Skin contact sensor

Abstract

A sensor for detecting a target substance from a subject's skin includes a sensor housing, drive electronics housed within the sensor housing, an electrical connector providing an electrical connection between a contact interface and the drive electronics, and a removable substrate. The removable substrate comprises a plurality of electrodes disposed on the substrate and configured to provide electrical contact via a conductive gel layer with the subject's skin, conductive elements providing electrical connections between the electrodes and the contact interface, and the contact interface providing a removable electrical interface between the conductive elements and the electrical connector.

Description

[0001] Skin Contact Sensor

[0002] Technical Field

[0003] The technology relates to the field of non-invasive medical sensors, specifically sensors designed for detecting and monitoring target substances or biomarkers present in the interstitial fluid in an individual's skin. This field encompasses various applications, including monitoring glucose levels in diabetic patients, measuring hydration levels in athletes or patients with certain medical conditions, detecting the presence of specific biomarkers for early disease diagnosis, and assessing skin barrier function.

[0004] Background

[0005] Flexible medical patches have been widely investigated in recent years due to their potential for non-invasive, continuous monitoring of various physiological parameters and biomarkers. These patches are typically designed to be worn on the skin and can be used for a wide range of applications, including monitoring glucose levels in diabetic patients, measuring hydration levels in athletes, detecting the presence of specific biomarkers for early disease diagnosis, and assessing skin barrier function. One of the challenges in the development and use of flexible medical patches is the integration of these patches with reusable electronics, such as drive electronics 20 and processing unit, which are necessary for the proper functioning of the patch. The lack of standardized designs and interfaces for flexible medical patches and reusable electronics makes it difficult to create integrated disposable systems that can effectively combine the two components.

[0006] Another challenge is the absence of reusable and easy-to-use interconnection systems between medical patches and reusable electronics. Current interconnection systems are often complex and difficult to use, making it challenging for users to establish a reliable connection between the patch and the electronics. This complexity contributes to the lack of user-friendly interconnection systems between medical patches and reusable electronics.

[0007] Furthermore, there is a need for dependable and strong interconnection systems for med- ical patches with high pin count and reusable electronics. High pin count interconnections require precise alignment and secure contacts to ensure reliable data transfer. However, existing interconnection systems may not provide the necessary contact reliability, leading to the need for more reliable and robust interconnection systems for medical patches with high pin count and reusable electronics.

[0008] In addition to the challenges associated with interconnection systems, there is also a need for cost-effective processes to produce flexible patches with inbuilt interconnects on a large scale. The manufacturing processes for flexible patches with inbuilt interconnects can be expensive, particularly when using advanced materials and fabrication techniques. These high production costs make it difficult to develop affordable processes for mass- producing flexible patches with inbuilt interconnects, resulting in a need for cost-effective mass production methods.

[0009] In summary, the prior art presents several challenges in the development and use of flexible medical patches, including the need for disposable systems that can effectively combine flexible medical patches with reusable electronics, the absence of reusable and easy-to-use interconnection systems between medical patches and reusable electronics, the need for reliable and robust interconnection systems for medical patches with high pin count and reusable electronics, and the requirement for cost-effective mass production of flexible patches with inbuilt interconnects. Summary

[0010] According to a first aspect of the disclosure, a sensor is provided for detecting a target substance from a subject's skin. The sensor comprises a sensor housing, drive electronics housed within the sensor housing, an electrical connector providing an electrical connection between a contact interface and the drive electronics, and a removable substrate. The removable substrate comprises a plurality of electrodes disposed on the substrate and configured to provide electrical contact with the subject's skin, conductive elements providing electrical connections between the electrodes and the contact interface, and the contact interface providing a removable electrical interface between the conductive elements and the electrical connector. This configuration allows for a compact and effi- cient design, enabling the sensor to be easily worn by the subject and facilitating accurate detection of the target substance.

[0011] Optionally in some examples, the contact interface is a separate component from the removable substrate. This separation allows for greater flexibility in the design and manufacture of the sensor, and can facilitate easier replacement or repair of the contact interface if necessary.

[0012] Optionally in some examples, the contact interface is formed from the same material as the removable substrate. This can simplify the manufacturing process and reduce costs, as well as potentially improving the durability and reliability of the contact interface.

