Adhesive Liner Removal Mechanism for Skin Sensor Applicators
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Solution Overview
Problem
Existing in vivo analyte monitoring systems face issues with adhesive failure and decoupling of sensor control devices due to factors like perspiration, dirt accumulation, and chemical interactions, leading to reduced lifespan and functionality, necessitating a secure method for maintaining adhesive liners during manufacturing, storage, and transportation, and efficient removal before use.
Innovation Solution
The system includes an applicator with a sensor control device and an adhesive liner configuration that allows for secure retention of the liner during manufacturing and storage, with a design that enables easy and simultaneous removal of the adhesive liner just before use, using features like engagement elements, retention elements, and ratchet mechanisms in the applicator and sensor cap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the adhesive liner is removed early during manufacturing, then the manufacturing process is simplified, but the adhesive lifespan is reduced and reliability deteriorates
Solution Approach 1:
The adhesive liner is pre-applied to the adhesive patch during manufacturing and protected by the applicator cap, allowing the device to be prepared in advance while maintaining adhesive integrity. The liner is only removed at the point of use, combining preliminary preparation with preserved functionality.
2Reliability
If the adhesive liner is kept on during storage and transportation, then adhesive reliability is maintained, but device complexity increases
Solution Approach 1:
The adhesive liner retention function is merged with the applicator cap, which serves multiple purposes: protecting the sensor, maintaining adhesive liner integrity, and facilitating user application. This integration eliminates the need for separate retention mechanisms.
3Reliability
If the adhesive liner is removed immediately before use, then adhesive functionality is optimized, but time is lost in the removal process
Solution Approach 1:
The adhesive liner removal is extracted as a simple, intuitive action performed by the user by pulling the liner tab, separating this function from complex mechanisms. The liner is pre-positioned and only requires manual extraction at the point of use.
4Reliability
If the applicator cap includes retention elements for the adhesive liner, then liner security is improved, but applicator complexity increases
Solution Approach 1:
The applicator cap is designed as a multi-functional component that simultaneously protects the sensor, secures the adhesive liner through retention elements, and guides the application process. This universal design consolidates multiple functions into a single element.
Data Source
AI summary
An assembly for insertion of an analyte sensor is provided. The assembly can include an applicator having an applicator housing, a sharp, a carrier configured to releasably retain a sensor control device, and an applicator cap removably coupled with the applicator housing. The assembly can further include a sensor control device configured to be worn on skin of a user, which includes a sensor control device housing, sensor electronics disposed in the sensor control device housing, the analyte sensor, a sensor cap, a collar configured to snap-fit into the sensor cap, an adhesive patch comprising a distally-facing surface configured to adhere to the skin of the user, and an adhesive liner. The adhesive liner can be configured such that removal of the applicator cap and/or the sensor cap causes removal of the adhesive liner from the adhesive patch.