the aforementioned misalignment. In such embodiments, based on the position signal received from TAPS 11, processor 34 is configured to estimate a shift of TAPS 11 caused by the undesired movement of head 41 and compensate for the shift by adding an offset (e.g., a vector) to the measured position of position sensor 57.

[0037] In the exemplary configuration of inset 56, TAPS 11 is mounted on a substrate 58 that is configured to be coupled to the forehead of patient 22. In other configurations, TAPS 11 may be coupled to head 41 using any suitable technique. TAPS 11 and its assembly process are described in more detail in Figures 2-5 below.

[0038] System 20 typically includes additional modules and elements that are not directly relevant to the disclosed technology and, therefore, have been intentionally omitted from FIG.

[0039] The processor 34 may be programmed with software to perform functions used by the system and to store in memory 49 data processed or otherwise used by the software. This software may be downloaded to the processor in electronic form, for example over a network, or may be provided on a non-transitory tangible medium, such as an optical, magnetic, or electronic memory medium. Alternatively, some or all of the functions of the processor 34 may be performed by dedicated or programmable digital hardware components.

[0040] This particular configuration of system 20 is provided as an example to explain the particular problem that embodiments of the present invention address and to demonstrate the application of these embodiments in improving the performance of such systems, however, embodiments of the present invention are not limited to this particular type of exemplary system and the principles described herein may be applied to other types of medical diagnostic and / or treatment tools and / or systems as well.

[0041] Jig for assembling 3-axis position sensors 2 is a schematic, pictorial diagram of a jig 55 for assembling a three-axis position sensor (TAPS) 11, according to one embodiment of the present invention. In some embodiments, the TAPS 11 comprises a polyhedron typically made from or including ferrite or any other suitable material, or one or more alloys.

[0042] In this example, TAPS11 includes a ferrite cube (shown in FIG. 4 below) surrounded by (e.g., encapsulated in) a flexible printed circuit board (PCB) (shown in FIG. 3 below) having conductive traces to enable the three-axis position sensing capability of TAS11.

[0043] In some embodiments, jig 55 has a base 90 having a top surface 92 and four tracks, such as tracks 80A and 80B, formed (e.g., patterned) in base 90. The tracks are shown and described in more detail in FIG. 4 below. Base 90 is configured to receive a substrate, such as the PCB mentioned above, that is shaped as a flattened polyhedron having multiple facets. In this example, TAPS 11 includes a cube, such that the substrate is shaped as a flattened cube having six facets.

[0044] In some embodiments, jig 55 comprises four blocks 77A, 77B, 77C, and 77D configured to move along the aforementioned tracks on top surface 92 of base 90 to fold each one of the cubic facets. For example, blocks 77A and 77B move along tracks 80A and 80B, respectively. In the example of FIG. 2, block 77A is shown as a transparent element to illustrate TAPS 11 for conceptual clarity. In other embodiments, block 77A moved along track 80A has the same shape, color, and opacity as blocks 77B, 77C, and 77D.

[0045] In some embodiments, when coupled to the ferrite cube (as shown in FIG. 2), blocks 77A, 77B, 77C, and 77D are configured to hold the facets of the substrate in a folded three-dimensional configuration relative to respective solid facets of the ferrite cube. Further, when secured in place on base 90, blocks 77A, 77B, 77C, and 77D are configured to secure the four facets of the substrate to respective solid facets of the ferrite cube.

[0046] In the context of this disclosure and in the claims, the terms "substrate" and "PCB" are used interchangeably. Additionally, the terms "polyhedron" and "cube", which is a specific type of polyhedron, are used interchangeably. It should be noted that in the examples of Figures 2-4, TAPS 11 is shaped as a cube, but the embodiments described herein may be applied mutatis mutandis to fabricate any type of polyhedron. For example, TAPS 11 may be shaped as a pentagon, hexagon, octagon, or any other suitable shape.

[0047] In other embodiments, TAPS 11 may have any suitable shape other than a polyhedron, such as, but not limited to, an elliptical ball.