[0013] Optionally in some examples, the contact interface is secured to the removable substrate. This can provide a more stable and robust connection between the contact interface and the removable substrate, enhancing the reliability and performance of the sensor. Optionally in some examples, the electrical connection between the contact interface and the conductive elements is provided by one or more of the following: conductive tape or adhesive, through-hole plating, vias, rivets, folding of the removable substrate, embedded filaments, or printed conductive material. These various options for providing the electrical connection offer flexibility in the design and manufacture of the sensor, and can be selected based on factors such as cost, ease of manufacture, durability, and performance requirements.

[0014] Optionally in some examples, the contact interface is formed from a portion of the removable substrate. This can simplify the design and manufacture of the sensor, and can also reduce the overall size and complexity of the sensor. Optionally in some examples, the contact interface is formed by folding the removable substrate to provide an extended portion of the removable substrate. This can provide a compact and efficient design for the contact interface, and can also facilitate a secure and reliable electrical connection between the contact interface and the conductive elements.

[0015] Optionally in some examples, the sensor further comprises a support member for support- ing the removable substrate and allowing the contact interface to be compliant. This can provide additional stability and support for the removable substrate and contact interface, enhancing the reliability and performance of the sensor. The compliance of the contact interface can also facilitate a secure and reliable electrical connection with the electrical connector. Optionally in some examples, the support member is removably physically connected to the removable substrate. This allows for easy replacement or repair of the support member if necessary, and can also facilitate cleaning or maintenance of the sensor.

[0016] Optionally in some examples, the support member biases the contact interface into a protruding shape arranged to fit into the electrical connector. This can ensure a secure and reliable electrical connection between the contact interface and the electrical connector, enhancing the performance and reliability of the sensor.

[0017] Optionally in some examples, the support member is rigid. This can provide additional stability and support for the removable substrate and contact interface, enhancing the reliability and performance of the sensor.

[0018] Optionally in some examples, the support member is semi-rigid. This can provide a balance between flexibility and rigidity, allowing the support member to provide effective support for the removable substrate and contact interface while also accommodating some degree of movement or flexing.

[0019] Optionally in some examples, the electrical connector comprises pins for providing electrical connection between the conductive elements and the electrical connector upon contact with the contact interface . This can provide a secure and reliable electrical connection, enhancing the performance and reliability of the sensor. Optionally in some examples, the plurality of electrodes comprises between 3 and 6 electrodes per sensor 100 pixel. This can provide a high level of sensitivity and accuracy in the detection of the target substance, enhancing the performance of the sensor.

[0020] Optionally in some examples, the size of the electrodes is between 0.2 and 4 mm2. This can provide a balance between sensitivity and power consumption, enhancing the perfor- mance and efficiency of the sensor.

[0021] Optionally in some examples, the spacing between the electrodes is between 25 and 250 pm. This can provide a balance between sensitivity and power consumption, enhancing the performance and efficiency of the sensor.

[0022] Optionally in some examples, the sensor further comprises a securing adhesive for re- movably securing the removable substrate to the sensor housing. This can facilitate easy replacement or repair of the removable substrate, and can also provide a secure and stable connection between the removable substrate and the sensor housing, enhancing the reliability and performance of the sensor.

[0023] Optionally in some examples, the securing adhesive is a double-sided adhesive tape, This can provide a simple and effective means of securing the removable substrate to the sensor housing, and can also facilitate easy replacement or repair of the removable substrate. Optionally in some examples, the double-sided adhesive tape is an acrylic adhesive double-sided tape, a silicone adhesive double-sided tape, or a mixed acrylic-silicone adhesive double-sided tape. These types of adhesive tape can provide a strong and durable bond between the removable substrate and the sensor housing, enhancing the reliability and performance of the sensor. They can also be selected based on factors such as cost, ease of use, and compatibility with the materials of the removable substrate and sensor housing.

[0024] Brief Description of the Figures

[0025] Examples are described in more detail below with reference to the appended drawings. Figure la is a perspective view of the two-part version of the contact interface 80, viewed from above.

[0026] Figure lb is the assembled two-part contact interface 80 viewed from the same angle.

[0027] Figure 2a is a perspective view of the two-part version of the contact interface 80, viewed from below. Figure 2b is the assembled two-part contact interface 80 viewed from the same angle.

[0028] Figure 3 is a bottom view of the integrated contact interface 80, pre-assembly and with removable, protective liner in place.

