SENSOR INTERPOSER EMPLOYING CASTELLATED THROUGH-VIAS
An example sensor interposer employing castellated through-vias formed in a PCB includes a planar substrate defining a plurality of castellated through-vias; a first electrical contact formed on the planar substrate and electrically coupled to a first castellated through-via; a second electrical contact formed on the planar substrate and electrically coupled to a second castellated through-via, the second castellated through-via electrically isolated from the first castellated through-via; and a guard trace formed on the planar substrate, the guard trace having a first portion formed on a first surface of the planar substrate and electrically coupling a third castellated through-via to a fourth castellated through-via, the guard trace having a second portion formed on a second surface of the planar substrate and electrically coupling the third castellated through-via to the fourth castellated through-via, the guard trace formed between the first and second electrical contacts to provide electrical isolation between the first and second electrical contacts.
1 . A wearable biosensor comprising:
a sensor interposer comprising:
a planar substrate;
a first electrical contact formed on the planar substrate;
a second electrical contact formed on the planar substrate; and
an alignment feature;
a sensor physically coupled to the sensor interposer, the sensor comprising at least two electrodes, a first electrode of the at least two electrodes electrically coupled to the first electrical contact, and a second electrode of the at least two electrodes electrically coupled to the second electrical contact; and
a printed circuit board (“PCB”) having a plurality of electrical contacts defined on a first surface of the PCB, the PCB further comprising a surface feature configured to engage with the alignment feature of the sensor interposer to enable alignment of the first and second electrical contacts of the sensor interposer with respective corresponding electrical contacts of the PCB;
wherein the sensor interposer is physically coupled to the first surface of the PCB.
2 . The wearable biosensor of claim 1 , further comprising a controller in communication with the sensor, the controller configured to receive sensor signals from the sensor and determine an analyte concentration based on the sensor signals.
3 . The wearable biosensor of claim 1 , further comprising a guard trace formed between the first and second electrical contacts, the guard trace being configured to provide electrical isolation between the first and second electrical contacts.
4 . The wearable biosensor of claim 1 , wherein the first electrical contact of the sensor interposer is electrically coupled to a first castellated through-via formed in the planar substrate.
5 . The wearable biosensor of claim 4 , wherein the second electrical contact of the sensor interposer is electrically coupled to a second castellated through-via formed in the planar substrate, the second castellated through-via being electrically isolated from the first castellated through-via.
6 . The wearable biosensor of claim 5 , wherein the alignment feature comprises an opening defined in the planar substrate of the sensor interposer.
7 . The wearable biosensor of claim 1 , further comprising a sensor chemical disposed on a distal end of the sensor.
8 . The wearable biosensor of claim 7 , wherein the sensor chemical comprises glucose oxidase.
9 . The wearable biosensor of claim 7 , wherein the sensor chemical comprises a chemical configured to react with one or more of glucose, lactate, or cholesterol.
10 . The wearable biosensor of claim 1 , wherein the sensor comprises a first material and a second material, the second material formed coaxially around the first material, a first portion of the first material extending beyond the second material at a first end of the sensor,
wherein the first portion of the first material is electrically coupled to the first electrical contact, and the second material is coupled to the second electrical contact.
11 . A method of manufacturing a wearable biosensor, the method comprising:
providing a sensor interposer comprising:
a planar substrate,
a first electrical contact formed on the planar substrate,
a second electrical contact formed on the planar substrate; and
an alignment feature;
a sensor physically coupled to the sensor interposer, the sensor comprising at least two electrodes, a first electrode of the at least two electrodes electrically coupled to the first electrical contact, and a second electrode of the at least two electrodes electrically coupled to the second electrical contact; and
providing a printed circuit board (“PCB”) having a plurality of electrical contacts defined on a first surface of the PCB, the PCB further comprising a surface feature configured to engage with the alignment feature of the sensor interposer to enable alignment of the first and second electrical contacts of the sensor interposer with respective corresponding electrical contacts of the PCB; and
wherein the sensor interposer is physically coupled to the first surface of the PCB.
12 . The method of claim 11 , wherein a controller is in communication with the sensor, the controller being configured to receive sensor signals from the sensor and determine an analyte concentration based on the sensor signals.
13 . The method of claim 11 , wherein the wearable biosensor further comprises a guard trace formed between the first and second electrical contacts, the guard trace being configured to provide electrical isolation between the first and second electrical contacts.
14 . The method of claim 11 , wherein the first electrical contact of the sensor interposer is electrically coupled to a first castellated through-via formed in the planar substrate.
15 . The method of claim 14 , wherein the second electrical contact of the sensor interposer is electrically coupled to a second castellated through-via formed in the planar substrate, the second castellated through-via being electrically isolated from the first castellated through-via.
16 . The method of claim 11 , wherein the alignment feature comprises an opening defined in the sensor interposer planar substrate.
17 . The method of claim 11 , further comprising a sensor chemical disposed on a distal end of the sensor.
18 . The method of claim 17 , wherein the sensor chemical comprises glucose oxidase.
19 . The method of claim 17 , wherein the sensor chemical comprises a chemical configured to react with one or more of glucose, lactate, or cholesterol.
20 . The method of claim 11 , wherein the sensor comprises a first material and a second material, the second material formed coaxially around the first material, a first portion of the first material extending beyond the second material at a first end of the sensor,
wherein the first portion of the first material is electrically coupled to the first electrical contact, and the second material is coupled to the second electrical contact.