On-Skin Sensor Applicator With Needle Retraction for Easy Glucose Monitoring

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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 with a needle carrier assembly, drive assembly, and activation element for inserting and retracting an on-skin sensor assembly, utilizing various drive mechanisms such as rotating drive elements, torsion springs, and linkage elements to facilitate easy and efficient sensor application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional finger pricking methods are used for glucose monitoring, then measurement can be performed, but the process is uncomfortable and inconvenient leading to infrequent measurements

Engineering Contradiction:

Improveease of sensor applicationVSAvoidfrequency of glucose measurements

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The sensor assembly is designed to be self-contained with integrated needle carrier, sensor, and adhesive components that automatically position and attach to the skin without requiring manual manipulation or complex alignment procedures by the user

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The sensor assembly is pre-assembled with the needle carrier and sensor positioned in advance, so that application only requires activating the drive mechanism rather than manually assembling multiple components during the application process

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If conventional finger pricking methods are used, then glucose levels can be measured, but the discomfort leads to only 2-4 measurements per day

Engineering Contradiction:

Improvecomfort of measurement processVSAvoidfrequency of glucose measurements

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The painful finger pricking action is extracted and replaced by a transcutaneous sensor that measures glucose through the skin without penetration, eliminating the discomfort while maintaining measurement capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical needle penetration system is replaced with an electronic transcutaneous sensor system that uses electrical or optical methods to measure glucose through the skin, eliminating the need for physical penetration

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If sensor application process is complex, then precise sensor placement can be achieved, but the application becomes less user-friendly

Engineering Contradiction:

Improveprecision of sensor placementVSAvoiduser-friendliness of application process

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The sensor assembly automatically positions itself on the skin through the drive mechanism that pushes the needle carrier and sensor into the correct placement position, eliminating the need for the user to manually align or position components with precision

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The drive assembly acts as an intermediary mechanism between the user's simple activation action and the complex sensor placement task, automatically performing the precise positioning and attachment functions

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables convenient and reliable attachment of on-skin sensors, allowing for continuous glucose monitoring, reducing the discomfort and improving the frequency of glucose level measurements.

Implementation Method 1

a spring configured to, upon activation of the drive assembly, rotate the rotating drive element in a single rotational direction thereby driving the insertion element from the proximal starting position to the distal insertion position, and from the distal insertion position to the proximal retraction position

Methodology Applied

Scientific EffectTorsion spring: Torsion Spring

Implementation Method 2

a rotating drive element coupled to the needle carrier assembly and includes a pin configured to travel in the guide during rotation of the rotating drive element

Methodology Applied

Scientific EffectRotational to linear motion conversion: Mechanical Advantage

Data Source

PatentUS20260083400A1Transcutaneous analyte sensors, applicators therefor, and associated methods

Publication Date: 2026.03.26 DEXCOM INC

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.