[0029] Figure 4a is a cross-sectional view of the two-part version of the contact interface 80, showing the separate contact interface 80 and removable substrate 40 in a semi-rigid or flexible support member 90.

[0030] Figure 4b is a cross-sectional view of the two-part version of the contact interface 80, showing the separate contact interface 80 and removable substrate 40 in a semi-rigid or flexible support member 90, with the pieces connected.

[0031] Figure 4c shows the disposable patch with the fixed contact connector separately. Figure 4d shows the contact between the disposable patch with the fixed contact connector.

[0032] Figure 5a is a cross-sectional view of the two-part version of the contact interface 80, showing the contact interface 80 and removable substrate 40 in a rigid support member 90. Figure 5b is a cross-sectional view of the two-part version of the contact interface 80 with the fixed contact connector.

[0033] Figure 5c shows the contact between the disposable patch and the fixed contact connector. Figure 6a is a perspective view from the top of the one-piece version of the contact interface 80 before forming and showing the interconnect vias 68.

[0034] Figure 6b is a perspective view from the bottom of the one-piece version of the contact interface 80 before forming and showing the interconnect vias 68.

[0035] Figure 7a is a perspective view from the top of the one-piece version of the contact inter- face 80 after forming.

[0036] Figure 7b is a perspective view from the bottom of the one-piece version of the contact interface 80 after forming.

[0037] Figure 8a is a cross-sectional view of the one-part patch with a flexible element in the middle, where the element is a semi-rigid bar and black vias 68 connect the conductive layer below to the top.

[0038] Figure 8b is a cross-sectional view of the one-part patch with a rigid element in the middle, where the element is a rigid bar and black vias 68 connect the conductive layer below to the top.

[0039] Figure 9a is a top view of sensor housing 10 and components for securing the housing to the patient.

[0040] Figure 9b shows the same view as figure 9a but the bottom surface of the sensor housing 10 is shown, including electrical connector 30.

[0041] Features Description Text

[0042] The detailed description set forth below provides information and examples of the dis- closed technology with sufficient detail to enable those skilled in the art to practice the disclosure.

[0043] 1. Figure la

[0044] Figure la provides a perspective view of the sensor 100 from above, showcasing the removable substrate 40 and the contact interface 80. The removable substrate 40 is a component of the sensor 100 that plays a role in the detection of a target substance from a subject's skin. It is designed to support various elements of the sensor 100, including a plurality of electrodes 60 and conductive elements 70. The removable substrate 40 is designed to be easily detached and replaced, allowing for the sensor 100 to be reused with different substrates. This feature enhances the versatility and cost-effectiveness of the sensor 100, as it allows for the sensor 100 to be adapted to different detection tasks by simply replacing the removable substrate 40. The contact interface 80 is also visible in this figure, providing a removable electrical interface between the conductive elements 70 and the electrical connector 30.

[0045] 1.1. Removable Substrate Details

[0046] The removable substrate 40 is a component of the sensor 100 that supports various elements, including the electrodes 60 and conductive elements 70. The substrate 40 is designed to be easily detached and replaced, allowing for the sensor 100 to be reused with different substrates. This feature enhances the versatility and cost-effectiveness of the sensor 100, as it allows for the sensor 100 to be adapted to different detection tasks by simply replacing the removable substrate 40. The substrate 40 is designed to provide electrical contact with the subject's skin, facilitating the detection of the target substance. The substrate 40 may be made from a variety of materials, depending on the specific requirements of the detection task.

[0047] 1.1.1. Securing Adhesive Details

[0048] The removable substrate 40 is secured to the sensor housing 10 using a securing adhesive. This adhesive is designed to provide a strong yet removable bond between the substrate 40 and the sensor housing 10, allowing for the substrate to be easily detached and replaced. The adhesive may be a double-sided adhesive tape, which provides a secure bond while also allowing for easy removal. The adhesive may be an acrylic adhesive double-sided tape or a silicone adhesive double-sided tape, or a mixed acrylic-silicone adhesive double-sided tape, depending on the specific requirements of the sensor 100. The use of a securing adhesive enhances the versatility and reusability of the sensor 100, as it allows for different substrates to be used with the same sensor housing 10.

