U.S. patent application number 17/378152 was filed with the patent office on 2021-11-04 for transcutaneous analyte sensors, applicators therefor, and associated methods.
The applicant listed for this patent is DexCom, Inc.. Invention is credited to Daniel E. Apacible, Alan Baldwin, John Charles Barry, Jennifer Blackwell, Cameron Brock, Patrick John Castagna, David DeRenzy, Justen Deering England, Remy E. Gagnon, Christian Michael Andre George, John Michael Gray, Jason Halac, Andrew Joncich, David A. Keller, Mark Douglas Kempkey, Randall Scott Koplin, Young Woo Lee, Thomas Metzmaker, Paul V. Neale, Kenneth Pirondini, Andrew Michael Reinhardt, Neel Narayan Shah, Peter C. Simpson, Carol Wood Sutherland, Warren Terry, Louise Emma van den Heuvel, Maria Noel Brown Wells, Jason C. Wong.
Application Number | 20210338161 17/378152 |
Document ID | / |
Family ID | 1000005720420 |
Filed Date | 2021-11-04 |
United States Patent
Application |
20210338161 |
Kind Code |
A1 |
Gray; John Michael ; et
al. |
November 4, 2021 |
TRANSCUTANEOUS ANALYTE SENSORS, APPLICATORS THEREFOR, AND
ASSOCIATED METHODS
Abstract
The present embodiments relate generally to applicators of
on-skin sensor assemblies for measuring an analyte in a host, as
well as their method of use and manufacture. In some aspects, an
applicator for applying an on-skin sensor assembly to a skin of a
host is provided. The applicator includes an applicator housing, a
needle carrier assembly comprising an insertion element configured
to insert a sensor of the on-skin sensor assembly into the skin of
the host, a holder releasably coupled to the needle carrier
assembly and configured to guide the on-skin sensor assembly while
coupled to the needle carrier assembly, and a drive assembly
configured to drive the insertion element from a proximal starting
position to a distal insertion position, and from the distal
insertion position to a proximal retraction position.
Inventors: |
Gray; John Michael; (San
Diego, CA) ; Blackwell; Jennifer; (San Diego, CA)
; Neale; Paul V.; (San Diego, CA) ; England;
Justen Deering; (San Francisco, CA) ; Joncich;
Andrew; (Madison, WI) ; Brock; Cameron; (San
Francisco, CA) ; Simpson; Peter C.; (Cardiff by the
Sea, CA) ; Metzmaker; Thomas; (San Diego, CA)
; Shah; Neel Narayan; (Carlsbad, CA) ; Kempkey;
Mark Douglas; (Vista, CA) ; Castagna; Patrick
John; (San Diego, CA) ; Terry; Warren; (Poway,
CA) ; Halac; Jason; (San Diego, CA) ; George;
Christian Michael Andre; (San Diego, CA) ; Apacible;
Daniel E.; (Chula Vista, CA) ; Barry; John
Charles; (San Diego, CA) ; Wells; Maria Noel
Brown; (Vista, CA) ; Pirondini; Kenneth; (San
Diego, CA) ; Reinhardt; Andrew Michael; (Santee,
CA) ; Wong; Jason C.; (San Diego, CA) ;
Gagnon; Remy E.; (San Diego, CA) ; DeRenzy;
David; (San Diego, CA) ; Koplin; Randall Scott;
(San Diego, CA) ; Baldwin; Alan; (San Jose,
CA) ; Lee; Young Woo; (San Diego, CA) ;
Keller; David A.; (Encinitas, CA) ; van den Heuvel;
Louise Emma; (Somerville, MA) ; Sutherland; Carol
Wood; (Somerville, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DexCom, Inc. |
San Diego |
CA |
US |
|
|
Family ID: |
1000005720420 |
Appl. No.: |
17/378152 |
Filed: |
July 16, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17200664 |
Mar 12, 2021 |
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17378152 |
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16016493 |
Jun 22, 2018 |
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17200664 |
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16016354 |
Jun 22, 2018 |
10863944 |
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16016493 |
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62658486 |
Apr 16, 2018 |
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62524247 |
Jun 23, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61B 5/6833 20130101;
A61B 5/14546 20130101; A61B 5/6849 20130101; A61B 5/1473 20130101;
A61B 5/6848 20130101; A61B 5/0004 20130101; A61B 5/14532 20130101;
A61B 2560/063 20130101; A61B 5/14503 20130101 |
International
Class: |
A61B 5/00 20060101
A61B005/00; A61B 5/145 20060101 A61B005/145 |
Claims
1. A transcutaneous analyte sensor system comprising: a
transcutaneous analyte sensor; and sensor electronics operably
connectable to the transcutaneous analyte sensor.