[0048] In some embodiments, jig 55 comprises a fixture 72 configured to secure a facet of the substrate to a top solid facet (shown in FIG. 4 below) of a ferrite cube of TAPS 11. In some embodiments, fixture 72 comprises a mechanical support, referred to herein as bridge 74, which is secured to top surface 92 at two locations. Bridge 74 is configured to provide mechanical support to knobs 76 that pass through it, as described herein. In some embodiments, knobs 76 are configured to secure at least one of the facets of the substrate to a respective solid facet of the solid cube of TAPS 11.

[0049] In one embodiment, knob 76 is shaped as a screw (not shown) and bridge 74 has a corresponding threaded bore configured to fit snugly over the screw. In this embodiment, when knob 76 is rotated (e.g., clockwise), distal end 84 of knob 76 is configured to push toward the top facet of TAPS 11, securing the respective facet of the substrate to the top facet of the cube.

[0050] In some embodiments, after all facets of the substrate are secured to their respective solid facets of the cube, edges of adjacent facets of the substrate may be joined together (e.g., using welding, soldering, adhesive bonding, or any other suitable technique) to complete the assembly of TAPS 11. The assembly process is described in more detail in FIG. 5 below.

[0051] This particular configuration of jig 55 is presented as an example to explain the particular problems addressed by embodiments of the present invention and to demonstrate the application of these embodiments in improving the performance of such jigs for assembling TAPS 11 and other types of devices. However, embodiments of the present invention are by no means limited to this particular type of exemplary jig, and the principles described herein may be applied to other types of jigs and devices to be assembled as well.

[0052] For example, if TAPS 11 is molded as a volume hexagon having a bottom facet, a top facet, and six additional facets, jig 55 may have six tracks and six respective blocks for holding the six facets of the substrate against the six additional facets of the volume hexagon. In another example, if TAPS 11 is molded as a ball, at least one edge of the blocks (contacting the ball) may be molded as an arc to fit snugly onto the ball to hold a section of the substrate against the surface of the ball.

[0053] Base material for assembling 3-axis position sensors 3 is a schematic, pictorial illustration of a bendable substrate used to fabricate TAPS 11, according to one embodiment of the present invention. In this example, the bendable substrate comprises a printed circuit board (PCB) 99 having a number of bendable sections, such as section 94, disposed between six facets 88A, 88B, 88C, 88D, 88E, and 88F that correspond to the six solid facets of the aforementioned solid cube of TAPS 11 (shown in FIG. 4 below).

[0054] In some embodiments, facets 88A-88F may be flexible or rigid, but section 94 is flexible to allow folding of facets 88A-88F around the cube of TAPS 11. Note that facet 88E, which is intended to be fixed to the bottom solid facet of the cube of TAPS 11, is surrounded by four sections 94.

[0055] In some embodiments, facets 88A-88F have edges configured to be bonded together. For example, facets 88C and 88D are bonded together by bonding between edge 97A of facet 88C and edge 97B of facet 88D. Similarly, facets 88C and 88F are bonded together by bonding between edge 97C of facet 88C and edge 97D of facet 88F. After all facets 88A-88F are secured to respective solid facets of the cube as described above, edges of adjacent facets of PCB 99 (e.g., edges 97A and 97B of respective facets 88C and 88D) may be bonded together to complete assembly of TAPS 11.

[0056] In some embodiments, the bond between adjacent edges may be performed using one or more bonding techniques, such as, but not limited to, welding, microwelding, soldering, gluing, stapling, clipping, or any other suitable technique.

[0057] In some embodiments, one or more facets of PCB 99 may have bands for the bonding process. In the example of Figure 3, facets 88A, 88C, and 88F have bands 95 configured to bond adjacent facets of PCB 99 to one another. The assembly process is described in more detail in Figure 5 below.

[0058] Mechanical structure of the base of the jig for assembling the 3-axis position sensor 4 is a schematic, pictorial illustration of a base 90 and blocks 77B and 77C of jig 77, according to one embodiment of the invention. In some embodiments, base 90 has tracks 80A, 80B, 80C, and 80D configured to set corresponding directions of movement of blocks 77A, 77B, 77C, and 77D, respectively.

