Flexible Printed Circuit Assembly for Patient Sensor
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Solution Overview
Problem
Conventional patient-worn sensors face challenges with adhesion and electrical contact reliability, particularly during patient movement, and require safe and easy disconnection methods for battery replacement without causing accidental contact with the patient's face.
Innovation Solution
The design incorporates push tabs on a sensor and adapter for easy disconnection, a flexible printed circuit with a rigid portion and a movable flexible portion, and a sensor assembly with a grip and rotatable connector to facilitate secure and safe attachment and detachment, while the flexible printed circuit includes a stiffener to prevent trace fatigue and improve mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional sensor assembly is disconnected from the adapter by pulling apart, then the sensor can be removed for battery replacement, but the strong disengagement force may cause the sensor to accidentally hit the patient's face
Solution Approach 1:
A flexible printed circuit board (FPC) is introduced as an intermediary component between the sensor assembly and the adapter. The FPC includes a flexible portion that can bend and deform, serving as a mechanical buffer that absorbs the disengagement force and prevents the sensor from directly contacting the patient's face during removal
Solution Approach 2:
The flexible portion of the FPC is designed to deform beforehand during the disconnection process, absorbing the impact force before it can reach the sensor assembly. This cushioning effect prevents the harmful accidental contact with the patient's face while still allowing successful battery replacement
2Reliability
If the flexible printed circuit includes a rigid portion with stiffener, then the electrical components are securely connected, but the overall flexibility of the circuit is reduced
Solution Approach 1:
The FPC is designed with non-uniform properties: a rigid portion with a stiffener is provided where electrical components are connected to ensure secure mounting and stable electrical connections, while the flexible portion remains compliant to accommodate patient movement and skin contours. Each portion has the quality needed for its specific function
3Reliability
If the connector is allowed to move independently in two or three dimensions, then the electrical contact reliability is improved during patient movement, but the mechanical complexity of the connection increases
Solution Approach 1:
The connector is designed with dynamic characteristics, allowing it to move independently in two or three dimensions relative to the FPC. This movement capability enables the connector to maintain optimal electrical contact with the adapter even when the patient moves, as the flexible portion absorbs the mechanical stress and prevents contact loss without requiring complex active adjustment mechanisms
Data Source
AI summary
A patient-monitoring device includes an adapter with a flexible printed circuit, the flexible printed circuit includes a rigid portion with a rigid stiffener and a flexible portion with a trace, and with a connector that is connected to one end of the trace, that is movable in two or three dimensions independent of the rigid portion, and that is connectible to an electrode assembly.