Sensor Cable Support Assembly With Conductive Pucks for Wearables
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing invasive biosensors for wearable monitoring devices are complex to use and costly, with exposed sensor wires prone to damage from high temperatures during assembly and susceptible to moisture ingress, leading to performance issues and bulkiness due to multiple parts.
Innovation Solution
A sensor cable support device with a rigid body and legs that includes conductive pucks and electrical traces to securely and electrically connect sensor cables to a printed circuit board, providing structural support, alignment, and passive strain relief while avoiding high-temperature assembly and minimizing moisture exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sensor wires are connected to sensing circuitry using a two-step approach (implantation then connection), then the connection can be performed by medical professionals, but the process becomes overly complicated and costly for patients to perform on their own
Solution Approach 1:
The sensor wire and sensing circuitry are pre-assembled into a single integrated unit during manufacturing. The sensor wire is soldered or welded to the printed circuit board within the monitoring device housing, combining what were previously separate components that required two-step connection into one unified device that requires only single-step application.
Solution Approach 2:
The connection between sensor wire and sensing circuitry is performed in advance during device manufacturing rather than at the time of use. The sensor wire is pre-connected to the printed circuit board through soldering or welding, so that when the device is applied to the patient, the connection is already established and no additional connection steps are needed.
2Reliability
If sensor wires are soldered or welded to the printed circuit board, then electrical connection is established, but the high localized temperatures may damage the sensor wires especially if coated with a membrane
Solution Approach 1:
A compliant coating layer is introduced as an intermediary between the sensor wire and the soldering/welding process. This coating layer protects the sensor wire membrane from direct exposure to high temperatures during soldering or welding operations, allowing electrical connection to be established without thermal damage to the sensitive membrane-coated wire.
3Volume of moving object
If multiple parts are used to accommodate sensing circuitry and power source, then the device can be compact, but the device becomes bulky and creates multiple areas for moisture ingress
Solution Approach 1:
Multiple functional components (sensing circuitry, power source, sensor wire connection) are integrated into a single unified housing structure rather than being separate parts. This consolidation reduces the total number of seals and interfaces where moisture could ingress, improving reliability while maintaining a compact form factor suitable for wearable applications.
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 enhances user convenience, reduces device bulk, and improves durability by securely connecting sensor cables without high-temperature exposure, while maintaining moisture protection and efficient use of space within the monitoring device.
Implementation Method 1
a first puck of the pair of pucks mechanically retains the first portion in electrical contact with the first conductive opening and a second puck of the pair of pucks mechanically retains the second portion in electrical contact with the second conductive opening
Implementation Method 2
a first electrical trace electrically coupling a first opening of the pair of openings and a distal end of a first leg of the set of rigid legs. The support device also includes a second electrical trace electrically coupling a second opening of the pair of openings and a distal end of a second leg of the set of rigid legs
Data Source
AI summary
A sensor cable support device is described. The sensor cable support device can be used to implemented in wearable monitoring device to support a proximal portion of a sensor cable and electrically connect the proximal portion with a sensing circuitry. A distal portion of the sensor cable is insertable into a person's skin. The sensor cable support device may include a rigid body defining a pair of openings, a set legs attached to the rigid body, and a pair of electrical traces extending between the pair of openings and distal ends of a pair of legs of the set of legs. The pair of openings may be sized and configured to receive a pair of pucks that mechanically retain a sensor cable to the body and electrically connect the sensor cable with the electrical traces.