[0059] In some embodiments, the base 90 has a bore 82 configured to secure the bridge 74 to the top surface 92 of the base 90, and the bridge 74 in turn has two corresponding bores (not shown) configured to secure the bridge 74 to the top surface 92 of the base 90. In such embodiments, a pin (not shown) can be inserted into each bore 82, and the corresponding bore of the bridge 74 can fit over the pin to secure the bridge 74 to the top surface 92 of the base 90.

[0060] In some embodiments, during the assembly process of TAPS11, PCB 99 is placed on top surface 92 such that facet 88E is positioned at the center of base 90, facets 88A, 88B, 88C, and 88D are positioned on tracks 80A, 80B, 80C, and 80D, respectively, and facet 88F is also coupled to facet 88A and is also positioned on track 80A.

[0061] In some embodiments, after PCB 99 is positioned on surface 92, cube 66 made from or including ferrite is positioned on facet 88E (hidden by cube 66). Blocks 77A-77D then move along tracks 80A-80D to fold respective facets of PCB 99 and hold PCB 99 in a folded three-dimensional configuration against respective facets of cube 66. In the example of FIG. 4, block 77C has already been moved along track 80C of base 90 and reaches cube 66 to fold and hold facet 88A against a corresponding solid facet of cube 66.

[0062] In some embodiments, block 77B is moved in direction 86 along track 80B to fold and hold facet 88B against solid facet 66B of cube 66. As shown in FIG. 4, facet 88B has been folded by the movement of block 77B, but is not yet secured to solid facet 66B, because block 77B has not yet reached solid facet 66B.

[0063] In some embodiments, base 90 has bores, such as bores 83A, 83C, and 83D, for fixing the position of each block (e.g., blocks 77A, 77C, and 77D) to top surface 92 of base 90. Note that base 90 has an additional bore for fixing block 77B to top surface 92 of base 90. In the example of FIG. 4, the additional bore is hidden by block 77B.

[0064] In some embodiments, at least one of blocks 77A-77D has a bore for securing the respective block to top surface 92 of base 90. In this configuration, all blocks 77A-77D have respective bores, for example, block 77C (shown as a transparent block for purposes of illustration and conceptual clarity) has bore 78C. In the example of FIG. 4, bore 78C (in block 77C) and bore 83C (in base 90) are aligned when block 77C holds facet 88C against a corresponding solid facet of cube 66.

[0065] In some embodiments, a robot or an operator of jig 55 (neither shown) can insert pin 79C (shown in dashed lines for illustrative and conceptual clarity) through bores 78C and 83C to secure block 77C to top surface 92 and thus secure facet 88C to a solid facet of cube 66. In the case of manual securement, after inserting pin 79C through bores 78C and 83C, block 77C is secured to top surface 92 and the operator's hand is free to insert and move block 77B in direction 86. In such an embodiment, by moving block 77B along track 80B in direction 86, jig 55 folds facet 88B (shown as a dashed arc) and once block 77B reaches the position of cube 66, facet 88B is secured to solid facet 66B of cube 66.

[0066] In the context of this disclosure and the claims, the terms “fixed to” and “held against” are used interchangeably and are used to describe how jig 55 is used to effect a bond between a facet of PCB 99 and a corresponding facet of cube 66.

[0067] In some embodiments, blocks 77A and 77D (shown in FIG. 2 above) are configured to move along respective tracks 80A and 80D such that facets 88A and 88D are secured to respective solid facets of cube 66, using the techniques described for facets 77B and 77C. As described above, cube 66 is positioned on facet 88E such that facets 88A-88D are secured to corresponding facets of cube 66. An operator (or robot) can then fold facet 88F over solid facet 66F of cube 66 and rotate knob 76 (e.g., clockwise), moving distal end 84 toward cube 66 to secure facet 88F to solid facet 66F.