[0049] 1.1.2. Active Area Details

[0050] The active area 50 is a component of the removable substrate 40 that interfaces with the patient's skin. The active area 50 is designed to detect the target substance from the subject's skin, facilitating the detection process. The active area 50 is located on the lower face of the removable substrate 40, facing the patient's skin. The active area 50 supports the electrodes 60, which provide electrical contact with the patient's skin via a conductive gel interface.

[0051] 1.1.3. Electrodes Details The electrodes 60 are a component of the removable substrate 40 and are a part of the sensor 100. They are designed to provide electrical contact with the subject's skin via a conductive gel interface, facilitating the detection of the target substance. Collectively, the combined electrodes 60 comprise a so-called “sensor 100 pixel”. In some configurations, there can be up to 16 sensor pixels. The number of sensor pixels can vary depending on the specific requirements of the detection task. The electrodes 60 are disposed on the substrate 40 and are configured to interact with the skin of the subject. In some configurations, there can be up to 6 electrodes 60 per sensor 100 pixel. The number of electrodes 60 can vary between 3 and 6 per sensor 100 pixel, depending on the specific requirements of the detection task. The size of the electrodes 60 can be between 0.2 and 4 mm2, and the spacing between the electrodes 60 within a sensor 100 pixel can be between 25 and 250 pm. The electrodes 60 are a part of the active area 50 of the removable substrate 40 and play a role in the detection of the target substance from the subject's skin.

[0052] 1.1.3.1. Reservoir Details

[0053] Each sensor 100 pixel contains a reservoir, which is a defined volume containing conduc- tive gel positioned directly above the electrodes 60. The reservoir serves two essential functions: (1) it provides the conductive medium through which electrical contact is made between the electrodes 60 and the skin, and (2) it acts as the collection chamber into which the target and reference substances are extracted from the interstitial fluid beneath the skin surface. The reservoir supports the gel, which contains the enzyme that reacts with the target substance to facilitate its detection.

[0054] 1.1.3.2. Gel Details

[0055] The function of the gel is [1] the (conductive) medium through which electric contact is made between the extraction electrodes and the skin, and [2] the medium into which interstitial fluid is extracted and in which glucose - or any target analyte - is subsequently detected and quantified, optionally with the help of an enzyme (as is the case with glucose). The gel may be disposed on the sensor pixels and is configured to interact with the skin of the subject. The gel may contain an enzyme that reacts with the target substance to facilitate its detection. The gel is a part of the active area 50 of the removable substrate 40 and plays a role in the detection of the target substance from the subject's skin. The gel enhances the accuracy and reliability of the sensor 100, as it allows for a more detailed and precise detection of the target substance.

[0056] 1.1.3.3. Enzyme Details

[0057] The enzyme, incorporated into the conductive gel within the reservoir, may be designed to react with the target substance to facilitate its detection from the subject's skin. The enzyme facilitates the detection and measurement of the target substance. The enzyme provides the sensor 100 with specificity of responses to the target and / or reference substances. For example, glucose oxidase can be used for detecting glucose.

[0058] 1.1.4. Extraction Electrodes Details The extraction electrodes are a component of the electrodes 60 and are designed to apply a current to the subject's skin. This current causes transdermal iontophoretic extraction of the target substance and a reference substance into each reservoir of the one or more sensor pixels. This process facilitates the detection of the target substance from the subject's skin. 1.1.5. Target Detection Electrodes Details

[0059] The target detection electrodes are designed to detect a current that corresponds to an amount of the target substance extracted into each of the one or more sensor pixels.

[0060] 1.1.6. Reference Detection Electrodes Details

[0061] The reference detection electrodes are designed to detect a current that corresponds to an amount of the reference substance extracted into each of the one or sensor pixels.

[0062] This process facilitates the detection of the reference substance from the subject's skin and provides a reference point for the detection of the target substance.

[0063] 1.1.7. Conductive Elements Details

[0064] The conductive elements 70 provide electrical connections between the electrodes 60 and the contact interface 80. The conductive elements 70 facilitate the flow of electrical signals between the electrodes 60 and the contact interface 80, enabling the detection of the target substance from the subject's skin. The conductive elements 70 can be manufactured using a variety of techniques, including thin film deposition techniques, chemical or laser etching processes, application of conductive adhesive material, additive manufacturing processes, or conductive printing technology.