Description
INCORPORATION BY REFERENCE TO RELATED APPLICATIONS
[0001] Any and all priority claims identified in the Application
Data Sheet, or any correction thereto, are hereby incorporated by
reference under 37 CFR 1.57. This application is a continuation of
U.S. application Ser. No. 17/200,664, filed Mar. 12, 2021, which is
a continuation of U.S. application Ser. No. 16/016,493, filed Jun.
22, 2018, which is a continuation of U.S. application Ser. No.
16/016,354, filed Jun. 22, 2018, now U.S. Pat. No. 10,863,944,
issued Dec. 15, 2020, which claims the benefit of U.S. Provisional
Application No. 62/524,247, filed Jun. 23, 2017 and U.S.
Provisional Application No. 62/658,486, filed Apr. 16, 2018. Each
of the aforementioned applications is incorporated by reference
herein in its entirety, and each is hereby expressly made a part of
this specification.
FIELD
[0002] Systems and methods for measuring an analyte in a host are
provided. More particularly, systems and methods are provided for
applying a transcutaneous analyte measurement system to a host.
BACKGROUND
[0003] Diabetes mellitus is a disorder in which the pancreas cannot
create sufficient insulin (Type I or insulin dependent) and/or in
which insulin is not effective (Type 2 or non-insulin dependent).
In the diabetic state, the victim suffers from high blood sugar,
which can cause an array of physiological derangements associated
with the deterioration of small blood vessels, for example, kidney
failure, skin ulcers, or bleeding into the vitreous of the eye. A
hypoglycemic reaction (low blood sugar) can be induced by an
inadvertent overdose of insulin, or after a normal dose of insulin
or glucose-lowering agent accompanied by extraordinary exercise or
insufficient food intake.
[0004] Conventionally, a person with diabetes carries a
self-monitoring blood glucose (SMBG) monitor, which typically
requires uncomfortable finger pricking methods. Due to the lack of
comfort and convenience, a person with diabetes normally only
measures his or her glucose levels two to four times per day.
Unfortunately, such time intervals are spread so far apart that the
person with diabetes likely finds out too late of a hyperglycemic
or hypoglycemic condition, sometimes incurring dangerous side
effects. Glucose levels may be alternatively monitored continuously
by a sensor system including an on-skin sensor assembly. The sensor
system may have a wireless transmitter which transmits measurement
data to a receiver which can process and display information based
on the measurements.
[0005] The process of applying the sensor to the person is
important for such a system to be effective and user friendly. The
application process should result in the sensor assembly being
attached to the person in a state where it is capable of sensing
glucose level information, communicating the sensed data to the
transmitter, and transmitting the glucose level information to the
receiver.
[0006] This Background is provided to introduce a brief context for
the Summary and Detailed Description that follow. This Background
is not intended to be an aid in determining the scope of the
claimed subject matter nor be viewed as limiting the claimed
subject matter to implementations that solve any or all of the
disadvantages or problems presented above.
SUMMARY
[0007] The present systems and methods relate to systems and
methods for measuring an analyte in a host, and for applying a
transcutaneous analyte measurement system to a host. The various
embodiments of the present systems and methods for applying the
analyte measurement system have several features, no single one of
which is solely responsible for their desirable attributes. Without
limiting the scope of the present embodiments as expressed by the
claims that follow, their more prominent features now will be
discussed briefly. After considering this discussion, and
particularly after reading the section entitled "Detailed
Description," one will understand how the features of the present
embodiments provide the advantages described herein.
[0008] An applicator for applying an on-skin sensor assembly to a
skin of a host is provided. The applicator includes an applicator
housing, a needle carrier assembly, which includes an insertion
element configured to insert a sensor of the on-skin sensor
assembly into the skin of the host, a holder releasably coupled to
the needle carrier assembly and configured to guide the on-skin
sensor assembly while coupled to the needle carrier assembly, and a
drive assembly configured to drive the insertion element from a
proximal starting position to a distal insertion position, and from
the distal insertion position to a proximal retraction
position.