[0068] After all facets 88A-88F are held in their folded three-dimensional configuration and secured to their respective solid facets of cube 66, an operator (or robot) may complete the assembly process by bonding the edges of adjacent facets together, for example, by bonding between edges 97A and 97B of respective facets 88C and 88D, as described above.

[0069] Assembly process of 3-axis position sensor 5 is a flow chart that generally illustrates a method for manufacturing TAPS 11 using jig 55, according to one embodiment of the present invention. The method begins with substrate placement step 100, in which a PCB 99 having six facets (e.g., facets 88A-88F), or any other suitable foldable substrate, is placed on top surface 92 of base 90 of jig 55.

[0070] In a cube placement step 102, a cube 66 or any other suitable type of solid polyhedron is placed on facet 88E (also referred to herein as the first facet of PCB 99) as described in FIG. 4 above. In a first folding step 104, facets 88A, 88B, 88C, and 88D (also referred to herein as the second, third, fourth, and fifth facets of PCB 99) are folded by moving four respective blocks 77A, 77B, 77C, and 77D onto top surface 92 towards cube 66. In a first fixing step 106, facets 88A, 88B, 88C, and 88D are fixed to (e.g., held against) corresponding solid facets of cube 66 using blocks 77A, 77B, 77C, and 77D, respectively.

[0071] In some embodiments, after the facets of PCB 99 are secured, the blocks are secured to base 90 by inserting respective pins through the bores of each block and into respective bores in base 90. For example, as depicted in FIG. 4 above, pin 79C is inserted through bore 78C of block 77C and into bore 83C of base 90 to secure block 90 in a desired position on top surface 92 of base 90.

[0072] In a second folding step 108, facet 88F (also referred to herein as the sixth facet of PCB 99) is folded onto solid facet 66F, which is the top solid facet of cube 66. In a second fastening step 110, facet 88F is fastened to (e.g., held against) solid facet 66F by rotating knob 76 of fastener 72 as described above in Figures 2 and 4, or by using any other suitable technique.

[0073] In an edge bonding step 112, the PCB 99 is assembled into the cube 66 by bonding the edges of adjacent PCB facets together. For example, facets 88C and 88D are bonded together by bonding between their respective edges 97A and 97B, as described above in FIG. 3. Note that the jig 55 is configured to hold the PCB 99 in a folded three-dimensional configuration that wraps around the cube 66, as described above in FIGS. 2-4, such that an operator or robot as previously described is free to bond the edges of fixed facets of the PCB 99.

[0074] 5, the TAPS 11 of FIGS. 1 and 2 above (including the cube 66 encased with the PCB 99) is removed from the jig 11. In some embodiments, removal of the TAPS 11 may be performed by rotating the knob 76 counterclockwise, pulling on a pin (e.g., pin 79C) and moving a respective block (e.g., block 77C) away from the assembled TAPS 11.

[0075] In some embodiments, after concluding the method of FIG. 5, TAPS 11 may be coupled to cable 54 and inserted or molded into any suitable housing configured to be attached to the forehead of patient 22, as described in FIG. 1 above.

[0076] Although the embodiments described herein primarily address assembly position sensors used in medical applications, the methods and systems described herein may be used in other applications, such as in assembling any device wrapped and / or packaged in a bendable substrate.

[0077] Therefore, it will be understood that the above-described embodiments are cited by way of example, and that the present invention is not limited to what has been particularly shown and described above. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described in the above specification, as well as variations and modifications thereof not disclosed in the prior art that would occur to one skilled in the art upon reading the foregoing description. Documents incorporated by reference into this patent application shall be considered an integral part of this application, except that to the extent that any term is defined in such incorporated documents in a manner that is inconsistent with the definition expressly or impliedly made herein, only the definition in this specification shall be considered.

