System and Method for Manufacturing a Swallowable Sensor Device

Abstract

Methods and systems for manufacturing a swallowable sensor device are disclosed. Such a method includes mechanically coupling a plurality of internal components, wherein the plurality of internal components includes a printed circuit board having a plurality of projections extending radially outward. A cavity is filled with a potting material, and the mechanically coupled components are inserted into the cavity. The cavity may be pre-filled with the potting material, or may be filled after the mechanically coupled components have been inserted therein. A distal end of each projection abuts against a wall of the cavity thereby preventing the potting material from covering each distal end. The cavity is sealed with a cap causing the potting material to harden within the sealed cavity to form a housing of the swallowable sensor device, wherein the distal end of each projection is exposed to an external environment of the swallowable sensor device.

1 . A method for manufacturing a swallowable sensor device, comprising:
 mechanically coupling a plurality of internal components of the swallowable sensor device, wherein the plurality of internal components includes a printed circuit (PC) board having a plurality of projections extending radially outward;   filling a cavity with a potting material;   inserting the mechanically coupled components into the cavity, a distal end of each projection abutting against a side wall of the cavity thereby preventing the potting material from covering the distal end of each projection; and   sealing the cavity with a cap, wherein the potting material hardens within the sealed cavity to form a housing of the swallowable sensor device such that the distal end of each projection is exposed to an external environment of the swallowable sensor device.   
     
     
         2 . The method of  claim 1 , wherein the cavity is filled with the potting material before inserting the mechanically coupled components therein. 
     
     
         3 . The method of  claim 1 , wherein the cavity is filled with the potting material after inserting the mechanically coupled components therein. 
     
     
         4 . The method of  claim 1 , wherein the plurality of internal components are mechanically coupled using a post. 
     
     
         5 . The method of  claim 4 , wherein a first end of the post abuts against a base of the cavity and a second end of the post abuts against the cap thereby preventing the potting material from covering the first and second ends of the post. 
     
     
         6 . The method of  claim 5 , further comprising:
 providing a voltage between the first and second ends of the post to test operability of the swallowable sensor device.   
     
     
         7 . The method of  claim 4 , wherein the post provides an electrical coupling between the plurality of PC boards. 
     
     
         8 . The method of  claim 4 , wherein the post comprises a transducer configured to convert electrical energy to mechanical energy. 
     
     
         9 . The method of  claim 4 , wherein the plurality of internal components are annularly-shaped and mechanically coupled by the post along a common central axis. 
     
     
         10 . The method of  claim 1 , wherein at least one of the projections comprises an electrode, and the method further comprises electrically coupling a sensor to the electrode. 
     
     
         11 . The method of  claim 1 , wherein at least one of the projections comprises a hollow tubing coupled to a container included inside the housing of the swallowable sensor device. 
     
     
         12 . The method of  claim 1 , wherein the plurality of internal components includes a battery. 
     
     
         13 . The method of  claim 1 , wherein the plurality of internal components includes a transducer that is configured to convert electrical energy to mechanical energy. 
     
     
         14 . A system for manufacturing a swallowable sensor device, comprising:
 means for mechanically coupling a plurality of internal components of the swallowable sensor device, wherein the plurality of internal components includes a printed circuit (PC) board having a plurality of projections extending radially outward;   means for filling a cavity with a potting material;   means for inserting the mechanically coupled components into the cavity, a distal end of each projection abutting against a side wall of the cavity thereby preventing the potting material from covering the distal end of each projection; and   means for sealing the cavity with a cap, wherein the potting material hardens within the sealed cavity to form a housing of the swallowable sensor device such that the distal end of each projection is exposed to an external environment of the swallowable sensor device.   
     
     
         15 . The system of  claim 14 , wherein the means for filling the cavity comprises means for filling the cavity with the potting material before inserting the mechanically coupled components therein. 
     
     
         16 . The system of  claim 14 , wherein the means for filling the cavity comprises means for filling the cavity with the potting material after inserting the mechanically coupled components therein. 
     
     
         17 . The system of  claim 14 , wherein the means for mechanically coupling the plurality of internal components comprises a post. 
     
     
         18 . The system of  claim 17 , wherein a first end of the post abuts against a base of the cavity and a second end of the post abuts against the cap thereby preventing the potting material from covering the first and second ends of the post. 
     
     
         19 . The system of  claim 18 , further comprising:
 means for providing a voltage between the first and second ends of the post to test operability of the swallowable sensor device.   
     
