Planar Flexible Glucose Sensor Layout for Continuous Low-Pain Sensing
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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-effective large-scale production, leading to suboptimal glycemic control for diabetic patients.
Innovation Solution
Development of a planar flexible analyte sensor with a platinum-sputtered layer on a polyester substrate, featuring an insulating dielectric layer, silver/silver chloride ink, and a glucose oxidase layer, fabricated using roll-to-roll processes to reduce production costs and enhance sensor accuracy and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If subcutaneous implantation is used for continuous monitoring, then continuous glucose measurement is achieved, but insertion pain and infection risk increase
Solution Approach 1:
The patent replaces the mechanical insertion process of traditional subcutaneous sensors with a microneedle array system that utilizes minimally invasive percutaneous insertion. The microneedles are designed to penetrate the skin barrier with reduced pain and trauma, substituting the harmful mechanical insertion with a gentler alternative that achieves the same continuous monitoring function.
Solution Approach 2:
The sensor employs a flexible substrate that allows the microneedle array to conform to the skin surface and adapt during insertion. This flexibility reduces mechanical stress and pain during insertion while maintaining the integrity of the sensor components, thereby reducing insertion pain without compromising continuous monitoring capability.
2Measurement precision
If traditional meter and test strip systems are used, then blood glucose measurement is achieved, but frequent painful finger-sticks are required
Solution Approach 1:
The microneedle array is pre-loaded with glucose sensing reagents and enzymes before insertion. Once inserted, the sensor continuously measures glucose in the interstitial fluid without requiring repeated blood draws. This preliminary preparation eliminates the need for frequent finger-sticks while maintaining measurement precision.
Solution Approach 2:
The sensor provides continuous glucose monitoring by maintaining a persistent connection to the interstitial fluid through the microneedle array. This continuous action replaces the discrete, repeated finger-stick measurements with an uninterrupted measurement stream, eliminating repeated pain while sustaining measurement accuracy.
3Ease of manufacture
If roll-to-roll fabrication is used, then production cost is reduced, but manufacturing precision may be compromised
Solution Approach 1:
The patent employs roll-to-roll fabrication with precisely controlled deposition parameters for forming the microneedle arrays, electrode patterns, and encapsulation layers. By optimizing parameters such as deposition thickness, needle spacing, and material composition during the rolling process, high manufacturing precision is achieved while maintaining the cost advantages of continuous production.
Solution Approach 2:
The fabrication process applies different material properties and structural characteristics to specific regions of the sensor. The microneedle tips, for example, are designed with specific geometries and material compositions optimized for painless insertion, while the substrate and encapsulation layers have different properties optimized for flexibility and protection. This localized optimization maintains high precision throughout the device despite mass production methods.
4Duration of action of stationary object
If microneedle array with encapsulation is used, then sensor durability is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into unified structures to manage complexity. The encapsulation layer simultaneously protects the microneedle array from mechanical damage, seals the sensing reagents from contamination, and provides a biocompatible interface with tissue. The flexible substrate combines structural support, electrical connectivity, and mechanical flexibility in a single component. This merging of functions extends sensor lifespan while controlling overall device complexity.
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, enabling more effective glycemic control and increased adoption of continuous glucose monitoring.
Implementation Method 1
a layer of sputtered platinum on the polyester substrate
Implementation Method 2
a glucose oxidase layer
Implementation Method 3
the glucose oxidase is used to catalyze the reaction between glucose and oxygen
Implementation Method 4
silver/silver chloride ink
Data Source
AI summary
Analyte sensors and methods for fabricating analyte sensors are provided. In an exemplary embodiment, a method for fabricating a planar flexible analyte sensor includes sputtering platinum onto a polyester base layer to form a layer of platinum. The method includes patterning the layer of platinum to form working electrodes and additional electrodes. Further, the method includes forming an insulating dielectric layer over the base layer, wherein the insulating dielectric layer is formed with openings exposing portions of the working electrodes and portions of the additional electrodes. Also, the method includes partially singulating individual sensors from the base layer, wherein each individual sensor is connected to the base layer by a tab. The method further includes depositing an enzyme layer over the exposed portions of the working electrodes and coating the working electrodes with a glucose limiting membrane.