On-Skin Sensor Applicator with Controlled Needle Insertion

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Solution Overview

Problem

Conventional methods for applying on-skin glucose sensors are uncomfortable and inconvenient, leading to infrequent glucose level measurements, which can result in delayed detection of hyperglycemic or hypoglycemic conditions in diabetic patients.

Innovation Solution

An applicator system for transcutaneous analyte measurement systems, featuring a needle carrier assembly, drive assembly, and activation elements, which facilitates the controlled insertion and retraction of on-skin sensor assemblies using various mechanical components like rotating drive elements, torsion springs, and linkage elements to ensure secure and efficient attachment to the skin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional finger pricking methods are used for glucose monitoring, then the measurement can be obtained, but the comfort and convenience deteriorate leading to infrequent measurements

Engineering Contradiction:

Improvecomfort and convenience of applicationVSAvoidfrequency of glucose level measurements

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces the manual finger pricking mechanical system with an automated applicator system that uses a drive assembly, needle carrier, and activation mechanism to insert the sensor transcutaneously. This substitution eliminates the discomfort of manual pricking while enabling continuous monitoring without requiring frequent user intervention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The sensor system is designed to be self-applying through the applicator mechanism, which automatically inserts the sensor into the skin and establishes connection. This self-service capability removes the burden of repeated manual application, making continuous monitoring more acceptable to users.

Inventive Principle:

Principle #25Self-service

2Reliability

If continuous glucose monitoring is implemented, then glucose levels can be monitored continuously, but the application process complexity increases

Engineering Contradiction:

Improvecontinuous monitoring capabilityVSAvoidapplication process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The applicator system is segmented into distinct functional components: an applicator body housing, a removable needle carrier assembly, a drive assembly with torsion springs, and a sensor assembly. This segmentation allows each component to be optimized independently and simplifies the overall application process by making the system modular and easier to handle.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor is pre-loaded into the needle carrier assembly before application. The drive assembly is pre-configured with torsion springs that will automatically drive the needle carrier forward when activated. This preliminary preparation eliminates complex real-time adjustments during application, reducing operational complexity while ensuring reliable continuous monitoring.

Inventive Principle:

Principle #10Preliminary action

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 applicator system enables comfortable and efficient application of on-skin sensors, allowing for continuous glucose monitoring, reducing the discomfort associated with traditional methods and enabling more frequent glucose level measurements.

Implementation Method 1

The drive assembly may include a rotating drive element, one or more springs (e.g., torsion springs), and/or a linkage element

Methodology Applied

Scientific EffectTorsion spring: Torsion Spring

Data Source

PatentEP4008240B1Transcutaneous analyte sensors, applicators therefor, and associated methods

Publication Date: 2025.11.05 DEXCOM INC

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AI summary

The present embodiments relate generally to applicators of on-skin sensor assemblies for measuring an analyte in a host, as well as their method of use and manufacture. In some aspects, an applicator for applying an on-skin sensor assembly to a skin of a host is provided. The applicator includes an applicator housing, a needle carrier assembly comprising an insertion element configured to insert a sensor of the on-skin sensor assembly into the skin of the host, a holder releasably coupled to the needle carrier assembly and configured to guide the on-skin sensor assembly while coupled to the needle carrier assembly, and a drive assembly configured to drive the insertion element from a proximal starting position to a distal insertion position, and from the distal insertion position to a proximal retraction position.