[0078] [Embodiment] (1) A jig, a base having an upper surface configured to receive a substrate shaped as a flattened polyhedron having a plurality of facets; one or more moveable blocks configured to move on the base to fold a respective one of the plurality of facets and to hold the substrate in a folded three-dimensional configuration; Equipped with a jig. (2) The jig of embodiment 1, wherein the base at least includes a track for moving at least one of the movable blocks. (3) The jig of embodiment 1, wherein the substrate includes a bendable section between adjacent facets, and at least one of the movable blocks is configured to bend the bendable section and secure one of the adjacent facets to a respective solid facet of a solid polyhedron. (4) The jig of embodiment 1, further comprising a fixing device configured to fix at least one of the movable blocks in a predetermined position on the base. (5) The jig of embodiment 1, further comprising a knob secured to the base and configured to secure at least one of the facets to a respective solid facet of the solid polyhedron.

[0079] (6) The jig of claim 5, further comprising a mechanical support configured to be secured to the base and having a bore, the knob being configured to pass through the bore, and a distal end of the knob being configured to be moved toward the solid polyhedron to secure the at least one of the facets to the respective solid facet. (7) The jig of claim 6, wherein the mechanical support comprises a bridge on the solid polyhedron, the bores being aligned with the respective solid facets when the bridge is secured to the base. (8) The jig of embodiment 6, wherein the knob comprises a screw and the bore comprises a threaded bore configured to fit snugly over the screw. (9) The jig of embodiment 8, wherein the knob is configured to be rotated in opposite first and second directions, and wherein when the knob is rotated in the first direction, the distal end is configured to move toward the solid polyhedron and when the knob is rotated in the second direction, the distal end is configured to move away from the solid polyhedron. (10) The jig of embodiment 1, wherein the substrate comprises an upper facet, a lower facet, and one or more additional facets, a solid polyhedron is positioned on the lower facet, and the one or more movable blocks are configured to secure each one of the additional facets to a respective solid facet of the solid polyhedron, and the one or more movable blocks comprise knobs configured to secure the upper facet to an upper solid facet of the solid polyhedron.

[0080] (11) An assembly method comprising the steps of: disposing a substrate shaped as a flattened polyhedron having a plurality of facets on an upper surface of the base; positioning a solid polyhedron on at least one of said facets; moving one or more moveable blocks over the base for folding respective ones of the plurality of facets onto respective solid facets of the solid polyhedron; holding the substrate in a folded three-dimensional configuration relative to the solid polyhedron; Including, an assembly method. 12. The method of claim 11, wherein moving the block includes at least moving the block along a track on the base. 13. The method of claim 11, wherein the substrate includes a bendable section between adjacent facets, and moving the block includes bending the bendable section. 14. The method of claim 11, wherein holding the substrate comprises fixing at least one of the movable blocks in a predetermined position on the base. (15) The method of claim 11, comprising fixing at least one of the facets to a respective solid facet of the solid polyhedron.

[0081] (16) The method of claim 15, comprising: fixing a mechanical support having a bore to the base; and moving the knob through the bore toward the solid polyhedron to secure the at least one of the facets to the respective solid facet. (17) The method of embodiment 16, wherein moving the knob includes (i) rotating the knob in a first direction to move a distal end of the knob toward the solid polyhedron, and (ii) rotating the knob in a second direction to move the distal end away from the solid polyhedron. (18) The method of embodiment 11, wherein the substrate comprises an upper facet, a lower facet, and one or more additional facets, and wherein positioning the solid polyhedron comprises positioning the solid polyhedron on the lower facet, and wherein holding the block comprises fixing each one of the additional facets to a respective solid facet of the solid polyhedron, and wherein fixing the upper facet to an upper solid facet of the solid polyhedron. 19. The method of claim 11, further comprising bonding adjacent edges of the folded facets together to encase the polyhedron with the substrate. (20) The method of claim 19, wherein joining the adjacent edges comprises using a joining technique selected from the list consisting of: (a) welding, (b) soldering, (c) adhesive bonding, (d) stapling, and (e) clipping.

Claims

1. It is a jig, a base having an upper surface configured to receive a flat substrate having a plurality of facets that can be assembled into a polyhedron, the substrate being bendable between adjacent facets, the plurality of facets including an upper facet, a lower facet, and one or more additional facets; one or more movable blocks configured to move on the base along the top surface, wherein movement of the one or more movable blocks causes the one or more additional facets to fold relative to the lower facet; Equipped with a jig.

