Pre-connected Analyte Sensor Carrier for Glucose Monitoring

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Solution Overview

Problem

Conventional self-monitoring blood glucose methods for diabetes patients are uncomfortable and inconvenient, leading to infrequent glucose level measurements, which can result in delayed detection of hyperglycemic or hypoglycemic conditions and associated dangerous side effects.

Innovation Solution

A method and apparatus for manufacturing a continuous analyte sensor involving a sensor carrier with conductive portions for establishing electrical connections, including QR code identifiers for tracking and calibration data, and a membrane coating for environmental sealing, facilitating accurate and efficient handling and integration with testing and calibration equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional self-monitoring blood glucose methods are used, then glucose levels can be measured, but the process is uncomfortable and inconvenient leading to infrequent measurements

Engineering Contradiction:

Improveconvenience of glucose monitoringVSAvoidtime between glucose measurements

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The sensor is pre-assembled with the sensor carrier, electrical contacts, and sealing membrane before deployment. This preliminary assembly eliminates the need for complex manual assembly by the user and enables continuous monitoring without frequent interruptions for measurement or device handling.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sensor system is designed to be self-contained with integrated electronics, power management, and data processing capabilities. The sensor automatically performs measurements and transmits data without requiring user intervention for each measurement, enabling continuous monitoring.

Inventive Principle:

Principle #25Self-service

2Ease of manufacture

If manual handling and assembly of sensor components are used, then sensors can be assembled, but manual handling errors occur and assembly accuracy is reduced

Engineering Contradiction:

Improvesensor assembly processVSAvoidalignment accuracy of electrical contacts

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The sensor system is divided into modular components (sensor element, sensor carrier, electrical contacts, sealing membrane) that can be manufactured separately and then precisely assembled. The sensor carrier serves as a standardized interface that ensures accurate alignment of electrical contacts and other components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor carrier acts as an intermediary component that provides a standardized mechanical and electrical interface between the sensor element and the external world. It includes features like recesses, protrusions, and conductive portions that ensure precise alignment and connection without requiring complex manual adjustment.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If electrical connections are not properly sealed, then electrical contacts can be accessed, but environmental factors can interfere with sensor operation

Engineering Contradiction:

Improvesensor operation stabilityVSAvoidsealing structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A flexible sealing membrane is used to seal the electrical contacts and sensor elements. The membrane can conform to the irregular shapes of the components while providing effective environmental protection. It includes openings that allow electrical contacts to pass through while maintaining the seal.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The electrical contacts are nested within recesses in the sensor carrier, which are then sealed by the flexible membrane. This nested structure protects the electrical contacts from environmental factors while allowing them to maintain electrical connection.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Ease of operation

If sensors are pre-connected with sensor carriers, then handling and integration are improved, but manufacturing process complexity increases

Engineering Contradiction:

Improvesensor handling and integrationVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The sensor carrier is designed as a universal interface that handles multiple functions: mechanical support, electrical connection, environmental sealing, and positioning. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing process despite the pre-connection requirement.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11331022B2Pre-connected analyte sensors

Publication Date: 2022.05.17 DEXCOM INC

AI summary

Pre-connected analyte sensors are provided. A pre-connected analyte sensor includes a sensor carrier attached to an analyte sensor. The sensor carrier includes a substrate configured for mechanical coupling of the sensor to testing, calibration, or wearable equipment. The sensor carrier also includes conductive contacts for electrically coupling sensor electrodes to the testing, calibration, or wearable equipment.