Bio-Signal Holder Assembly With Sealed Self-Positioning Connector
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Solution Overview
Problem
Existing methods for assembling bio-signal devices with electrically conductive contact structures are costly, time-consuming, and prone to yield issues, particularly in the over-molding and use of special jigs for disposable electrodes.
Innovation Solution
A simplified assembly process using a holder apparatus with interlocking features and a sealant filler, eliminating the need for over-molding and complex jigs, allowing for a streamlined production flow and cost-effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If over-molding is used to assemble the holder with the electrically conductive contact structure, then the assembly is mechanically reliable, but the production cost increases and production time is extended
Solution Approach 1:
The assembly is divided into separate components: the holder and the electrically conductive contact structure are assembled as distinct parts using a simplified jig, rather than being formed as a single integrated piece through over-molding. This segmentation enables faster, more cost-effective assembly while maintaining mechanical reliability through precise positioning features.
2Manufacturing precision
If special jigs are used to hold the holder and electrically conductive contact structure assembly, then positioning accuracy is improved, but the device complexity and cost increase
Solution Approach 1:
The holder and contact structure components incorporate self-positioning features such as recesses, protrusions, and alignment guides that automatically ensure correct positioning during assembly. This self-service mechanism eliminates the need for complex external jigs, reducing device complexity and cost while maintaining manufacturing precision.
3Reliability
If multiple assembly phases are used to construct the holder with contact structure, then the assembly is more reliable, but the production time and cost increase
Solution Approach 1:
Multiple assembly operations are merged into a single phase: the electrically conductive contact structure is inserted into the holder, positioned using self-aligning features, and secured with adhesive all in one continuous operation. This consolidation reduces production time and complexity while maintaining assembly reliability through integrated design features.
4Ease of manufacture
If adhesive is used to fix the electrically conductive contact structure, then the assembly is simplified, but the mechanical strength may be reduced
Solution Approach 1:
The bonding system uses a composite approach combining mechanical interlocking features (recesses, protrusions, alignment guides) with adhesive bonding. This composite method maintains mechanical strength through physical interlocking while preserving assembly simplicity through the use of adhesive, achieving both ease of manufacture and bond strength.
Data Source
Figure 1A~2
Figure 3~5
Figure 6~7
AI summary
A holder apparatus (10) of a bio-signal device comprises a holder (100), which comprises a pocket (100A) for a bio-signal processing device (200), an extension (100B) with a hollow (100C), the hollow (100C) and the pocket (100A) forming a continuous cavity (101) through the holder (100), a connector (106), and an elastic seal (108) with a hole (108A). A shape of the elastic seal (108) is matched with a shape of the hollow (100C) of the extension (100B) at an interface of the pocket (100A), and the hollow (100C) and a shape of the hole (108A) is matched with a shape of the connector (106) for sealing an interface between the connector (106) and the holder (100) while the connector (106) and the elastic seal (108) are within the hollow (100C) and the connector (106) is in contact with the elastic seal (108). Sealant filler (204) fills the hollow (100C) of the extension (100B) and is in physical contact with the connector (106), which is in the hollow (100C) against the seal (108), the elastic seal (108) and the sealant filler (204) allowing the connector (106) to mate electrically with a counter-connector (202) moved within the cavity (101) in a direction from the pocket (100A) toward the hollow (100C).