[0009] In some embodiments, the on-skin sensor assembly includes an
electronics unit. In some embodiments, the sensor is connected to
the electronics unit in the applicator housing. In some
embodiments, the holder is configured to release the on-skin sensor
assembly after the sensor is inserted at least partially into the
skin of the host. In some embodiments, the applicator further
includes an activation element configured to activate the drive
assembly. In some embodiments, the activation element includes a
deflectable feature. In some embodiments, the deflectable feature
is configured to provide resistance to activation. In some
embodiments, the deflectable feature is configured to return the
activation element to a starting position. In some embodiments, the
activation element includes one of a button, a switch, a toggle, a
slide, a trigger, and a knob. In some embodiments, the applicator
further includes a safety element configured to prevent operation
of the activation element. In some embodiments, the safety element
includes a tab coupled to the activation element by at least one
frangible member. In some embodiments, the distal direction and the
proximal direction extend along an insertion axis of the insertion
element. In some embodiments, the holder includes an elastomer.
[0010] In a first aspect, the applicator housing includes a guide.
The drive assembly includes a rotating drive element coupled to the
needle carrier assembly and includes a pin configured to travel in
the guide during rotation of the rotating drive element, and a
spring configured to, upon activation of the drive assembly, rotate
the rotating drive element in a single rotational direction thereby
driving the insertion element from the proximal starting position
to the distal insertion position, and from the distal insertion
position to the proximal retraction position. In some embodiments,
the rotating drive element is configured to convert rotational
motion into linear motion. In some embodiments, the rotating drive
element includes a wheel cam. In some embodiments, the pin is
radially offset from an axis of rotation of the rotating drive
element. In some embodiments, the pin is positioned approximately
30 degrees from a bottom center orientation relative to the axis of
rotation of the rotating drive element when the insertion element
is in the proximal starting position. In some embodiments, the pin
is positioned approximately 180 degrees from a bottom center
orientation relative to the axis of rotation of the rotating drive
element when the insertion element is in the distal insertion
position. In some embodiments, the pin is positioned approximately
330 degrees from a bottom center orientation relative to the axis
of rotation of the rotating drive element when the needle carrier
assembly is in the proximal retracted position. In some
embodiments, the pin travels in the guide in a direction
perpendicular to a direction of extension of the insertion element.
In some embodiments, the guide includes a slot. In some
embodiments, the slot is stationary during sensor insertion. In
some embodiments, the slot includes a horizontal slot. In some
embodiments, the slot includes a vertical slot configured to
receive at least the pin of the rotating drive element when loaded
through a bottom of the applicator housing. In some embodiments,
the applicator housing is stationary. In some embodiments, the
rotating drive element further includes a protrusion in contact
with a retention element configured to prevent the rotating drive
element from rotating. In some embodiments, the applicator further
includes an activation element configured to deflect the retention
element, thereby allowing the rotating drive element to rotate. In
some embodiments, the rotating drive element further includes a
protrusion configured to decouple the on-skin sensor assembly from
the needle carrier assembly. In some embodiments, the protrusion is
configured to apply a force to the on-skin sensor assembly during
rotation of the rotating drive element. In some embodiments, the
protrusion of the rotating drive element is configured to pass
through a slot in the needle carrier assembly as the rotating drive
element rotates.
[0011] In a second aspect, the drive assembly includes a torsion
spring. The torsion spring includes a first end coupled to the
applicator housing, and a second end coupled to the needle carrier
assembly. Upon activation of the drive assembly, the first end and
the second end unwind in opposite directions, thereby driving the
insertion element from the proximal starting position to the distal
insertion position, and from the distal insertion position to the
proximal retraction position. In some embodiments, the first end
and the second end unwinding in opposite directions drives the
torsion spring in an arc. In some embodiments, the arc extends in a
direction perpendicular to the distal direction and the proximal
direction. In some embodiments, a spool coupled to the torsion
spring. In some embodiments, the torsion spring is wrapped around
the spool. In some embodiments, the second end of the torsion
spring is configured to drive the insertion element. In some
embodiments, the torsion spring is a double torsion spring. In some
embodiments, the first end of the torsion spring is coupled to a
protrusion of the applicator housing. In some embodiments, the
second end of the torsion spring is coupled to a protrusion of the
needle carrier assembly.
