Reusable Applicator Design for Transcutaneous Sensor Insertion

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Solution Overview

Problem

Existing systems for applying transcutaneous analyte sensors are costly and wasteful due to the use of single-use applicators, which require multiple disposals, leading to inefficiencies and increased production costs.

Innovation Solution

A reusable applicator system with a grippable housing, actuator, and releasable coupler for inserting and retracting a needle to guide the sensor into the skin, allowing for multiple uses and reducing waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If single-use applicators are used for sensor insertion, then reliability and hygiene are improved, but cost and waste increase

Engineering Contradiction:

Improvesensor insertion reliabilityVSAvoidapplicator waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The applicator is divided into disposable components (needle, adhesive patch) and reusable components (housing, actuator mechanism). The reusable housing can be sterilized and reused multiple times, while only the needle and patch are discarded after single use, reducing overall waste while maintaining insertion reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system recovers and reuses the applicator housing and actuator mechanism after sensor insertion. The reusable components are retained in the applicator device for subsequent applications, while only the consumable needle and adhesive patch are discarded, thereby reducing material waste

Inventive Principle:

Principle #34Discarding and recovering

2Reliability

If multiple single-use applicators are produced and distributed, then each individual application is reliable, but production costs and environmental waste increase

Engineering Contradiction:

Improveapplication reliabilityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The applicator housing and actuator mechanism are designed as universal reusable components that can accommodate multiple different needles and sensor types. This multi-functionality allows a single reusable applicator body to perform numerous applications, reducing the need for producing multiple complete applicators and improving production efficiency

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of substance

If a reusable applicator is used, then cost and waste are reduced, but device complexity increases

Engineering Contradiction:

Improveapplicator reuseVSAvoidapplicator structure

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The needle is nested within the reusable applicator housing, and the adhesive patch is nested with the needle assembly. This nesting allows compact storage of multiple components within the reusable housing, managing complexity through organized integration rather than separate handling of multiple independent devices

Inventive Principle:

Principle #7Nested doll (Nesting)

4Ease of operation

If single-use applicators are used, then ease of operation is maintained, but multiple disposals require time and effort

Engineering Contradiction:

Improveapplication easeVSAvoiddisposal time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The disposable needle and adhesive patch are extracted as separate removable components from the reusable applicator housing. This allows the user to quickly remove and discard only the contaminated needle and patch after use, while retaining the clean reusable housing for the next application, thereby reducing disposal time and effort

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12364508B2Reusable applicators for transcutaneous analyte sensors, and associated methods

Publication Date: 2025.07.22 DEXCOM INC

AI summary

The present embodiments relate generally to systems and methods for measuring an analyte in a host. More particularly, the present embodiments provide sensor applicators and methods of use to insert the sensor into an individual's skin. Applicators are disclosed for inserting the sensor. Such applicators may be reusable applicators configured to implant multiple different sensors.