Biosensor Connector Contact Wire Flexing to Reduce Strip Abrasion
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Solution Overview
Problem
Existing biosensor systems face reliability issues due to abrasion between test strip contact pads and meter connector contact wires, leading to reduced longevity and accuracy, especially with repeated insertions and exposure to harsh environments.
Innovation Solution
A connector system with contact wires that flex and engage test strips with a rounded, curved surface to minimize friction and abrasion, using soft conductive materials for plating and optimizing the radius of curvature to reduce normal force and frictional forces during insertion and extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin film test strip patterns with noble metals are used to improve dimensional resolution and edge quality, then manufacturing precision is improved, but reliability deteriorates due to susceptibility to scratching and abrasion
Solution Approach 1:
The patent applies composite materials by combining a rigid connector body with a flexible contact wire made of different materials. The contact wire is formed from a flexible conductive material that can be plated with noble metals, creating a composite structure that combines the electrical conductivity and edge quality of thin film metallization with the flexibility and abrasion resistance of a wire-based structure.
Solution Approach 2:
The patent uses a flexible contact wire that can bend and conform during test strip insertion and removal. This flexibility allows the contact wire to engage and disengage from the test strip contact pad without applying excessive abrasive force, while maintaining reliable electrical contact. The flexible nature of the contact wire resolves the contradiction by preventing the rigidity-induced abrasion that would damage thin film test strip patterns.
2Reliability
If connector contact wire and test strip contact pad are made to ensure reliable electrical connection, then electrical conductivity is improved, but longevity deteriorates due to abrasive contact during repeated insertions
Solution Approach 1:
The patent implements dynamics by making the contact wire flexible rather than rigid. The contact wire can dynamically adjust its position and shape during test strip insertion and removal, bending to accommodate the movement while maintaining electrical contact. This dynamic flexibility reduces the abrasive forces that would otherwise occur between rigid components, thereby extending the longevity of both the connector and test strip while maintaining reliable connection.
Solution Approach 2:
The patent changes the physical parameters of the contact wire by using a flexible conductive material with specific mechanical and electrical properties. The contact wire's flexibility parameter allows it to conform during insertion/removal cycles, reducing friction and wear. Additionally, the contact wire can be plated with noble metals to optimize electrical conductivity while the underlying flexible structure maintains low abrasion, resolving the contradiction between connection reliability and longevity.
3Ease of operation
If test strip miniaturization is performed to reduce sample size, then ease of operation is improved, but reliability deteriorates due to increased susceptibility to abrasion damage
Solution Approach 1:
The flexible contact wire acts as a soft interface that can adapt to the miniaturized test strip dimensions without applying excessive abrasive force. The flexibility allows the contact wire to gently engage the small contact pad area, reducing the risk of scratching or damaging the thin film metallization on miniaturized test strips while maintaining reliable electrical connection for accurate measurement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces abrasion and enhances the reliability and longevity of biosensor systems by minimizing damage to test strips and connectors, allowing for more reliable and accurate measurements with smaller sample sizes.
Implementation Method 1
Upon further insertion, the test strip creates a normal force acting upon the contact wire's distal portion. The normal force deflects the contact wire from its resting position and flexes portions of the contact wire in a spring fashion.
Implementation Method 2
The contact portion of the contact wire that engages the test strip or contact pad has a desired radius of curvature, which may be at least about 3 mm, 4 mm, or 6 mm. Controlling the contact portion's radius of curvature reduces the frictional force that develops between the contact wire and test strip during insertion and removal, and minimizes the resulting abrasion.
Data Source
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AI summary
A connector for establishing electrical connection between a testing device (30) and a test strip (40) with a biological fluid thereon includes a contact pad (42) on the test strip (40), and one or more contact wires in the testing device. When the strip is inserted into the testing device, part of the strip' s end engages a contact portion (72) of a contact wire (60) and deflects it in a direction normal to the direction of insertion. In certain embodiments the radius of curvature (in the direction of insertion) of the contact portion is controlled to reduce abrasion of the strip by the wire. In other embodiments the radius of curvature (perpendicular to the direction of insertion) is controlled to reduce the abrasion of the strip by the wire. Sometimes the contact portion and/or contact pad is plated with a sacrificial material to reduce the coefficient of friction. In other embodiments various numbers of contacts receive the end of the strip substantially simultaneously, or are staggered in rows to distribute the resistance presented.