[0065] 1.1.8. Tracks Details The tracks 65 are an example of conductive elements 70 and are designed to provide electrical connections between the electrodes 60 of the active area 50 and the contact interface 80.

[0066] 1.1.9. Contact Interface Details The contact interface 80 is a component of the removable substrate 40 and is a part of the sensor 100. It is designed to provide a removable electrical interface between the conductive elements 70 and the electrical connector 30.

[0067] In some configurations, the contact interface 80 is formed from the same continuous material as the removable substrate 40. This design choice can offer several advantages. Firstly, it can simplify the manufacturing process, as the same piece of material can be used for both components, potentially reducing costs and complexity.

[0068] 1.1.10. Pins Details

[0069] The pins are a component of the contact interface 80 and are designed to provide electrical connection between the conductive elements 70 and the electrical connector 30 upon contact.

[0070] 2. Figure lb

[0071] Figure lb provides a perspective view of the assembled two-part contact interface 80, viewed from the same angle as Figure la. This figure showcases the contact interface 80 and the removable substrate 40 in their assembled state, providing a clear view of how these components fit together within the sensor 100. The contact interface 80 is shown as a separate component from the removable substrate 40, providing a removable electrical interface between the conductive elements 70 and the electrical connector 30. The removable substrate 40 comprises the electrodes 60 and conductive elements 70.

[0072] 3. Figure 2a Figure 2a provides a perspective view of the two-part version of the contact interface 80, viewed from below. This figure showcases the contact interface 80 and the removable substrate 40 from a different angle, providing a view of the underside of these components.

[0073] In this figure, support member 90 is shown supporting the removable substrate 40 and allowing the contact interface 80 to be compliant. The support member 90 provides sta- bility and support to the contact interface 80, ensuring consistent and secure electrical connection with the drive electronics 20. The support member 90 can be either rigid or semi-rigid, depending on the specific requirements of the sensor 100. A rigid support member 90 provides stability and support to the contact interface 80, ensuring consistent and secure electrical connection with the drive electronics 20. A semi-rigid support member 90 provides a balance between flexibility and rigidity, providing a versatile solution for a wide range of applications and user scenarios. 4. Figure 2b

[0074] Figure 2b provides a perspective view of the assembled two-part contact interface 80, viewed from below. This figure showcases the contact interface 80 and the removable substrate 40 in their assembled state, providing a view of the underside of these components. The contact interface 80 is shown as a separate component from the removable substrate 40, providing a removable electrical interface between the conductive elements 70 and the electrical connector 30.

[0075] 5. Figure 3

[0076] Figure 3 presents a bottom view of the integrated contact interface 80, pre-assembly, and with a removable, protective liner in place. The contact interface 80 is formed from a portion of the removable substrate 40.

[0077] 6. Figure 4a

[0078] Figure 4a illustrates a cross-sectional view of the two-part version of the contact interface 80, showing the separate contact interface 80 and removable substrate 40 in a semirigid or flexible support member 90. The support member 90 is designed to support the removable substrate 40 and allow the contact interface 80 to be compliant. This design choice provides a balance between flexibility and rigidity, providing a versatile solution for a wide range of applications and user scenarios. The support member 90 enhances the accuracy and reliability of the sensor 100, as it provides stability and support to the contact interface 80, ensuring consistent and secure electrical connection with the drive electronics 20.

[0079] 6.1. Semi-Rigid Portion Details

[0080] The semi-rigid portion 95 enables the compressible portion of the support member 90 to the contact interface 80 to flex. This design choice allows for reliable connection to compliant contacts within the electrical connector 30, increasing reliability of the overall system. The semi-rigid portion 95 allows for a balance between flexibility and rigidity, providing a versatile solution for a wide range of applications and user scenarios.

[0081] 7. Figure 4b Figure 4b shows the same cross-sectional view as Figure 4a but with the separate contact interface 80 and removable substrate 40 connected. This figure provides a clear visual representation of the assembled sensor 100, showcasing the relationship between its various components and their roles in the detection of the target substance from the subject's skin.

[0082] 8. Figure 4c

[0083] Figure 4c presents a cross-sectional view of the sensor 100 with the disposable patch and the fixed contact connector shown separately.

