Analyte Sensor Connector Assembly for Low-Heat PCB Attachment

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Solution Overview

Problem

Existing in vivo blood glucose monitoring systems face challenges in manufacturing sensors for continuous glucose monitoring and attaching them to electronics units, particularly with electrodes on different surfaces, which complicates the connection process.

Innovation Solution

The use of analyte sensor connectors, such as rivets, to physically and electrically connect analyte sensors to electronics units, providing a method for attaching and maintaining connections between sensors and control units, allowing for improved attachment and reduced temperature requirements during the connection process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional attachment methods are used to connect analyte sensors to electronics units, then the connection process becomes complicated, but the manufacturing process requires high temperature which may damage sensor materials or affect sensing chemistry

Engineering Contradiction:

Improveconnection processVSAvoidtemperature damage to sensor

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The connection system is divided into separate components: an analyte sensor with electrodes on one surface, an electronics unit with corresponding electrodes, and a separate connector element. This segmentation allows each component to be optimized independently and connected at lower temperatures, avoiding damage to the sensor materials while maintaining manufacturing feasibility.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If electrodes are positioned on different surfaces of the sensor substrate, then the sensor design becomes more flexible, but the connection process becomes more complex

Engineering Contradiction:

Improveelectrode positioningVSAvoidconnection process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A connector element acts as an intermediary between the analyte sensor and electronics unit. This mediator component bridges the gap created by electrodes on different surfaces, providing alignment features and conductive pathways that simplify the connection process while maintaining the flexibility of having electrodes positioned on different surfaces of the sensor substrate.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11806141B2Connectors for making connections between analyte sensors and other devices

Publication Date: 2023.11.07 ABBOTT DIABETES CARE INC

AI summary

Glucose monitoring devices and related systems and methods, the glucose monitoring devices including a sensor electronics unit having a housing and a printed circuit board disposed within the housing, a transcutaneous glucose sensor assembly, and a conductive sensor connector. The printed circuit board includes a first electrical contact, the transcutaneous glucose sensor assembly includes a distal portion having a working electrode and proximal portion having a working-electrode contact in electrical communication with the working electrode, and the conductive sensor connector electrically connects the working-electrode contact with the first electrical contact. Further, the conductive sensor connector extends through a hole in the proximal portion of the transcutaneous glucose sensor assembly and through a hole in the printed circuit board.