Wearable Infusion Pump Assembly With Optical Plunger Sensing
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Solution Overview
Problem
Existing wearable infusion devices for therapeutic delivery suffer from malfunctions, size, weight, and cost challenges, and frequent re-location issues, while requiring precise control over fluid delivery.
Innovation Solution
A wearable infusion pump assembly with a reservoir, controller, optical sensors, and valve assemblies for precise fluid delivery, featuring a reusable and disposable housing design, and a bi-modal valve mechanism for fluid control, utilizing shape-memory actuators for actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wearable infusion devices are designed to be portable and controlled, then therapeutic delivery is enabled, but malfunction rate increases and device size/weight/cost challenges arise
Solution Approach 1:
The device is divided into modular components: a reusable pump assembly containing the motor, control circuitry, and electronics, and a disposable cartridge containing the reservoir and fluid delivery system. This segmentation isolates the complex controlled components in the reusable portion while the disposable portion contains simpler fluid handling components, allowing the complex automatic delivery function to be achieved while managing reliability through modular design where the disposable cartridge can be replaced if issues arise.
Solution Approach 2:
The disposable cartridge is pre-filled with therapeutic fluid and pre-assembled with the reservoir and fluid delivery components before use. This preliminary preparation reduces the complexity of assembly and operation during actual therapeutic delivery, allowing the automatic delivery function to operate reliably without requiring complex user intervention or assembly steps that could introduce errors.
2Volume of moving object
If device size is reduced for wearability, then portability is improved, but manufacturing precision and component integration become more challenging
Solution Approach 1:
The device is segmented into two main portions: a reusable pump assembly and a disposable cartridge. The reusable portion contains the motor, control circuitry, and electronics housed in a compact casing, while the disposable cartridge contains the reservoir and fluid delivery system. This segmentation allows each portion to be optimized independently for size and manufacturing precision, with the reusable portion being more precisely manufactured and the disposable portion being simpler to manufacture at higher volumes.
Solution Approach 2:
The disposable cartridge is designed to be received and held within the reusable pump assembly, creating a nested configuration. The cartridge fits into the pump assembly housing, with the pump plunger extending into the cartridge reservoir. This nesting arrangement minimizes the overall device volume by utilizing internal spaces and allowing components to be housed within one another, achieving compact wearability while maintaining manufacturing precision through standardized interface dimensions.
3Measurement precision
If optical sensors are added for precise pump plunger position detection, then fluid delivery precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical position sensing mechanisms with optical sensors. Instead of using mechanical encoders, potentiometers, or complex linkages to detect pump plunger position, the invention uses optical sensors that detect the position of the pump plunger by sensing light reflection or interruption. This substitution reduces mechanical complexity while achieving high measurement precision for fluid delivery control.
Solution Approach 2:
The optical sensors use light as an intermediary to detect pump plunger position. Rather than direct mechanical contact or complex electrical connections between the moving plunger and the sensor system, light serves as the intermediary medium that can non-contactly detect position. This approach simplifies the overall system complexity while maintaining high measurement precision for controlling fluid delivery.
4Manufacturing precision
If valve assemblies are integrated for fluid isolation, then fluid control precision is improved, but device size and component count increase
Solution Approach 1:
The patent combines multiple valve functions into integrated valve assemblies that are built into the fluid delivery system. Rather than having separate valves for different fluid isolation functions, the invention merges these functions into unified valve assemblies that can perform multiple fluid control operations. This merging reduces the total component count and device size while maintaining precise fluid delivery control through coordinated valve operation.
Solution Approach 2:
The valve assemblies are designed with multi-functionality to perform various fluid control tasks: isolating the pump assembly from the reservoir, isolating the pump assembly from the external infusion set, controlling fluid flow direction, and preventing backflow. By making the valves universal and multi-functional, the patent reduces the number of specialized valve components needed, thereby reducing device size and component count while achieving precise fluid delivery control through the versatile valve 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 solution provides reliable, precise, and cost-effective therapeutic delivery with reduced device size and weight, enhancing user convenience and sanitation through modular design and improved fluid control mechanisms.
Implementation Method 1
at least one optical sensor assembly for sensing the starting position and ending position of the pump plunger distance of travel
Implementation Method 2
utilizing shape-memory actuators for actuation
Data Source
AI summary
A wearable infusion pump assembly. The wearable infusion pump assembly includes a reservoir for receiving an infusible fluid and a fluid delivery system configured to deliver the infusible fluid from the reservoir to an external infusion set. The fluid delivery system includes a controller, a pump assembly for extracting a quantity of infusible fluid from the reservoir and providing the quantity of infusible fluid to the external infusion set, the pump assembly comprising a pump plunger, the pump plunger having distance of travel, the distance of travel having a starting position and an ending position, at least one optical sensor assembly for sensing the starting position and ending position of the pump plunger distance of travel and sending sensor output to the controller, and a first valve assembly configured to selectively isolate the pump assembly from the reservoir, wherein the controller receives the sensor output and determines the total displacement of the pump plunger.