Sensor Dispensing Cartridge with Segmented Sealing
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Solution Overview
Problem
Existing sensor-dispensing devices face challenges with maintaining humidity levels for test sensors, sealing issues in cartridges, and high replacement costs due to disposable mechanisms, which can lead to sensor damage and contamination.
Innovation Solution
A sensor-dispensing device with a cartridge assembly featuring a disposable outer cartridge and inner cartridge, a gripping mechanism, and a sealing mechanism that forms a moisture-tight seal, allowing for easy extraction of sensors while maintaining humidity and reducing replacement costs by allowing the cartridge to be reused with new sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pushing mechanism is used to move sensors through two openings in the cartridge, then sensors can be dispensed, but sealing the cartridge becomes difficult and sensor integrity may be compromised
Solution Approach 1:
The cartridge is divided into an inner cartridge containing the sensor stack and an outer cartridge that provides structural support and sealing. This segmentation allows the inner cartridge to be sealed independently while the outer cartridge provides the necessary openings for sensor dispensing, thus resolving the contradiction between ease of operation and cartridge sealing reliability.
Solution Approach 2:
The pushing mechanism is extracted from the disposable cartridge and relocated to the reusable sensor-dispensing device. This allows the cartridge to maintain its sealed integrity while the sensor stack is moved by the external pushing mechanism, eliminating the need for two openings in the cartridge and preserving both sealing reliability and ease of operation.
2Ease of operation
If the mechanism for moving sensors is located in the disposable cartridge, then sensor movement is enabled, but the cost of replacing the cartridge increases
Solution Approach 1:
The mechanism for moving sensors (pushing mechanism) is extracted from the disposable cartridge and placed in the reusable sensor-dispensing device. This allows the cartridge to be a simple, low-cost disposable component while the expensive moving mechanism is reused across multiple cartridges, significantly reducing replacement costs while maintaining ease of operation.
Solution Approach 2:
The design separates disposable components (cartridge with sensor stack) from recoverable components (pushing mechanism and housing). The cartridge is discarded after use, but the expensive pushing mechanism is recovered and reused with new cartridges, reducing overall operational costs while maintaining sensor movement functionality.
3Ease of operation
If packages are designed to be opened by tearing or bursting, then sensors can be accessed, but the process becomes difficult and risk of sensor damage or contamination increases
Solution Approach 1:
The sensor stack is pre-loaded into the sealed inner cartridge in a controlled manufacturing environment. The cartridge is then sealed to maintain proper humidity levels, eliminating the need for users to tear or burst packages. This preliminary action protects sensors from damage and contamination while maintaining ease of operation during actual use.
Solution Approach 2:
The inner cartridge is designed as a disposable component that maintains sensor integrity throughout storage and use. Once sensors are depleted, the entire sealed cartridge is discarded, eliminating the need for users to manually open packages and risking sensor damage or contamination. The disposable nature ensures sensors remain protected until use.
4Reliability
If a single opening is used in the cartridge, then sealing is improved, but sensor extraction becomes more difficult
Solution Approach 1:
The cartridge system is segmented into an inner cartridge with the sensor stack and an outer cartridge with a single opening. The inner cartridge can be sealed independently, maintaining reliability, while the outer cartridge provides a single opening that accommodates both the sensor extraction process and maintains sealing integrity through the reusable pushing mechanism.
Solution Approach 2:
The sensor extraction process is extracted from the cartridge structure itself and performed by an external pushing mechanism through a single opening. This allows the cartridge to maintain its sealed integrity with a single opening while the reusable mechanism handles the extraction process, resolving the contradiction between sealing reliability and ease of operation.
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 solution effectively protects sensors from atmospheric moisture, reduces replacement costs by allowing the cartridge to be reused, and simplifies the process of extracting and using sensors, thereby improving user experience and operational efficiency.
Implementation Method 1
The fluid is drawn into a capillary channel that extends in the sensor from the testing end to the reagent material by capillary action so that a sufficient amount of fluid to be tested is drawn into the sensor.
Data Source
AI summary
A cartridge assembly is adapted to be used in a sensor-dispensing device. The cartridge assembly comprises an end cap, a disposable cartridge and a sealing mechanism. The end cap includes one opening. The disposable cartridge comprises an outer and inner cartridge. The inner cartridge contains sensors arranged in a stack therein. Each of the sensors carries a reagent sufficient to produce a signal in response to the analyte concentration in a fluid. The outer cartridge forms an opening of sufficient dimensions to permit a sensor to pass through the opening. The outer cartridge includes a holding mechanism that holds at least one of the sensors in place during movement of the inner cartridge. The sealing mechanism is adapted to form a substantially moisture-tight seal.