[0084] 8.1. Sensor Details The sensor 100 comprises several components, including a sensor housing 10, drive electronics 20, and a processing unit. The sensor 100 is designed to provide accurate and reliable detection of the target substance, enhancing the overall performance and reliability of the disclosure. The sensor 100 is designed to be versatile and adaptable, capable of detecting a wide range of target substances from a subject's skin. The sensor 100 is designed to be easy to use and to maintain and includes a removable substrate 40 that can be easily replaced when needed.

[0085] 8.1.1. Sensor Housing Details

[0086] The sensor housing 10 is designed to house the drive electronics 20 and the electrical connector 30. The sensor housing 10 provides a protective enclosure for these components, shielding them from external factors that could potentially interfere with their operation. In one configuration, sensor housing 10 is secured to the patient using strap 12, shown in Figure 9a and 9b. Strap 12 may be directly attached to sensor housing 10 or attached to housing bracket 14, wherein housing bracket 14 secures sensor housing 10.

[0087] 8.1.2. Drive Electronics Details The drive electronics 20 are housed within the sensor housing 10 and are designed to receive and process electrical signals from the active area 50. The drive electronics 20 also provide power and control signals to the active area 50, facilitating the detection of the target substance from the subject's skin. The drive electronics 20 comprise several components, including a processing unit, which further includes a processor, memory, and a sensor interface.

[0088] 8.1.3. Processing Unit Details

[0089] The processing unit is a component of the drive electronics 20 and is designed to process the electrical signals received from the active area 50. The processing unit comprises several components, including a processor and a memory. The processing unit is designed to execute computer program code stored in the memory, facilitating the detection of the target substance from the subject's skin. 8.1.6. Sensor Interface Details

[0090] The sensor interface is a component of the processing unit within the drive electronics 20 of the sensor 100. The sensor interface is designed to handle the electrical signals generated by the active area 50 when the target substance interacts directly or indirectly with the electrodes 60. These signals are then processed by the processor, which is also a part of the processing unit.

[0091] 8.1.7. Electrical Connector Details

[0092] The electrical connector 30 is a component of the sensor 100 and is designed to provide an electrical connection between the contact interface 80 and the drive electronics 20. The electrical connector 30 is designed to be robust and reliable, capable of maintaining a secure and consistent electrical connection between the contact interface 80 and the drive electronics 20. This ensures that the electrical signals generated by the active area 50 can be accurately transmitted to the drive electronics 20 for processing. The electrical connector 30 is designed to be easy to use and to maintain and allow for easy connection and disconnection of the contact interface 80. This enhances the versatility and reusability of the sensor 100, as it allows for the sensor 100 to be easily adapted to different detection tasks by simply replacing the contact interface 80.

[0093] 9. Figure 4d

[0094] Figure 4d provides a visual representation of the contact between the disposable patch and the fixed contact connector within the sensor 100. This figure showcases the relation- ship between the disposable patch, which includes the removable substrate 40 and the contact interface 80, and the fixed contact connector, which is a part of the sensor housing

[0095] 10. The disposable patch is designed to be easily attached and detached from the fixed contact connector, allowing for the sensor 100 to be reused with different patches. This enhances the versatility and cost-effectiveness of the sensor 100, as it allows for the sen- sor 100 to be adapted to different detection tasks by simply replacing the disposable patch.

[0096] The fixed contact connector is designed to provide a secure and consistent electrical connection with the contact interface 80, ensuring that the electrical signals generated by the active area 50 can be accurately transmitted to the drive electronics 20 for processing. 10. Figure 5a

[0097] Figure 5a provides a cross-sectional view of the two-part version of the contact interface 80, showing the separate contact interface 80 and removable substrate 40 in a rigid support member 90. The rigid support member 90 is designed to provide stability and support to the contact interface 80, ensuring consistent and secure electrical connection with the drive electronics 20. This design choice enhances the accuracy and reliability of the sensor 100, as it ensures that the contact interface 80 maintains its position and orientation for reliable and repeatable connections. The rigid support member 90 is also designed to withstand the rigors of regular use, contributing to the overall durability and longevity of the sensor 100. This figure provides a clear visual representation of the sensor 100 from a different perspective, showcasing the relationship between its various components and their roles in the detection of the target substance from the subject's skin.

