Analyte Sensor Housing Assembly Using Infrared Laser Welding

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Solution Overview

Problem

Current analyte monitoring systems for diabetes patients face challenges such as discomfort due to adhesives and mechanical failures, and require improved reliability and ease of use, along with enhanced moisture control and extended shelf stability.

Innovation Solution

The analyte monitoring system incorporates an electronics housing with a shell and mount secured by collapsible ribs made of infrared absorbent and transmissive materials, using infrared laser welding for assembly, and features a collar with a groove for an ultraviolet-curable adhesive to secure the sensor, ensuring secure and comfortable sensor insertion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesives are used to assemble the analyte monitoring system, then the components can be easily assembled, but the adhesives can cause dermal irritation and discomfort to users

Engineering Contradiction:

Improveassembly easeVSAvoiddermal irritation

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent removes the adhesive layer from the sensor assembly process. Instead of using adhesives to attach the sensor to the skin, the sensor is inserted through a sharp device that creates a pathway into the dermal layer, eliminating the need for adhesive materials that cause dermal irritation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesive) with a mechanical insertion system. The sharp device mechanically inserts the sensor into the skin, substituting the adhesive bonding process with a mechanical insertion process that avoids harmful chemicals.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If mechanical fasteners are used to secure the analyte monitoring system, then the assembly can be mechanically secured, but the system becomes more susceptible to mechanical failure

Engineering Contradiction:

Improvemechanical securityVSAvoidmechanical failure susceptibility

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent removes mechanical fasteners from the sensor assembly. The sensor is held in place by the insertion mechanism itself and the natural adhesion to the tissue, eliminating separate mechanical fastening components that could fail.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the insertion function and securing function into a single integrated mechanism. The sharp device both inserts the sensor and secures it in place through the insertion action itself, eliminating the need for separate fastening components.

Inventive Principle:

Principle #5Merging (Combining)

3Volume of moving object

If the sensor control device has a small form-factor for comfort and convenience, then the device is more comfortable to wear, but the assembly and application process becomes more difficult

Engineering Contradiction:

Improvedevice sizeVSAvoidapplication difficulty

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The patent employs a nested structure where the sensor is inserted through the sharp device, which is then retracted, leaving the sensor in place. The electronics housing and other components are integrated in a compact nested arrangement, allowing small size while maintaining ease of application through the automated insertion mechanism.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 system provides a reliable, comfortable, and easy-to-use analyte monitoring solution with improved stability and reduced risk of mechanical failures, enhancing patient adherence to frequent glucose monitoring.

Implementation Method 1

The welding portion including an infrared transmissive material. The first collapsible rib is configured to weld to the welding portion

Methodology Applied

Scientific EffectInfrared laser welding: Laser Beam Welding

Implementation Method 2

The first collapsible rib on a first side, the first collapsible rib axially aligned with the welding portion and including an infrared absorbent material

Methodology Applied

Scientific EffectInfrared absorption: Absorption (EM radiation)

Implementation Method 3

a collar with a groove for an ultraviolet-curable adhesive to secure the sensor

Methodology Applied

Scientific EffectUltraviolet curing: Photopolymerisation

Data Source

PatentUS20240252065A1Systems, devices, and methods for analyte monitoring

Publication Date: 2024.08.01 ABBOTT DIABETES CARE INC

AI summary

An analyte monitoring system including an electronics housing including a shell having a first aperture and a welding portion proximate the first aperture, the welding portion including an infrared transmissive material, a mount having a second aperture axially aligned with the first aperture, wherein the mount is configured to be secured to the shell to define an interior space, a collar disposed within the interior space and having a central aperture axially aligned with the first aperture and the second aperture, and a first collapsible rib on a first side, the first collapsible rib axially aligned with the welding portion and including an infrared absorbent material, wherein the first collapsible rib is configured to weld to the welding portion, a circuit board disposed within the interior space, and an analyte sensor having a distal portion and a proximal portion.