Conductive Plastic Electrodes in Diagnostic Apparatus
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Solution Overview
Problem
Current diagnostic apparatus manufacturing processes are complex and costly, often involving photo processes, metal deposition, and etching, which limit yield and increase defect rates, and there is a need for a simpler and more cost-effective method to produce a disposable diagnostic cartridge.
Innovation Solution
A diagnostic apparatus is manufactured using injection molding to form electrodes and a base plate with conductive plastic and insulators, respectively, allowing for a tapered electrode design and simplified production without complex semiconductor processes, using materials like carbon nanotubes, graphene, and polycarbonate, and enabling smooth fluid flow via electrowetting signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photo processes, metal deposition, and etching are used to manufacture diagnostic apparatus, then manufacturing precision can be improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent replaces complex semiconductor manufacturing processes (photo processes, metal deposition, etching) with a simpler injection molding process. Conductive plastic material is injected directly into a mold to form electrodes, eliminating the need for multiple sequential manufacturing steps while maintaining acceptable manufacturing precision for the diagnostic apparatus application.
Solution Approach 2:
The patent changes the material parameter from traditional metal electrodes to conductive plastic material. This parameter change enables the use of injection molding instead of complex deposition and etching processes, significantly simplifying the manufacturing process while maintaining the necessary electrical conductivity and structural integrity for electrode function.
2Manufacturing precision
If complex manufacturing processes are used, then manufacturing precision is improved, but productivity decreases due to longer production time and lower yield
Solution Approach 1:
The injection molding process replaces multiple sequential manufacturing steps with a single or few-step process. The conductive plastic is injected directly into the mold cavity and formed into the final electrode shape in one operation, dramatically reducing production time and increasing manufacturing yield compared to traditional multi-step semiconductor processes.
Solution Approach 2:
The mold design incorporates preliminary action by pre-forming the electrode structure with the desired geometry and integrating it with the base plate structure before actual production. The injection molding process itself performs preliminary shaping and positioning, eliminating the need for subsequent machining or assembly steps that would reduce productivity.
3Reliability
If traditional manufacturing methods are used, then electrode performance can be maintained, but manufacturing cost increases due to multiple process steps
Solution Approach 1:
The patent changes the material parameter from metal to conductive plastic, which maintains the necessary electrical conductivity and structural properties for electrode performance. The conductive plastic material can be formulated with appropriate conductivity levels and mechanical properties, achieving reliable electrode function while enabling simpler, lower-cost injection molding manufacturing.
Solution Approach 2:
The patent merges the electrode formation process with the base plate manufacturing process into a single injection molding operation. The conductive plastic is injected into the mold along with or integrated into the base plate structure, eliminating the need for separate electrode fabrication and assembly steps, thereby reducing manufacturing cost while maintaining electrode performance.
4Ease of operation
If disposable cartridge design is implemented, then ease of operation and hygiene are improved, but manufacturing cost per unit increases
Solution Approach 1:
The injection molding process enables cost-effective disposable cartridge manufacturing by forming all components including electrodes and base plates in a single operation. The simplicity of the injection molding process allows for high-volume production of disposable units at low per-unit cost, making the disposable model economically viable while improving ease of operation and hygiene.
Solution Approach 2:
The use of conductive plastic material allows for integration of multiple functions into a single molded component, reducing the number of parts and assembly steps required. This parameter change in material selection enables the entire disposable cartridge to be manufactured as an integrated unit, significantly reducing per-unit manufacturing cost while maintaining the convenience and hygiene benefits of disposable design.
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 reduces manufacturing costs and defect rates, enables the production of a disposable diagnostic cartridge, and enhances the yield of the diagnostic apparatus by simplifying the manufacturing process and ensuring smooth fluid flow along the electrodes and reservoir.
Implementation Method 1
one or more electrodes formed by penetrating through the base plate and causing a fluid located on a surface to be moved based on an applied voltage
Data Source
AI summary
The present invention relates to a diagnostic apparatus and a method for manufacturing the same. The diagnostic apparatus according to an embodiment of the present invention comprises a base plate including an insulator, and one or more electrodes formed by penetrating through the base plate and causing a fluid located on a surface to be moved based on an applied voltage, in which the base plate is formed by injecting the insulator into a first space of a mold by a first injection gate, and the electrode is formed by injecting conductive plastic into a second space of the mold by a second injection gate distinct from the first injection gate.