Folded Flex Circuit Assembly for Low-Noise Optical Probes
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Solution Overview
Problem
Existing optical probes face challenges in efficiency and cost-effectiveness in the field of non-invasive physiological monitoring of the field of non-invasive physiological monitoring of bodily functions, such as blood pressure and oxygen saturation, require low-noise optical probes that are both disposable and reusable, but current technologies face difficulties in providing these at low cost and minimizing motion-induced noise.
Innovation Solution
A method of assembling a physiological optical sensor using a flexible circuit assembly with a nested configuration to maximize material usage, allowing for efficient manufacturing of low-cost, low-noise optical probes that can be folded into various configurations, reducing waste and increasing production yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional optical probe designs are used, then functional performance is achieved, but material waste increases and manufacturing cost increases
Solution Approach 1:
The flexible circuit board is configured in a nested arrangement where multiple circuit traces are layered and positioned to maximize material utilization. The circuit board nesting allows efficient packing of electrical pathways within the probe structure, reducing overall material consumption while maintaining functional integrity
Solution Approach 2:
The patent transitions from traditional linear or planar circuit layouts to a three-dimensional nested configuration. By utilizing vertical layering and spatial optimization, the design maximizes material usage efficiency without compromising electrical performance or probe functionality
2Ease of manufacture
If optical probes are designed for low cost, then manufacturing efficiency improves, but motion-induced noise increases
Solution Approach 1:
The patent employs a flexible circuit board with a thin-film structure that can accommodate motion while maintaining electrical connections. The flexible nature of the circuit board allows it to deform with probe movement without generating excessive noise or failing, thus reducing motion-induced noise while keeping manufacturing costs low
Solution Approach 2:
The circuit board design incorporates dynamic flexibility to adapt to probe motion. The flexible traces and connections are engineered to move with the probe rather than resist motion, reducing mechanical stress and noise generation during dynamic operation
3Loss of substance
If flexible circuit board nesting is implemented, then material usage is maximized, but assembly complexity increases
Solution Approach 1:
The nested flexible circuit board is divided into distinct segments or modules that can be independently positioned and connected. This segmentation allows for systematic assembly where each nested layer can be installed in a standardized sequence, reducing overall assembly complexity despite the nested configuration
Data Source
Figure 1A~1B
Figure 2A
Figure 2B~2C
AI summary
The present invention discoses a method of assembling a physiological sensor, the method comprising: obtaining an individual flexible circuit configured to be attached to a plurality of components, the individual flexible circuit comprising: a connector end, and a detector end (206) comprising an emitter (226), a detector (228), and a hook portion (227a, 227b, 227d), wherein the hook portion is configured to form an opening (227c) that the emitter (226) can attach to; covering the physiological sensor on both top and bottom with a layer of foam (646), wherein the foam covering covers the individual flexible circuit and forms a covering which extends from the emitter and the detector to the connector end; providing an applicator tape (668); and applying the applicator tape to a portion of the individual flexible circuit.