Keyed Sensor Connector Foil for Reliable Multi-Pad Coupling
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Solution Overview
Problem
Current sensor sets for monitoring body characteristics, such as glucose levels, face compatibility issues due to the potential for attaching incompatible components, and have limited contact pads, which can compromise sensor data and restrict the number of electrodes that can be used.
Innovation Solution
A sensor set with a mounting base and connector system that includes a tubular element with a key formed at one end, allowing the sensor to fold around the key such that contact pads are on both sides, providing a stable and reliable connection, and featuring compressible pins and latch arms for secure coupling, along with a test plug for testing electronics without sensor data, ensuring compatibility and increased electrode functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mounting base with connector is used for sensor sets, then the sensor can be coupled to monitoring devices, but incompatible components can be attached together compromising sensor data
Solution Approach 1:
The connector fitting includes a key with a specific asymmetric geometry that must match a corresponding recess in the connector. This asymmetric design ensures that only compatible components can be coupled together, preventing mismatched sensors from being attached to incompatible connectors, thereby maintaining sensor data accuracy while enabling easy coupling.
2Ease of manufacture
If a simple connector structure is used, then manufacturing is easier, but the number of contact pads is limited restricting electrode functionality
Solution Approach 1:
The key structure is formed by removing material from a cylindrical element to create flat surfaces, transitioning from a simple cylindrical shape to a multi-faceted geometry. This dimensional modification allows multiple contact pads to be arranged around the key structure without significantly complicating the manufacturing process, thereby increasing adaptability while maintaining ease of manufacture.
3Device complexity
If contact pads are arranged on a single side of the connector, then the structure is simpler, but the number of electrodes that can be used is restricted
Solution Approach 1:
The key structure provides flat surfaces on multiple sides of the cylindrical element, allowing contact pads to be arranged around the key in different orientations. This multi-dimensional arrangement enables multiple electrodes to be connected without significantly increasing device complexity, as the key structure naturally provides the necessary mounting surfaces.
Solution Approach 2:
The key structure serves multiple functions: it provides mechanical alignment, structural support, and mounting surfaces for multiple contact pads. This multi-functionality allows the connector to support multiple electrodes without requiring separate structures for each function, thereby increasing adaptability while maintaining simplicity.
4Reliability
If a secure coupling mechanism is added to prevent incompatible components, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The key and recess form an asymmetric mechanical interlocking mechanism that provides secure coupling. This asymmetric design ensures that only compatible components with matching geometries can be connected, improving connection reliability and preventing incompatible attachments without requiring additional complex security features.
Data Source
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AI summary
A connector system comprises a connector foil having contact pads thereon at an end portion, a connector fitting having a cylindrical element with a key formed at its distal end, said key being defined by cut-away portions of me element to produce two flat surfaces each parallel to the axis of the element, which flat surfaces face away from one another, wherein the end portion of the connector foil lies against a first one of said flat surfaces with the contact pads facing away from the first flat surface, and a socket unit with a tubular recess sized to accommodate the cylindrical element and having contacts positioned to engage the contact pads of the connector foil, the socket unit having a structure occupying the space vacated by said cutaway portions; wherein the structure occupying the space vacated by said cut-away portions comprises spring contacts on one side of the key and a projection on the inside of the tubular recess on the other side of the key.