[0098] 11. Figure 5b

[0099] Figure 5b provides a cross-sectional view of the two-part version of the contact interface 80, showing the separate contact interface 80 and removable substrate 40 in a semi-rigid support member 90. The semi-rigid support member 90 is designed to provide a balance between flexibility and rigidity, providing a versatile solution for a wide range of applications and user scenarios. The semi-rigid support member 90 allows for the contact interface 80 to flex, ensuring a reliable connection to compliant contacts within the electrical connector 30. This design choice enhances the accuracy and reliability of the sensor 100, as it allows for a more detailed and precise detection of the target substance. The semi-rigid support member 90 is also designed to enhance the durability and longevity of the contact interface 80, contributing to the overall robustness and reliability of the medical patch and reusable electronics system. 12. Figure 5c

[0100] Figure 5c provides a cross-sectional view of the two-part version of the contact interface 80, showing the removable substrate 40 in a semi-rigid support member 90 connected to electrical connector 30.

[0101] 13. Figure 6a Figure 6a provides a perspective view from the top of the one-piece version of the contact interface 80 before forming and showing the interconnect vias 68 for each pixel.

[0102] 13.1. Vias Details The vias 68 are a component of the conductive elements 70 and are designed to provide electrical connections between the conductive elements 70 and the contact interface 80. The vias 68 facilitate the flow of electrical signals between the conductive elements 70 and the contact interface 80, enabling the detection of the target substance from the subject's skin. The vias 68 can be manufactured using a variety of techniques, including through- hole plating, which provides a secure and reliable electrical connection.

[0103] 14. Figure 6b

[0104] Figure 6b provides a perspective view from the bottom of the one-piece version of the contact interface 80 before forming and showing the interconnect vias 68 for each pixel. The contact interface 80 is formed from a portion of the removable substrate 40.

[0105] 15. Figure 7a

[0106] Figure 7a provides a perspective view from the top of the one-piece version of the contact interface 80 after forming and showing the interconnect vias 68 for each pixel.

[0107] 15.1. Contact Interface Details The contact interface 80 is a component of the removable substrate 40 and is a part of the sensor 100. It is designed to provide a removable electrical interface between the conductive elements 70 and the electrical connector 30. The contact interface 80 is formed from a portion of the removable substrate 40. This design choice simplifies the manufacturing process and enhances the compatibility between the contact interface 80 and the removable substrate 40, resulting in a more reliable and robust connection between these components. The contact interface 80 provides a removable electrical interface between the conductive elements 70 and the electrical connector 30, facilitating the detection of the target substance from the subject's skin. The contact interface 80 is a part of the sensor 100 and plays a role in the detection of the target substance from the subject's skin.

[0108] 15.1.1. Interconnect Vias Details

[0109] The interconnect vias 68 are a component of the conductive elements 70 and are designed to provide electrical connections between the conductive elements 70 and the contact interface 80. The interconnect vias 68 facilitate the flow of electrical signals between the conductive elements 70 and the contact interface 80, enabling the detection of the target substance from the subject's skin. The interconnect vias 68 can be manufactured using a variety of techniques, including through-hole plating, which provides a secure and reliable electrical connection. The interconnect vias 68 are a part of the conductive elements 70 of the removable substrate 40 and play a role in the detection of the target substance from the subject's skin. The interconnect vias 68 enhance the accuracy and reliability of the sensor 100, as they allow for a more detailed and precise detection of the target substance. 16. Figure 7b

[0110] Figure 7b provides a perspective view from the bottom of the one-piece version of the contact interface 80 after forming and showing the interconnect vias 68 for each pixel.

[0111] 17. Figure 8a

[0112] Figure 8a presents a cross-sectional view of the one-part patch with a flexible element in the middle, where the element is a semi-rigid bar, and black vias 68 connect the conductive layer below to the top. The flexible element in the middle of the one-part patch is designed to allow a balance between flexibility and rigidity, providing a versatile solution for a wide range of applications and user scenarios. The flexible element allows for the contact interface 80 to flex, ensuring a reliable connection to compliant contacts within the electrical connector 30. This design choice enhances the accuracy and reliability of the sensor 100, as it allows for a more detailed and precise detection of the target substance. The black vias 68 are designed to provide electrical connections between the conductive layer below and the top, facilitating the flow of electrical signals and enabling the detection of the target substance from the subject's skin. 18. Figure 8b

[0113] Figure 8b provides a cross-sectional view of the one-part patch with a rigid element in the middle, where the element is a rigid bar, and black vias 68 connect the conductive layer below to the top. The rigid element in the middle of the one-part patch is designed to provide stability and support to the contact interface 80, ensuring consistent and se- cure electrical connection with the drive electronics 20. This design choice ensures that the contact interface 80 maintains its position and orientation for reliable and repeatable connections. The rigid element is also designed to withstand the rigors of regular use, contributing to the overall durability and longevity of the sensor 100.

