Wearable Sensor Patch Liner Removal for Reliable Skin Attachment
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Solution Overview
Problem
Conventional methods for applying transcutaneous analyte sensors, such as glucose monitors, are uncomfortable and infrequent, leading to inadequate monitoring of blood glucose levels, which can result in dangerous hyperglycemic or hypoglycemic conditions due to the lack of continuous and convenient glucose level tracking.
Innovation Solution
A system and method for deploying and attaching a transcutaneous analyte sensor to the skin using an applicator housing with a liner removal component that decouples the liner from the sensor, allowing for easy application and secure attachment of the sensor to the skin, featuring a patch with a puncture layer for needle insertion and a stabilizing body to maintain sensor position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional finger pricking methods are used for glucose monitoring, then the monitoring frequency is limited to 2-4 times per day, but the comfort and convenience are poor
Solution Approach 1:
The monitoring system is segmented into a disposable sensor assembly that can be applied to the skin and a separate reusable receiver unit. The sensor assembly includes further segmentation into functional layers (adhesive layer, sensor layer, protective layers) that can be independently optimized. This segmentation enables frequent application of comfortable sensors without requiring complex reusable components to be frequently handled.
Solution Approach 2:
The patent employs disposable sensor assemblies that are applied to the skin for continuous monitoring over several days. Each sensor assembly is designed as a single-use component that combines the sensor, adhesive, and protective elements, eliminating the need for repeated skin punctures and allowing comfortable frequent monitoring without reusing potentially contaminated components.
2Ease of operation
If the liner is not properly removed from the patch, then the sensor cannot be properly applied to the skin, but complete removal may damage the adhesive layer
Solution Approach 1:
The liner is pre-configured with a tab or pull feature that provides a convenient gripping point for removal. The adhesive layer is pre-treated or designed with controlled adhesion properties that allow easy separation from the liner during application while maintaining strong bonding to the skin. This preliminary design of the removal mechanism and adhesive characteristics ensures proper application without damage.
Solution Approach 2:
The liner acts as an intermediary protective layer that is temporarily bonded to the adhesive but designed for clean separation. The interface between the liner and adhesive is engineered with specific surface properties that allow easy peeling during application while the adhesive maintains its integrity for skin bonding. This intermediary layer protects the adhesive during storage and handling while enabling controlled removal.
3Reliability
If the sensor is inserted too deeply into the skin, then analyte collection may be improved, but patient comfort decreases and tissue damage risk increases
Solution Approach 1:
The sensor insertion element features local quality variations along its length, with different structural characteristics in different zones. The tip portion is designed with specific geometry and material properties for gentle tissue penetration, while the shaft provides structural support. The sensor array is locally positioned at an optimal depth to collect interstitial fluid without requiring deep insertion, and the adhesive layer is locally configured to secure the sensor at the correct position.
Solution Approach 2:
The insertion element parameters (length, diameter, tip angle, material hardness) are optimized to achieve sufficient analyte collection with minimal insertion depth. The sensor membrane permeability and surface area parameters are adjusted to compensate for reduced insertion depth, maintaining collection efficiency while minimizing tissue trauma. The adhesive layer thickness and bonding strength parameters are tuned to secure the sensor without requiring deep penetration.
Data Source
AI summary
The present embodiments relate generally to apparatuses, systems, and methods for deploying a medical device to skin of a host. The apparatuses, systems, and methods may be directed to removing a liner for a medical device so that the medical device may couple to the skin of the host. The medical device may comprise an on-skin wearable medical device.