Reusable Sensor Applicator With Disposable Needle Assembly
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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 are discarded after each use, leading to increased production and waste.
Innovation Solution
A reusable applicator system with a grippable housing, an actuator for inserting a needle, a releasable coupler for retaining and releasing the needle, and a retraction mechanism to facilitate multiple uses, reducing waste and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single-use applicators are used to apply transcutaneous analyte sensors, then the application process is simple and reliable, but the cost increases and waste is generated due to multiple applicators being produced and discarded
Solution Approach 1:
The applicator is divided into two distinct segments: a reusable applicator body that remains and a disposable needle assembly that is attached, used, and then discarded. This segmentation allows the complex, expensive applicator mechanism to be reused while only the contaminated needle portion is discarded, resolving the contradiction between reliability and waste.
Solution Approach 2:
The system implements a discard-and-recover strategy where the needle assembly is discarded after single use, but the applicator body is recovered and reused for subsequent sensor applications. This approach maintains the reliability benefits of a controlled application process while eliminating the waste associated with discarding the entire applicator.
2Reliability
If single-use applicators are used to apply transcutaneous analyte sensors, then each application is independent and hygienic, but production costs increase due to manufacturing multiple applicators
Solution Approach 1:
By segmenting the applicator into a reusable body and a disposable needle assembly, the system maintains hygienic application standards (each needle is new and sterile) while dramatically reducing production costs (the expensive applicator body is manufactured once and reused many times rather than being manufactured anew for each use).
Solution Approach 2:
The reusable applicator body is designed with universal functionality to accommodate different needle assemblies and sensor types. This multi-functionality allows a single applicator design to serve multiple purposes and remain in production for extended periods, reducing per-unit production costs while maintaining hygienic standards through disposable needle changes.
3Loss of substance
If reusable applicators are implemented, then costs and waste are reduced, but the device complexity increases with multiple components including actuator, coupler, and retraction mechanism
Solution Approach 1:
The patent merges several functions into the reusable applicator body: the actuator mechanism, the releasable coupler for needle attachment/detachment, and the retraction mechanism for needle withdrawal are all integrated into a single housing. This consolidation reduces the number of separate components that would need to be managed and assembled, making the increased complexity more manageable while maintaining the waste reduction benefits of reusability.
Solution Approach 2:
The applicator incorporates self-service features such as automatic needle retraction upon sensor insertion and automated needle release mechanisms that simplify the user interface. These self-service capabilities reduce the operational complexity for the user, compensating for the increased structural complexity by making the device easier to operate despite having more internal components.
Data Source
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.