Stacked Analyte Sensor Electrode Layout for Stable Connector Alignment
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Solution Overview
Problem
Existing analyte monitoring systems face challenges in manufacturing sensors for in vivo use, particularly in attaching electrodes to system components like electronics units, especially when electrodes are positioned on different surfaces, leading to difficulties in creating stable and long-lasting connections.
Innovation Solution
The use of sensor connectors, such as rivets, to physically and electrically connect analyte sensors with electrodes to electronics units, allowing for improved attachment and alignment, even when electrodes are on different surfaces, using conductive materials like copper or non-conductive materials like polycarbonate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrodes are positioned on different surfaces of the sensor, then the sensor can be designed with compact stacking configuration, but it becomes difficult to create stable and long-lasting connections to electronics units
Solution Approach 1:
The patent transitions from planar electrode arrangement to a three-dimensional stacked configuration where electrodes are positioned on different surfaces (top and bottom) of the sensor substrate. This vertical stacking enables compact sensor design while maintaining functional integrity by utilizing the third dimension (depth) rather than expanding in the horizontal plane.
Solution Approach 2:
The patent introduces conductive traces and connection elements as intermediaries that bridge the gap between electrodes on different surfaces and the electronics unit. These intermediaries transmit electrical signals through the sensor structure, enabling stable connections despite the spatial separation of electrodes on opposite surfaces.
2Reliability
If conductive traces are positioned on different surfaces of the sensor, then manufacturing complexity increases, but connection reliability can be improved
Solution Approach 1:
The patent divides the sensor into distinct functional layers with conductive traces positioned on different surfaces (top and bottom). This segmentation allows independent optimization of each layer's function and simplifies the manufacturing process by enabling separate fabrication and assembly of trace patterns on each surface, rather than attempting to create complex three-dimensional traces in a single step.
Solution Approach 2:
The conductive traces serve multiple functions: they provide electrical connection between electrodes on different surfaces, act as signal transmission pathways, and serve as structural elements within the sensor assembly. This multi-functionality reduces the need for additional dedicated connection components, thereby managing manufacturing complexity while maintaining connection reliability.
3Volume of moving object
If narrower first electrode is used in stacked configuration, then sensor profile is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs asymmetric electrode design where the first electrode has a narrower width compared to the second electrode. This asymmetry optimizes the sensor profile by reducing the overall width of the stacked structure. The narrower first electrode is strategically positioned to minimize the lateral extent of the sensor while maintaining adequate spacing and alignment with corresponding elements on opposite surfaces.
Solution Approach 2:
The patent applies different electrode widths at different locations within the stacked structure. The narrower first electrode is used where space is constrained, while the wider second electrode is used where broader contact area is needed for connection. This local variation in electrode quality optimizes both the compact profile and the manufacturing feasibility by concentrating precision requirements to specific critical areas rather than uniformly across all electrodes.
Data Source
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AI summary
Analyte sensor connectors that connect analyte sensors, e.g., conductive members of analyte sensors, to other devices such as sensor electronics units, e.g., sensor control units, are provided. Also provided are systems that include analyte sensors, analyte sensor connectors, and analyte sensor electronics units, as well as methods of establishing and maintaining connections between analyte sensors and analyte sensor electronics units, and methods of analyte monitoring/detection. Also provided are methods of making analyte sensor connectors and systems that include analyte sensor connectors.