Light-Blocking Wall Structure for Non-Invasive Glucose Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional manufacturing methods for non-invasive blood glucose monitoring devices are complex, costly, and limited to small areas, with light-blocking walls formed with widths greater than 200µm, affecting manufacturing accuracy and light-blocking efficiency.
Innovation Solution
A manufacturing method that forms light-blocking walls on a substrate using injection molding or electroplating, creating a staged and three-dimensional structure with narrower widths, improving material uniformity and reducing bubble formation, thus enhancing light reflectance and reducing light transmittance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional half-cutting and dispensing methods are used to form light-blocking walls, then the manufacturing process can be implemented, but the manufacturing complexity increases and the light-blocking wall width becomes larger than 200μm
Solution Approach 1:
The light-blocking wall is divided into two distinct structures: a lower wall-structure formed by injection molding and an upper wall-structure formed by electroplating. This segmentation allows each structure to be optimized for its specific function - the lower structure provides mechanical support and light blocking, while the upper structure provides precise light reflection with controlled width and shape.
Solution Approach 2:
The conventional mechanical half-cutting and dispensing methods are replaced with injection molding and electroplating processes. These alternative processes enable more precise control over the light-blocking wall dimensions and eliminate the limitations of cutting tool sizes, achieving widths below 200μm with better uniformity and fewer defects.
2Reliability
If conventional dispensing method is used to form light-blocking walls, then the light-blocking walls can be formed, but material uniformity decreases and bubbles are generated, reducing light-blocking rate
Solution Approach 1:
The dispensing method is replaced with injection molding followed by electroplating. Injection molding provides excellent material uniformity and eliminates bubble formation through controlled injection processes. The subsequent electroplating process adds a dense, uniform metallic layer that enhances light-blocking performance. This combination achieves superior material consistency and eliminates the defects associated with dispensing methods.
Solution Approach 2:
The light-blocking wall uses a composite structure combining plastic material from injection molding and metallic material from electroplating. This composite approach leverages the advantages of both materials - the plastic provides structural integrity and uniformity, while the metal layer provides enhanced light-blocking capability and precise dimensional control, achieving superior overall performance.
3Manufacturing precision
If light-blocking walls with width larger than 200μm are formed, then the manufacturing can be completed with conventional tools, but the manufacturing accuracy decreases
Solution Approach 1:
Conventional mechanical cutting tools are replaced with injection molding and electroplating processes. These processes are not limited by tool size in the same way - injection molding can form precise cavities and electroplating can deposit uniform layers at micrometer scales. This substitution enables control of light-blocking wall widths below 200μm with high precision, overcoming the limitations of mechanical cutting tools.
Solution Approach 2:
The manufacturing approach changes from mechanical removal of material (cutting) to additive and conformal deposition processes (molding and plating). By changing the fundamental manufacturing parameters from cutting depth and tool width to injection pressure, mold cavity dimensions, and electroplating current density, precise control over light-blocking wall dimensions is achieved without being constrained by tool size.
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 method simplifies the manufacturing process, reduces the width of light-blocking walls, improves material uniformity, and maintains high light reflectance and low light transmittance, enabling more accurate and efficient blood glucose monitoring.
Implementation Method 1
performing an injection molding process to form at least one light-blocking wall on the substrate
Implementation Method 2
performing an electroplating process to form at least one light-blocking wall on the substrate
Implementation Method 3
maintains high light reflectance and low light transmittance
Data Source
Figure 1
Figure 2(A)~2(E)
Figure 3
AI summary
The invention provides a manufacturing method for a non-invasive blood glucose monitoring device, which comprises the following steps: providing a substrate; performing an injection molding process or an electroplating process, to form at least one light-blocking wall on the substrate, wherein each light-blocking wall includes a lower wall-structure and an upper wall-structure, and the lower wall-structure connects the substrate and the upper wall-structure connects the lower wall-structure; arranging a light-emitting element and a light-receiving element on the substrate and separating the light-emitting element and the light-receiving element by the at least one light-blocking wall; forming a packaging structure on the substrate in which the light-emitting element and the light-receiving element are packaged; and disposing a transparent cover on the packaging structure and the at least one light-blocking wall and limiting the transparent cover to a configuration height by the at least one light-blocking wall.