     
         20 . The system of  claim 17 , wherein the post provides an electrical coupling between the plurality of internal components. 
     
     
         21 . The system of  claim 17 , wherein the post comprises a transducer configured to convert electrical energy to mechanical energy. 
     
     
         22 . The system of  claim 17 , wherein the plurality of internal components are annularly-shaped and mechanically coupled by the post along a common central axis. 
     
     
         23 . The system of  claim 14 , wherein at least one of the projections comprises an electrode, and the system further comprises means for electrically coupling a sensor to the electrode. 
     
     
         24 . The system of  claim 14 , wherein at least one of the projections comprises a hollow tubing coupled to a container, wherein the container is included inside the housing of the swallowable sensor device. 
     
     
         25 . The system of  claim 14 , wherein the plurality of internal components includes a transducer that is configured to convert electrical energy to mechanical energy. 
     
     
         26 . A swallowable sensor device configured to be ingested by an animal, comprising:
 one or more sensors each configured to sense a received stimulus; and   a communication module, coupled to the one or more sensors, that transmits a communication signal, the communication signal including information regarding stimuli sensed by the one or more sensors;   wherein the one or more sensors are covered by digestible material, enabling the one or more sensors to be released after the animal digests the digestible material.   
     
     
         27 . The swallowable sensor device of  claim 26 , wherein the one or more sensors are covered by respective thicknesses of the digestible material, enabling the one or more sensors to be released at respective times after the animal digests the respective thicknesses of the digestible material. 
     
     
         28 . The swallowable sensor device of  claim 26 , wherein the one or more sensors comprise a heme oxygenase enzyme material. 
     
     
         29 . The swallowable sensor device of  claim 26 , wherein the one or more sensors comprise a material that reacts with a CarcinoEmbryonicAntigen (CEA). 
     
     
         30 . A swallowable sensor device configured to be ingested by an animal, comprising:
 a communication module comprising an acoustic sensor that converts electrical energy to mechanical energy; and   a layered structure that covers the communication module, the layered structure having an acoustic impedance that varies with distance from an interior portion to an exterior portion of the layered structure.   
     
     
         31 . The swallowable sensor device of  claim 30 , wherein the layer structure comprises:
 an intermediate layer having an acoustic impedance substantially similar to an acoustic impedance of the acoustic sensor; and   an outer layer having an acoustic impedance substantially similar to an acoustic impedance of an environment within the animal.   
     
     
         32 . The swallowable sensor device of  claim 30 , wherein the layer structure comprises:
 an anisotropic layer having an acoustic impedance that decreases with distance from an interior portion to an exterior portion, such that the interior portion of the anisotropic layer has an acoustic impedance substantially similar to an acoustic impedance of the acoustic sensor and the exterior portion of the anisotropic layer has an acoustic impedance substantially similar to an acoustic impedance of an environment within the animal.   
     
     
         33 . The swallowable sensor device of  claim 32 , wherein the anisotropic layer comprises a UV-curable epoxy. 
     
     
         34 . A method for mechanically and electrically coupling internal components of a swallowable sensor device, comprising:
 preparing a plurality of printed circuit (PC) boards having opposing first and second surfaces, wherein each PC board has one or more spacers disposed on the first surface, a plurality of holes extending between the first and second surfaces, and a keyed hole extending between the first and second surfaces;   contiguously placing each PC board on a conductor that is aligned with the keyed hole of each PC board, such that the one or more spacers of a first PC board abut against the second surface of a second PC board; and   inserting a plurality of conductors through the plurality of holes in each PC board.   
     
     
         35 . A method for mechanically and electrically coupling internal components of a swallowable sensor device, comprising:
 preparing a plurality of printed circuit (PC) boards having opposing first and second surfaces, wherein each PC board has a plurality of keyed holes extending between the first and second surfaces;   placing each PC board on conductors aligned with the keyed holes of each PC board to form a PC assembly;   compressing the PC assembly with a pre-determined pressure; and   fixedly connected a first and last PC board of the PC assembly to the conductors.   
     
     
         36 . A method for testing swallowable sensor devices, comprising:
 providing an assembly having a plurality of wells formed therein, each well having connection points that are electrically coupled to edge connection points;   urging the respective swallowable sensor devices into the respective wells formed in the assembly, wherein tests points on the respective swallowable sensor devices are electrically connected to the electrical connection points of the respective wells; and   sending electrical signals through the edge connection points to test the swallowable sensor devices.   
     
     
         37 . The method of  claim 36 , further comprising:
 sealing the swallowable sensor devices within the assembly.