Light-Blocking Wall Injection Molding for Glucose Sensors
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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 by dispensing being difficult to control for uniformity and accuracy, affecting the device's light-blocking rate and glucose monitoring accuracy.
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 a lower and upper wall-structure, which simplifies the manufacturing process, reduces the width of the light-blocking walls, and improves material uniformity and light reflectance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional dispensing method is used to form light-blocking walls, then manufacturing process is simple, but manufacturing precision and light-blocking rate are poor due to uncontrollable uniformity and bubbles
Solution Approach 1:
The patent changes the manufacturing method from conventional dispensing to injection molding, fundamentally altering the process parameters to achieve better control over material uniformity and eliminate bubbles, thereby improving light-blocking rate while maintaining process simplicity
Solution Approach 2:
The patent replaces the manual dispensing mechanism with an automated injection molding system, substituting a simple but imprecise mechanical process with a more controlled mechanical system that delivers superior precision without significantly increasing overall device complexity
2Manufacturing precision
If half-cutting method is used to form grooves, then light-blocking walls can be formed, but the width is larger than 200 μm and cannot be further reduced due to cutting tool limitations
Solution Approach 1:
The patent replaces the mechanical half-cutting method with injection molding technology, substituting a mechanical cutting process with a molding process that can achieve much finer dimensional control and produce narrower light-blocking walls without increasing manufacturing difficulty
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from cutting-based to molding-based, enabling precise control over light-blocking wall width at the micrometer scale that was previously unattainable with cutting tools
3Manufacturing precision
If conventional dispensing method is used, then manufacturing cost is increased for small area devices, but manufacturing accuracy is affected
Solution Approach 1:
The patent adopts injection molding as a universal manufacturing method that can efficiently produce light-blocking walls for devices of various sizes, eliminating the cost penalty associated with small-area device manufacturing while simultaneously improving manufacturing accuracy
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
The method simplifies manufacturing processes, reduces the width of light-blocking walls, enhances material uniformity and light reflectance, and supports the transparent cover, improving the device's miniaturization and application flexibility while maintaining high light-blocking efficiency.
Implementation Method 1
performing an injection molding process or an electroplating process, to form at least one light-blocking wall on the substrate
Implementation Method 2
performing an injection molding process or an electroplating process, to form at least one light-blocking wall on the substrate
Implementation Method 3
each light-blocking wall includes a lower wall-structure and an upper wall-structure... improving material uniformity and light reflectance... maintaining high light-blocking efficiency
Data Source
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.