2. The jig of claim 1 , wherein the base comprises at least a track for moving at least one of the one or more moveable blocks.

3. 2. The jig of claim 1 , wherein the substrate comprises a bendable section between adjacent facets, and at least one of the one or more movable blocks is configured to bend the bendable section and secure one of the one or more additional facets to a solid facet of a solid polyhedron having a three-dimensional shape corresponding to the polyhedron.

4. The jig of claim 1 , comprising: a fixing device configured to fix at least one of the one or more moveable blocks in a predetermined position on the base.

5. The jig of claim 1, comprising a knob configured to secure the upper facet to a solid facet of a solid polyhedron having a three-dimensional shape corresponding to the polyhedron.

6. 6. The jig of claim 5, configured to be secured to the base and comprising a mechanical support having a bore, the knob configured to pass through the bore, and a distal end of the knob configured to be moved towards the solid polyhedron to secure the top facet to the solid facet.

7. The jig of claim 6 , wherein the mechanical support comprises a bridge on the solid polyhedron, the bore being aligned with the solid facet when the bridge is secured to the base.

8. The jig of claim 6 , wherein the knob comprises a screw and the bore comprises a threaded bore configured to fit snugly over the screw.

9. 9. The jig of claim 8, wherein the knob is configured to be rotated in opposite first and second directions, the distal end being configured to move toward the solid polyhedron when the knob is rotated in the first direction and the distal end being configured to move away from the solid polyhedron when the knob is rotated in the second direction.

10. The jig of claim 1, wherein a solid polyhedron is positioned on the lower facet, the one or more movable blocks are configured to secure the one or more additional facets to a solid facet of the solid polyhedron, and the one or more movable blocks are configured to secure the upper facet to an upper solid facet of the solid polyhedron, and the jig comprises a knob configured to secure the upper facet to an upper solid facet of the solid polyhedron.

11. 1. A method of assembly comprising: placing a flat substrate having a plurality of facets that can be assembled into a polyhedron on a top surface of a base, the substrate being bendable between adjacent facets, the plurality of facets including a top facet, a bottom facet, and one or more additional facets; positioning a solid polyhedron having a three-dimensional shape corresponding to said polyhedron over said lower facet; moving one or more moveable blocks on the base along the top surface, where movement of the one or more moveable blocks causes the one or more additional facets to fold onto a solid facet of the solid polyhedron; holding the substrate in a folded three-dimensional configuration relative to the solid polyhedron; Including, an assembly method.

12. The method of claim 11 , wherein moving the one or more moveable blocks comprises at least moving the one or more moveable blocks along a track on the base.

13. The method of claim 11 , wherein the substrate includes a bendable section between adjacent facets, and moving the one or more movable blocks includes bending the bendable section.

14. The method of claim 11 , wherein holding the substrate comprises fixing at least one of the moveable blocks in a predetermined position on the base.

15. The method of claim 11 , comprising fastening the top facet to the solid facet of the solid polyhedron.

16. 16. The method of claim 15, comprising: fixing a mechanical support having a bore to the base; and moving a knob through the bore toward the solid polyhedron to secure the top facet to the solid facet.

17. 17. The method of claim 16, wherein moving the knob comprises: (i) rotating the knob in a first direction to move a distal end of the knob toward the solid polyhedron; and (ii) rotating the knob in a second direction to move the distal end away from the solid polyhedron.

18. The method of claim 11, wherein holding the substrate includes fixing the one or more additional facets to the solid facet of the solid polyhedron, and includes fixing the upper facet to an upper solid facet of the solid polyhedron.

19. The method of claim 11 , comprising bonding adjacent edges of the folded one or more additional facets together to encase the solid polyhedron with the substrate.

20. 20. The method of claim 19, wherein joining the adjacent edges comprises using a joining technique selected from the list consisting of: (a) welding, (b) soldering, (c) adhesive bonding, (d) stapling, and (e) clipping.

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