Transcutaneous Sensor Applicator With Segmented Spring Deployment

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Solution Overview

Problem

Existing transcutaneous analyte measurement systems face issues with inconsistent and uncomfortable application processes, mechanical fatigue of components, unpredictable slingshotting, and tissue trauma due to large springs, leading to inaccurate sensor placement and user discomfort.

Innovation Solution

An applicator system with a predetermined force profile for sensor insertion and retraction, utilizing a combination of torsion and booster springs, a scotch yoke mechanism, and a cannula to ensure precise and consistent deployment of the sensor wire, minimizing tissue trauma and improving accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a single large spring is used to accommodate all motion required in insertion and retraction, then the spring can provide sufficient force, but it causes tissue trauma due to forceful insertion

Engineering Contradiction:

Improveinsertion forceVSAvoidtissue trauma

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The patent divides the single large spring into multiple smaller springs (first spring and second spring). The first spring provides force during insertion while the second spring provides force during retraction. This segmentation allows each spring to be optimized for its specific phase, reducing the forceful insertion that causes tissue trauma while maintaining sufficient force for both insertion and retraction movements.

Inventive Principle:

Principle #1Segmentation

2Speed

If a spring is maintained in a compressed or extended preloaded condition between manufacture and activation, then it can provide immediate force, but it undergoes mechanical fatigue and causes mechanical creep

Engineering Contradiction:

Improveactivation responseVSAvoidmechanical fatigue

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent preloads the first spring in a compressed condition and the second spring in an extended condition during manufacture, but maintains them in a constrained configuration that prevents mechanical fatigue. The springs are activated only when needed through a trigger mechanism, providing immediate force when activated while avoiding prolonged preloading that causes fatigue and creep.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If seals are used in the insertion mechanism, then they provide necessary sealing, but they are subject to slingshotting causing inaccurate sensor wire placement

Engineering Contradiction:

Improvesealing functionVSAvoidsensor wire placement accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent introduces a constraint mechanism as an intermediary between the seals and the insertion motion. This constraint prevents the seals from slingshooting during insertion and retraction while still allowing them to perform their sealing function. The constraint ensures accurate sensor wire placement by preventing unpredictable seal movement.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Measurement precision

If finger pricking methods are used for glucose monitoring, then measurement can be obtained, but the process is uncomfortable and inconvenient

Engineering Contradiction:

Improveglucose level measurementVSAvoiduser comfort

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent replaces the manual finger pricking mechanical system with an automated transcutaneous sensor insertion system. The applicator device automatically inserts the sensor through the skin using spring-loaded mechanisms, eliminating the need for manual finger pricking. This substitution maintains accurate glucose measurement capability while dramatically improving user comfort and convenience.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system achieves rapid, reproducible sensor placement with reduced variability, minimizing pain and tissue damage, and ensures reliable communication between the sensor and electronics unit.

Implementation Method 1

utilizing a combination of torsion and booster springs

Methodology Applied

Scientific EffectTorsion spring: Torsion Spring

Implementation Method 2

utilizing a combination of torsion and booster springs

Methodology Applied

Scientific EffectSpring: Spring

Data Source

PatentUS12357345B2Transcutaneous analyte sensors, applicators therefor, and associated methods

Publication Date: 2025.07.15 DEXCOM INC

AI summary

The present embodiments relate generally to systems and methods for measuring an analyte in a host. More particularly, the present embodiments provide sensor applicators and methods of use with activation that implant the sensor, withdraw the insertion needle, engage the transmitter with the housing, and disengage the applicator from the housing. Systems and methods according to present principles allow for such steps to occur without significant loss of spring force, and without deleterious effects such as seal slingshotting.