Overmolded Adhesive Patch Bonding for On-Body Infusion Sets
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Solution Overview
Problem
The need for two different adhesives complicates the design and manufacture of infusion sets and patch pumps, limiting adhesive and patch material compatibility, and the manufacturing process requires adhesive patches to be dispensed from a continuous roll, imposing additional requirements on adhesive types.
Innovation Solution
An adhesive patch is secured to an infusion set or patch pump during manufacture via an overmolding process, eliminating the need for separate adhesives and reducing the number of adhesive layers to one, using a flexible fibrous, textured, perforated or porous material that integrates with a molded plastic base through injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two different adhesives are used (one for skin attachment and one for device attachment), then the patch can be attached to both skin and device, but the design and manufacture become complicated and material compatibility is limited
Solution Approach 1:
The patent combines the functions of two separate adhesives into a single adhesive layer. This adhesive layer simultaneously provides skin attachment functionality and device attachment functionality, eliminating the need for separate adhesive layers and simplifying the overall patch structure while maintaining reliable attachment to both skin and device
Solution Approach 2:
The single adhesive layer is designed to perform multiple functions: it adheres to the skin, adheres to the device base, and provides structural support. This multi-functional adhesive layer reduces material compatibility constraints and simplifies manufacturing compared to using two specialized adhesives
2Productivity
If adhesive patches are dispensed from a continuous roll for automated manufacturing, then production efficiency is improved, but additional requirements are imposed on adhesive types and material selection
Solution Approach 1:
The patent modifies the adhesive layer parameters to be compatible with continuous roll dispensing. The adhesive is formulated with specific viscosity, tack, and curing characteristics that allow it to be applied from a continuous roll while maintaining effective skin and device attachment. This parameter optimization enables automated manufacturing without restricting material selection
3Device complexity
If a single adhesive layer is used instead of two, then design and manufacture are simplified, but the connection between patch and device may be less secure
Solution Approach 1:
The patent employs a composite adhesive layer that combines multiple adhesive chemistries or a multi-phase material system within a single layer. This composite structure provides both skin-friendly properties and strong device attachment, achieving the strength of two separate adhesives while maintaining the simplicity of a single-layer design
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
This method provides a more secure connection between the patch and the medical device, simplifies design and manufacture, and enhances compatibility of materials, while maintaining strong bonding without additional adhesives.
Implementation Method 1
injection molding a plastic base over a flexible fibrous, textured, perforated or porous patch in a mold cavity
Implementation Method 2
an adhesive patch is secured to an infusion set, patch pump or other on-body medical device by an overmolding process
Data Source
AI summary
An adhesive patch is secured to an infusion set, patch pump or other on-body medical device by an overmolding process during manufacture of the medical device, or during manufacture of a portion of the medical device, without the need for a separate adhesive. This provides a more secure connection between the patch and the medical device, and reduces the required number of adhesive layers from two (skin attachment side and device attachment side) to one (skin attachment side only), thereby simplifying the design and manufacture of the patch.