Flexible Sensing Electrode Connector With Sealed Detachable Interlock
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Solution Overview
Problem
Existing detachable electrical connectors face challenges in being thin, flexible, sealable, and cost-effective for embedding in curved systems, especially when exposed to harmful environments, and require easy assembly and periodic replacement.
Innovation Solution
A multi-part sensing electrode connector with a flexible substrate and interlock structure that insulates internal electronics from the ambient environment, allowing for detachable and flexible integration into curved surfaces, using a thin, disposable electrode portion and reusable interconnect portion with conductive traces and enclosures to form a seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional detachable electrical connectors are used, then connection and disconnection can be achieved, but the connector cannot be made thin and flexible enough for embedding in curved structures
Solution Approach 1:
The connector is divided into two separate parts: a reusable interconnect portion with enclosure and contacts, and a disposable electrode portion with flexible substrate and electrode traces. This segmentation allows each part to be optimized independently - the interconnect portion provides structural integrity and sealing, while the electrode portion achieves thin and flexible form factor for curved surface embedding.
Solution Approach 2:
The electrode portion uses a flexible substrate with thin electrode traces deposited on it, allowing the connector to be bent and conform to curved surfaces. The thin film structure enables the connector to be embedded in curved host structures while maintaining electrical functionality.
2Adaptability or versatility
If the connector is made open to allow ambient environment exposure, then sensing function is achieved, but internal electronics are exposed to harmful environmental factors
Solution Approach 1:
The sensing function is extracted by exposing only the electrode traces on the flexible substrate to the ambient environment, while the rest of the electronics are kept isolated. The electrode portion can be exposed to liquids and environment for sensing, but the interconnect portion with enclosure protects the internal electronics from harmful environmental factors.
Solution Approach 2:
The electrode traces are nested within the enclosure structure of the interconnect portion, allowing selective exposure. Only the necessary electrode contacts are exposed to the environment through the enclosure openings, while the bulk of the electronics remain protected inside the nested enclosure.
3Reliability
If fine patterns of conductive and non-conductive materials are used for detachable connection, then connection reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The connector combines mechanical interlocking through the enclosure and connector structures with electrical contact through the electrode traces. This merging of mechanical and electrical functions into a single integrated assembly simplifies manufacturing compared to separate components requiring precise alignment of fine conductive patterns.
Solution Approach 2:
The electrode portion is designed as a disposable component that can be easily manufactured and replaced. This allows the use of simpler, more cost-effective manufacturing processes for the electrode portion while the reusable interconnect portion maintains connection reliability through its robust enclosure and connector design.
4Reliability
If high-quality adhesives are used for connection assembly, then sealing and conductivity are improved, but cost becomes prohibitively expensive
Solution Approach 1:
The design replaces adhesive-based connection with a mechanical interlocking system using the enclosure and connector structures. The physical interlock provides both sealing and electrical contact functions without requiring expensive high-quality adhesives, thereby reducing manufacturing cost while maintaining reliability.
Data Source
AI summary
A thin form of an electrical connector for creating a detachable connection between two circuit elements is disclosed. When the connector is employed, only an outer electrode present on a portion of the connector is exposed to the ambient environment and the rest of the electronics of both the connector and of a device into which the device is integrated can be insulated from the ambient environment. The parts of the connector can create a small three-dimensional interlock structure to seal off contact area and to facilitate electrical contacts between two circuit elements. The connector includes two components: an electrode portion and an interconnect portion. The electrode portion could be disposable after a single use while the interconnect portion could be reusable multiple times.