Multianalyte Sensor Assembly Flexibility via Segmented Stacking
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Solution Overview
Problem
Existing multianalyte sensors for in vivo monitoring, such as glucose and lactate, face challenges in flexibility and comfort due to their thickness, which can lead to reduced sensor longevity and increased discomfort for patients.
Innovation Solution
A sensor assembly comprising two analyte sensors coupled together with a midlayer containing a coupling material and air gaps, allowing each sensor to flex independently, thereby enhancing flexibility and comfort while maintaining effective analyte monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple single analyte sensors are joined together to form a multianalyte sensor assembly, then the ability to monitor multiple analytes is improved, but the thickness of the sensor assembly increases
Solution Approach 1:
The sensor assembly is divided into multiple individual sensor layers, each dedicated to monitoring a specific analyte. These segmented sensor layers are stacked together with coupling material between them, allowing each layer to maintain its own flexibility while contributing to the overall multianalyte monitoring capability.
Solution Approach 2:
Multiple sensor layers are nested within a compact stacked configuration, with each sensor layer contained within the overall assembly structure. This nesting approach allows multiple sensors to occupy a small vertical space, reducing the overall thickness compared to lateral arrangements.
2Ease of manufacture
If the multianalyte sensor assembly is made thicker to accommodate multiple sensors, then manufacturing complexity is reduced, but sensor flexibility and patient comfort deteriorate
Solution Approach 1:
The coupling material between sensor layers is designed with localized properties - it provides mechanical bonding while incorporating features that enable independent flexing of each sensor layer. This local quality differentiation allows the assembly to be manufacturable while maintaining flexibility where needed.
Solution Approach 2:
The sensor assembly is designed to be dynamically flexible rather than rigidly fixed. Each sensor layer can flex independently within the stacked structure, allowing the assembly to adapt to movement and deformation without compromising the manufacturing simplicity of the stacked configuration.
3Ease of operation
If individual sensors are made thinner to improve flexibility, then patient comfort is improved, but the sensor assembly becomes more complex to manufacture
Solution Approach 1:
Multiple thin sensor layers are merged into a single integrated stacked assembly. While each individual layer remains thin and flexible, their combination creates a unified structure that monitors multiple analytes simultaneously, reducing the overall system complexity compared to managing separate sensors.
Solution Approach 2:
The stacked sensor assembly serves multiple functions within a single structure - each layer monitors a different analyte, and the entire assembly provides multianalyte monitoring capability. This multi-functionality reduces the need for separate sensor systems, simplifying the overall device architecture.
Data Source
AI summary
In one embodiment, a sensor assembly is disclosed. The sensor assembly includes a first analyte sensor being formed on a first substrate and a second analyte sensor being formed on a second substrate. Wherein the first analyte sensor is coupled to the second analyte sensor within a coupling area defined by an overlap between the first analyte sensor and the second analyte sensor.