Needle assemblies containing oriented needles and methods for production thereof
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of analyte sensors using acupuncture needles is hindered by the randomized bulk packaging, which complicates high-throughput manufacturing processes, making it difficult to orient these needles in existing manufacturing systems.
Innovation Solution
The needles are pre-oriented in a batch-wise manner and incorporated into a continuous support material via injection molding, allowing for high-throughput manufacturing by maintaining their orientation throughout the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acupuncture needles are packaged in randomized bulk, then manufacturing flexibility is maintained, but manufacturing precision and throughput are reduced
Solution Approach 1:
The patent applies preliminary action by pre-orienting acupuncture needles in a defined configuration within a holder before the manufacturing process. The needles are positioned in specific orientations (e.g., parallel or at defined angles) and secured in place prior to injection molding, enabling high-throughput automated manufacturing while maintaining precise needle orientation throughout production
2Ease of manufacture
If larger gauge needles are used, then ease of manufacture is improved, but tissue trauma increases
Solution Approach 1:
The patent applies parameter changes by transitioning from larger gauge needles to smaller diameter acupuncture needles (e.g., 0.1-0.6mm diameter). This parameter change reduces tissue trauma and improves user comfort while the needles are incorporated into a structured holder with defined orientations, maintaining manufacturability through systematic arrangement and injection molding processes
3Object-affected harmful factors
If acupuncture needles are used, then tissue trauma is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining multiple acupuncture needles into a single integrated holder structure. Multiple needles (e.g., 2-10 needles) are positioned in defined configurations and secured within a single holder component that is then injection molded, consolidating what would otherwise be separate manual assembly operations into a unified manufacturing process
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 enables the efficient production of analyte sensors with minimal tissue trauma, facilitating their use in continuous monitoring systems while maintaining manufacturing efficiency.
Implementation Method 1
injection molding polymeric material to form a first injection molded coupler that surrounds both the neck and a proximal portion of the acupuncture needle within each aperture, thereby connecting the acupuncture needle to a first location upon the support material
Data Source
AI summary
Acupuncture needles may be used for piercing tissue with less trauma than may occur when employing larger gauge needles. However, because acupuncture needles are fabricated and packaged differently than are larger gauge needles, acupuncture needles may be less compatible with certain manufacturing processes. Needle assemblies compatible with manufacturing processes may comprise a continuous support material having a plurality of apertures defined therein, and a first injection molded coupler that surrounds a proximal portion of an acupuncture needle and connects the acupuncture needle to a first location upon the continuous support material, such that the acupuncture needle is held in a pre-determined orientation with respect to a longitudinal axis of the first injection molded coupler. The acupuncture needles in adjacent apertures may also be spaced apart substantially uniformly.