Multi-Axis Analyte Sensor Structure for Flexibility and Durability
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Solution Overview
Problem
Conventional glucose sensors suffer from mechanical weaknesses, leading to breakage, and strengths that make them uncomfortable for patients, while also failing to provide reliable, continuous, and accurate measurements over extended periods.
Innovation Solution
A continuous analyte sensor design featuring an elongated conductive body with a Young's modulus of 160GPa to 220GPa and yield strength of at least 400 MPa, capable of multi-axis bending and flexing, incorporating a silver-containing material with specific particle size and shape, and a membrane with Shore hardness of 70A to 55D for durability and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional glucose sensors are made with high strength materials, then durability is improved, but patient comfort deteriorates due to rigidity and discomfort
Solution Approach 1:
The patent applies parameter changes by precisely controlling the Young's modulus within the range of 180-220 GPa and yield strength of at least 400 MPa. This optimization of material parameters achieves a balance where the sensor has sufficient strength to resist breakage during implantation and use, while maintaining enough flexibility to conform to tissue and provide patient comfort during extended wear.
2Ease of operation
If conventional sensors are made flexible for comfort, then patient comfort is improved, but reliability deteriorates due to increased breakage risk
Solution Approach 1:
The patent resolves this contradiction by establishing specific parameter thresholds: Young's modulus of 180-220 GPa and yield strength of at least 400 MPa. These parameter changes ensure the sensor maintains adequate flexibility for comfort while preserving sufficient mechanical strength and reliability to withstand implantation procedures and continuous use without premature failure.
3Ease of manufacture
If conventional sensors use standard materials, then manufacturing is simplified, but measurement precision deteriorates over extended periods due to mechanical failure
Solution Approach 1:
The patent applies parameter changes by specifying precise material properties (Young's modulus: 180-220 GPa, yield strength: ≥400 MPa) that ensure sensor durability and measurement reliability over extended periods. While this requires controlled manufacturing processes to achieve the specified parameters, it prevents sensor breakage and degradation that would compromise measurement precision, thereby ensuring accurate glucose monitoring throughout the sensor's operational lifespan.
Data Source
Figure 1A
Figure 1B~1C
Figure 1D~1G
AI summary
Analyte sensors and methods of manufacturing same are provided, including analyte sensors comprising multi-axis flexibility. For example, a multi-electrode sensor system 800 comprising two working electrodes and at least one reference/counter electrode is provided. The sensor system 800 comprises first and second elongated bodies El, E2, each formed of a conductive core or of a core with a conductive layer deposited thereon, insulating layer 810 that separates the conductive layer 820 from the elongated body, a membrane layer deposited on top of the elongated bodies El, E2, and working electrodes 802', 802" formed by removing portions of the conductive layer 820 and the insulating layer 810, thereby exposing electroactive surface of the elongated bodies El, E2.