Transcutaneous Sensor Applicator With Dual-Phase Spring Drive
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Solution Overview
Problem
Existing transcutaneous analyte measurement systems face issues with inconsistent sensor placement, mechanical fatigue, tissue trauma, and inaccurate insertion due to unpredictable slingshotting and the use of large springs, leading to discomfort and delayed glucose level detection in diabetic patients.
Innovation Solution
A method and device for applying a transcutaneous analyte sensor using a sensor insertion drive with a predetermined force profile, involving a crank slider, rack and pinion, or barrel cam mechanism, and a combination of springs to ensure precise and controlled insertion and retraction of the sensor, minimizing tissue damage and slingshotting, and incorporating a hybrid seal to stabilize the sensor wire during deployment.
Engineering Contradictions & Design Principles
Engineering 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 for the entire process, but it causes tissue trauma due to forceful insertion
Solution Approach 1:
The patent divides the insertion process into two distinct phases with separate spring mechanisms: a first spring (compression spring) for the insertion phase and a second spring (torsion spring) for the retraction phase. This segmentation allows each spring to be optimized for its specific function, with the first spring providing controlled force for insertion and the second spring providing force for retraction, thereby avoiding the tissue trauma caused by a single large spring
Solution Approach 2:
The patent ensures continuous force availability throughout the entire insertion and retraction process by having the second spring pre-loaded and ready to act immediately after the first spring completes insertion. The transition between phases is seamless, with the second spring's force becoming available as the first spring's force is exhausted, maintaining continuous useful action without interruption or excessive force application
2Adaptability or versatility
If seals are subjected to slingshotting during insertion movements, then the seals can accommodate the motion required, but the slingshotting causes inaccurate sensor wire placement
Solution Approach 1:
The patent applies preliminary anti-action by pre-loading the second spring in a compressed state before insertion begins. This pre-loaded spring is ready to counteract any slingshotting motion immediately when needed, providing opposing force to prevent the seal from deviating from its intended path and ensuring accurate sensor wire placement throughout the motion sequence
3Ease of operation
If a spring is maintained in a compressed or extended condition between manufacture and activation, then the spring is ready for immediate use, but it undergoes mechanical fatigue and causes mechanical creep
Solution Approach 1:
The patent segments the spring functions into two separate springs with different pre-loading strategies. The first spring is pre-loaded in compression and remains in a controlled state during storage, while the second spring is pre-loaded in compression within its housing and only activated when needed. This segmentation allows each spring to be maintained in a stable, low-stress condition during storage, reducing mechanical fatigue and creep while ensuring readiness for immediate use when activated
Solution Approach 2:
The patent prepares the second spring in advance by pre-loading it in a compressed state within the housing during manufacture, but keeps it constrained and inactive until the moment of use. This preliminary preparation ensures the spring is ready for immediate action when the insertion device is activated, while the constraint mechanism prevents mechanical fatigue and creep during the storage period by maintaining the spring in a stable, controlled condition
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 provides consistent and rapid sensor deployment, reducing pain, tissue damage, and sensor variability, enabling more frequent glucose level monitoring and improving user safety by ensuring accurate and reproducible sensor placement.
Implementation Method 1
a first spring configured to apply a first force having a first direction to the insertion member, the first direction alternating between a distal direction and a proximal direction
Implementation Method 2
a second spring configured to apply a second force having a proximal direction to the insertion member, the second force becoming available after the first spring completes its first cycle
Data Source
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AI summary
A method of applying an on-skin sensor assembly to skin of a host is provided. The method comprises providing an assembly comprising an applicator housing operatively coupled to a disposable housing, an insertion assembly comprising an insertion member, a first drive assembly containing a first amount of stored energy, and a second drive assembly containing a second amount of stored energy. The method further comprises activating a trigger of the assembly, wherein activating the trigger causes the first drive assembly to drive the insertion member in a distal direction during a first phase, wherein a sensor is inserted into the skin of the host; the first drive assembly to drive the insertion member in a proximal direction during a second phase, wherein the first drive assembly activates the second drive assembly while driving the insertion member in the proximal direction during the second phase; and the second drive assembly to drive the insertion member in the proximal direction during the second phase.