[0114] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises," "comprising," "includes," and / or "including" when used herein specify the presence of stated features, integers, actions, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, actions, steps, operations, elements, components, and / or groups thereof. It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the scope of the present disclosure. Relative terms such as "below" or "above" or "upper" or "lower" or "horizontal" or "vertical" may be used herein to describe a relationship of one element to another element as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present.

[0115] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. It is to be understood that the present disclosure is not limited to the aspects described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the present disclosure and appended claims. In the drawings and specification, there have been disclosed aspects for purposes of illustration only and not for purposes of limitation, the scope of the disclosure being set forth in the following claims.

Claims

1. Asensor (100) for detecting a target substance from a subject's skin, the sensor (100) comprising: a sensor housing (10); drive electronics (20) housed within the sensor housing (10); an electrical connector (30) providing an electrical connection between a contact interface (80) and the drive electronics (20); a removable substrate (40), comprising; a plurality of electrodes (60) disposed on the substrate (40) and configured to provide electrical contact with the subject's skin; conductive elements (70) providing electrical connections between the electrodes (60) and the contact interface (80); and the contact interface (80) providing a removable electrical interface between the conductive elements (70) and the electrical connector (30).

2. The sensor (100) according to claim 1, wherein the contact interface (80) is a separate component from the removable substrate (40).

3. The sensor (100) according to claims 1 or 2, wherein the contact interface (80) is formed from the same material as the removable substrate (40).

4. The sensor (100) according to any one of claims 1 to 3, wherein the contact interface (80) is secured to the removable substrate (40).

5. The sensor (100) according to any one of claims 1 to 4, wherein the electrical connection between the contact interface (80) and the conductive elements (70) is provided by one or more of the following: conductive tape or adhesive, through-hole plating, vias (68), rivets, folding of the removable substrate (40), embedded filaments, or printed conductive material.

6. The sensor (100) according to claim 1, wherein the contact interface (80) is formed from a portion of the removable substrate (40).

7. The sensor (100) according to claim 6, wherein the contact interface (80) is formed by folding the removable substrate (40) to provide an extended portion of the removable substrate (40).

8. The sensor (100) according to any one of claims 1 to 7, further comprising a support member (90) for supporting the removable substrate (40) and allowing the contact interface (80) to be compliant.

9. The sensor (100) according to claim 8, wherein the support member (90) is removablyphysically connected to the removable substrate (40).

10. The sensor (100) according to claim 8 or 9, wherein the support member (90) biases the contact interface (80) into a protruding shape arranged to fit into the electrical connector (30).

11. The sensor (100) according to any one of claims 8 to 10, wherein the support member (90) is rigid.

12. The sensor (100) according to any one of claims 8 to 10, wherein the support member (90) is semi-rigid.

13. The sensor (100) according to any one of claims 1 to 12, wherein the electrical con- nector (30) comprises pins for providing electrical connection between the conductive element (70) and the electrical connector (30) upon contact with the contact interface (80).

14. The sensor (100) according to any one of claims 1 to 13, wherein the plurality of electrode (60) comprises between 3 and 6 electrode (60) per sensor (100) pixel.

15. The sensor (100) according to any one of claims 1 to 14, wherein the size of the electrode (60) is between 0.2 and 4 mm2.

16. The sensor (100) according to any one of claims 1 to 15, wherein the spacing between the electrodes (60) is between 25 and 250 pm.

17. The sensor (100) according to any one of claims 1 to 16, further comprising a securing adhesive for removably securing the removable substrate (40) to the sensor housing(10).

18. The sensor (100) according to claim 17, wherein the securing adhesive is a doublesided adhesive tape.

19. The sensor (100) according to claim 18, wherein the double-sided adhesive tape is an acrylic adhesive double-sided tape or a silicone adhesive double-sided tape or a mixed acrylic-silicone adhesive double-sided tape.

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