Patch Electrode Holder for Tool-Less Bio-Signal Device Insertion
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Solution Overview
Problem
Existing methods for manufacturing bio-signal processing devices with disposable electrodes are costly, time-consuming, and prone to yield issues due to complex assembly processes involving injection molding, gaskets, screws, and manual labor, which can affect manufacturing at different stages.
Innovation Solution
A holder apparatus for patch electrodes using vacuum forming or injection molding to create a recess structure for bio-signal devices, allowing tool-less insertion and removal, and a double-sided adhesive sheet for secure attachment, along with an adapter component to prevent moisture ingress and reduce assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insertion injection molding with separate gaskets, PCB's, screws, assembly jigs and manual labor is used, then the holder can be assembled with electrically conductive contact structure, but the manufacturing process becomes slow, costly and problematic with yield issues
Solution Approach 1:
The patent combines multiple separate components (gaskets, PCBs, screws, contact structures) into an integrated holder assembly using insertion injection molding. This merging of components eliminates the need for separate assembly steps, reducing manufacturing time and complexity while maintaining assembly reliability through the integrated design.
Solution Approach 2:
The holder is designed as a multi-functional component that simultaneously provides mechanical support, electrical contact, and sealing functions. The electrically conductive contact structure is integrated directly into the holder body, allowing it to serve both structural and electrical purposes, thereby simplifying the overall assembly process.
2Manufacturing precision
If over-molding with liquid poured into assembly kept at correct position by assembly jigs is used, then the electrically conductive contact structure can be formed, but the process becomes slow, costly and problematic with yield issues
Solution Approach 1:
The manufacturing process is segmented into distinct injection molding phases where different materials (including electrically conductive compounds) are injected in sequence to form different functional regions of the holder. This segmentation allows precise control over the contact structure formation without requiring complex assembly jigs or multiple handling steps.
Solution Approach 2:
The holder design incorporates preliminary positioning features and integrated contact structure geometry that are formed during the injection molding process itself. This preliminary action eliminates the need for subsequent assembly operations to position components, reducing both process complexity and potential yield issues.
3Reliability
If multiple separate components and assembly jigs are used, then the holder can be constructed with electrically conductive contact structure, but assembly cost increases and manufacturing becomes more complex
Solution Approach 1:
The patent merges the contact structure, holder body, and sealing elements into a single integrated component manufactured through insertion injection molding. This eliminates the need for separate assembly operations with multiple components and jigs, significantly simplifying manufacturing while maintaining contact structure reliability through the integrated design.
Solution Approach 2:
The injection molding process itself performs the assembly function that would otherwise require separate components and assembly jigs. The mold design incorporates features that automatically position and integrate the electrically conductive contact structure during molding, making the manufacturing process self-sufficient and eliminating the need for additional assembly equipment.
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 solution provides a cost-effective, simple, and reliable assembly process for bio-signal devices with disposable electrodes, ensuring secure attachment and moisture protection while reducing material and energy consumption.
Implementation Method 1
The first cover part 104 may be formed using vacuum forming. In the vacuum forming a sheet or layer is placed on the mold. Then a suction force with potential heating is applied to the mold, the suction bending the sheet and forcing it against the walls of the mold.
Implementation Method 2
Instead of vacuum forming, the first cover part 104 may be formed by injection molding, for example. Injection molding is a thermoplastic process where melt polymer is mechanically forced into a shape of a mold that has the desired recess shape.
Data Source
Figure 1A
Figure 1B~2
Figure 3~4
AI summary
A holder apparatus (100) for a patch electrode structure (200) and a bio-signal processing device (300) comprises a first front and rear recesses (1040, 1042) of a first polymer cover part (104), the first front recess (1040) fitting to the bio-signal device (300). The first cover part (104) is attached with a double-sided adhesive sheet (110). An electric connector part (106) comprises a connector (1060) for the bio-signal processing device (300), and a flexible conductor cable (1064) that connects with a connector (1060) and holder electrodes (1066) of a support sheet (1062). The flexible conductor cable (1064) and/or the connector (1060) extend through a gap (1052) and a first aperture (1050) of the first cover part (104). An adapter component (108) is between the support sheet (1062) and the first cover part (104) for support of the connector (1060) and fills the first aperture (1050) of the first cover part (104). The first cover part (104) and the first front recess (1040) form a pocket (102A) for the bio-signal processing device (300).