Flexible Glucose Sensor Stack for Low-Pain Continuous Monitoring
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Solution Overview
Problem
Current glucose monitoring sensors are painful to insert, require frequent calibration with painful finger-sticks, and have limitations in long-term durability and cost-effectiveness for continuous glucose monitoring in diabetic patients.
Innovation Solution
A planar flexible analyte sensor with a platinum-sputtered layer on a polyester substrate, incorporating an insulating dielectric layer, glucose oxidase, and a glucose limiting membrane, fabricated using a roll-to-roll process to reduce production costs and enhance sensor accuracy and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If subcutaneously implanted sensors are used for continuous glucose monitoring, then continuous monitoring capability is improved, but insertion pain and risk of infection increase
Solution Approach 1:
The patent employs a flexible planar sensor design with thin film structures that can be inserted into subcutaneous tissue with minimal trauma. The flexible base layer and thin electrochemical sensing stack allow the sensor to conform to tissue contours, reducing insertion pain and improving patient comfort while maintaining continuous monitoring capability.
2Measurement precision
If traditional meters and test strips are used for blood glucose monitoring, then measurement capability is provided, but frequent painful finger-sticks are required
Solution Approach 1:
The patent extracts the measurement function from the painful finger-stick procedure by implementing a continuous glucose sensor that measures glucose levels in interstitial fluid through a minimally invasive subcutaneous insertion. This eliminates the need for repeated punctures of the finger while maintaining measurement capability through continuous monitoring of glucose in the interstitial fluid.
3Duration of action of moving object
If currently available continuous monitoring devices are used, then continuous glucose data is obtained, but frequent calibration with finger-sticks is required
Solution Approach 1:
The patent implements factory calibration of the electrochemical sensor during the manufacturing process, establishing a known relationship between the sensor signal and glucose concentration. This self-calibrating approach eliminates the need for frequent post-deployment calibration procedures, allowing the sensor to maintain accurate continuous monitoring without requiring additional patient time for calibration finger-sticks.
4Ease of manufacture
If roll-to-roll fabrication process is used for sensor production, then production cost is reduced, but manufacturing precision may be affected
Solution Approach 1:
The patent segments the sensor fabrication into discrete sequential steps including substrate preparation, electrode deposition, enzyme layer application, and membrane formation. Each step is optimized for roll-to-roll processing while maintaining precision through controlled deposition parameters and quality assurance measures at each stage, enabling cost-effective high-volume production without sacrificing sensor performance.
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 provides improved accuracy and reduced pain during use, along with longer sensor lifespan and lower production costs, addressing the limitations of traditional glucose monitoring systems.
Implementation Method 1
a first electrode formed from a layer of sputtered platinum on the base layer
Implementation Method 2
the glucose oxidase is used to catalyze the reaction between glucose and oxygen to yield gluconic acid and hydrogen peroxide (H 2 O 2 ). The hydrogen peroxide reacts electrochemically
Implementation Method 3
the glucose oxidase is used to catalyze the reaction between glucose and oxygen
Implementation Method 4
the glucose oxidase is used to catalyze the reaction between glucose and oxygen to yield gluconic acid and hydrogen peroxide
Implementation Method 5
an insulating dielectric layer over the base layer, wherein the insulating dielectric layer leaves a portion of the first electrode exposed
Implementation Method 6
a glucose limiting membrane over the glucose oxidase layer
Data Source
Figure 1~3
Figure 4
Figure 5~6
AI summary
Analyte sensors and methods for fabricating analyte sensors are provided. In an exemplary embodiment, a planar flexible analyte sensor includes a flexible base layer and a first electrode formed from a layer of sputtered platinum on the base layer. Also, the analyte sensor includes an insulating dielectric layer over the base layer, wherein the insulating dielectric layer leaves a portion of the first electrode exposed. Further, the analyte sensor includes an electrochemical sensing stack over the exposed portion of the first electrode, including a glucose oxidase layer over the layer of sputtered platinum and a glucose limiting membrane over the glucose oxidase layer.