Sensor Applicator Assembly With Self-Aligning Tray Insertion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current sensor application devices for long-term analyte monitoring suffer from user errors leading to malfunctions due to improper assembly, which can be caused by accidents, lack of education, poor coordination, and complicated procedures, relying heavily on precise user assembly.
Innovation Solution
The system provides a sterile applicator with an electronics housing and a separate container containing a sensor module and sharp module, allowing for a simplified assembly process where the applicator is inserted into the container in a specified manner to prevent tilting and ensure proper alignment, reducing the risk of malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the assembly process requires precise alignment and complex procedures, then the manufacturing precision can be improved, but the ease of operation deteriorates
Solution Approach 1:
The applicator and container are designed with asymmetric geometric features including tapered portions and complementary shapes that enable one-way insertion. The applicator has a tapered distal end that fits into a corresponding recess in the container, allowing easy insertion in the correct orientation while preventing removal or incorrect assembly, thus achieving both precision and ease of operation
Solution Approach 2:
The applicator is nested within the container during assembly, with the applicator shaft inserting into the container body. This nesting arrangement guides the applicator into proper alignment and position, ensuring precise assembly while simplifying the user's task to a single insertion motion
2Ease of operation
If the assembly procedure is simplified for ease of use, then the ease of operation is improved, but the reliability deteriorates due to potential misalignment
Solution Approach 1:
The asymmetric design with tapered portions and complementary geometric features ensures that the applicator can only be inserted in the correct orientation. This prevents misalignment and incorrect assembly while maintaining simplicity for the user, thus improving reliability without compromising ease of operation
Solution Approach 2:
The assembly mechanism is self-aligning through its geometric design. The tapered applicator shaft automatically centers itself within the container recess during insertion, and the complementary shapes guide proper positioning without requiring user skill or attention to alignment, making the process both simple and reliable
3Manufacturing precision
If the assembly process involves multiple steps and complex procedures, then the manufacturing precision can be maintained, but the device complexity increases
Solution Approach 1:
The assembly process merges multiple functions into a single insertion action. The applicator simultaneously achieves positioning, alignment, and securing within the container through one motion, eliminating the need for multiple separate steps while maintaining precision through the integrated geometric design
Solution Approach 2:
The nested arrangement of the applicator within the container allows the entire assembly to be accomplished through a single insertion motion. The geometric compatibility between nested components ensures proper alignment and positioning are achieved automatically, reducing assembly complexity while maintaining manufacturing precision
Data Source
AI summary
Systems, devices, and methods are provided for the assembly and subsequent delivery of an in vivo analyte sensor. An applicator with sensor electronics is inserted into a tray containing an assembly that includes a sharp and an analyte sensor. The insertion causes the assembly to couple with the sensor electronics and form a deliverable sensor control device retained within the applicator, which can then be placed in position on a body of a user to monitor that user's analyte levels.