Electrical Circuit Integration in Medical Devices
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Solution Overview
Problem
Existing methods for integrating electrical circuits, such as sensors, into tools like medical instruments face challenges in achieving a durable, sterilization-safe, and robust connection between different materials, particularly between metal and plastic, while ensuring reliable signal transmission and protection from temperature effects.
Innovation Solution
A method and device that form connecting elements on the integration surface of a first material, such as metal, to enhance adhesion with a second material, like plastic, through machining and additive manufacturing, allowing for a fluid-tight enclosure of electrical circuits and antennas, which can be used for signal transmission and temperature protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical circuits are integrated into composite parts (e.g., metal-plastic), then the durability and sterilization safety are improved, but the manufacturing complexity increases
Solution Approach 1:
The device is divided into distinct segments: a first part (e.g., metal tool body) and a second part (e.g., plastic handle) that are joined together. The electrical circuit is integrated into this segmented structure, allowing each segment to be manufactured separately and then assembled, which reduces overall manufacturing complexity while maintaining reliability
Solution Approach 2:
The invention uses composite materials by joining a first material (metal) and a second material (plastic) to form a composite part. The electrical circuit is embedded in this composite structure, leveraging the advantages of both materials (strength from metal, ease of processing and sterilization from plastic) while achieving durable integration
2Strength
If connecting elements are formed in the interface region between materials, then the adhesion between materials is improved, but the manufacturing steps increase
Solution Approach 1:
Connecting elements (such as recesses, protrusions, or mechanical interlocks) are pre-formed in the interface region during the manufacturing process. This preliminary structuring of the interface ensures strong adhesion when the first and second parts are joined, while the elements themselves can be manufactured using standard machining or molding techniques
Solution Approach 2:
The connecting elements are integrated into the interface region between the first and second parts, merging the joining function with the structural design. This combination allows the connecting elements to serve both as mechanical joints and as part of the overall device geometry, reducing the need for separate joining components
3Object-affected harmful factors
If the electrical circuit is fluid-tightly enclosed, then the protection from temperature effects and sterilization is improved, but the enclosure complexity increases
Solution Approach 1:
The electrical circuit is nested within the second part (e.g., plastic handle), which itself is joined to the first part (e.g., metal tool body). This nested arrangement provides multiple levels of protection: the plastic enclosure protects from temperature effects and mechanical damage, while the overall composite structure enables sterilization safety
Solution Approach 2:
The second part (plastic material) acts as an intermediary between the electrical circuit and the external environment. This intermediary material provides fluid-tight enclosure that protects the electrical circuit from temperature effects while allowing the overall device to be sterilized, without requiring complex sealing mechanisms
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
This approach enables a durable, long-lasting, and sterilization-safe integration of electrical circuits in tools, providing reliable signal transmission and protection from high temperatures, while maintaining the tool's functionality and ease of sterilization.
Implementation Method 1
a plurality of connecting elements are formed in the interface region between the two materials from a first of the materials to increase adhesion between the materials
Implementation Method 2
These recesses can be filled with the second material during its application, such as injection molding, thus enabling a robust grip or anchoring of the second material to the connecting elements
Implementation Method 3
applying a volume of the second material at least over the integration surface to fluid-tightly enclose the electrical circuit
Implementation Method 4
applying a volume of the second material at least over the integration surface to fluid-tightly enclose the electrical circuit
Implementation Method 5
These recesses can be filled with the second material during its application, such as injection molding, thus enabling a robust grip or anchoring of the second material to the connecting elements
Data Source
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AI summary
The invention relates to a method for integrating an electrical circuit (130) into a device (100). The device (100) has an integration surface (112) consisting of a first material (110). The method according to the invention comprises a step of processing the integration surface (112) in order to form connection elements (114) in order to increase an adhesion of a second material (120) to the integration surface (112). The second material (120) differs from the first material (110). The method also comprises a step of arranging the electrical circuit (130) adjacent to the processed integration surface (112). The method furthermore comprises a step of applying a volume of the second material (120) at least over the integration surface (112) in order to enclose the electrical circuit (130) in a fluid-tight manner.