[0012] In a third aspect, the drive assembly further includes a
linkage element, which includes a first end coupled to the first
end of the torsion spring, a second end coupled to the second end
of the torsion spring, and a hinge substantially aligned with a
winding axis of the torsion spring. In some embodiments, the
linkage element includes a flexible linkage.
[0013] In a fourth aspect, the drive assembly includes a linkage
element, which includes a first end coupled to the applicator
housing, a second end coupled to the needle carrier assembly, and a
hinge disposed between the first end and the second end. The drive
assembly further includes a torsion spring, which includes a first
end coupled to the needle carrier assembly, and a second end
coupled to the linkage element between the second end and the
hinge. Upon activation of the drive assembly, the second end is
configured to drive the linkage element such that the insertion
element is driven from the proximal starting position to the distal
insertion position, and from the distal insertion position to the
proximal retracted position.
[0014] In a fifth aspect, the drive assembly includes a linkage
element, which includes a first end coupled to the applicator
housing, a second end coupled to the needle carrier assembly, and a
hinge disposed between the first end and the second end. The drive
assembly further includes a torsion spring, which includes a first
end coupled to the applicator housing, and a second end coupled to
the linkage element between the first end and the hinge. Upon
activation of the drive assembly, the second end is configured to
drive the linkage element such that the insertion element is driven
the proximal starting position to the distal insertion position,
and from the distal insertion position to the proximal retracted
position.
[0015] In a sixth aspect, the drive assembly includes a linkage
element, which includes a first end coupled to the applicator
housing, a second end coupled to the needle carrier assembly, and a
hinge disposed between the first end and the second end. The drive
assembly further includes an extension spring coupled to the
linkage element. Upon activation of the drive assembly, the
extension spring is configured to drive the linkage element such
that the insertion element is driven in the distal direction to the
distal insertion position and in the proximal direction from the
distal insertion position.
[0016] In a seventh aspect, the drive assembly includes a leaf
spring, which includes a first end coupled to the applicator
housing, and a second end coupled to the needle carrier assembly.
Upon activation of the drive assembly, the leaf spring is
configured to decompress, thereby driving the insertion element at
least in the distal direction to the distal insertion position.
[0017] In an eighth aspect, the drive assembly includes a linkage
element, which includes a first end coupled to the applicator
housing, a second end coupled to the needle carrier assembly, and a
hinge disposed between the first end and the second end. The drive
assembly further includes a leaf spring, which includes a first end
coupled to the needle carrier assembly, and a second end coupled to
the linkage element between the second end and the hinge. Upon
activation of the drive assembly, the leaf spring is configured to
decompress, thereby driving the insertion element in the distal
direction to the distal insertion position and in the proximal
direction from the distal insertion position.
[0018] In a ninth aspect, the drive assembly includes a leaf
spring, which includes a first end coupled to the applicator
housing, and a second end coupled to the needle carrier assembly.
Upon activation of the drive assembly, the leaf spring is
configured to decompress, thereby driving the insertion element at
least in the distal direction to the distal insertion position.
[0019] In a tenth aspect, the drive assembly includes a linkage
element, which includes a first end coupled to the applicator
housing, a second end coupled to the needle carrier assembly; and a
hinge disposed between the first end and the second end. The drive
assembly further includes a leaf spring, which includes a first end
coupled to the needle carrier assembly, and a second end coupled to
the linkage element between the second end and the hinge. Upon
activation of the drive assembly, the leaf spring is configured to
decompress, thereby driving the insertion element in the distal
direction to the distal insertion position and in the proximal
direction from the distal insertion position.
[0020] In an eleventh aspect, the drive assembly includes an
insertion spring configured to, upon activation of the drive
assembly, drive the insertion element in the distal direction to
the distal insertion position, and a retraction spring in contact
with the needle carrier assembly and configured to drive the
insertion element from the distal insertion position to the
proximal retracted position. In some embodiments, the insertion
spring includes a compression spring. In some embodiments, the
retraction spring includes a leaf spring. In some embodiments, the
retraction spring is configured retract the insertion element from
the skin of the host. In some embodiments, upon activation of the
drive assembly, a portion of energy stored in the insertion spring
is transferred to the retraction spring as the insertion spring
drives the insertion element in the distal direction. In some
embodiments, the insertion spring includes a first end coupled to
the applicator housing and a second end coupled to the holder, and
the holder is coupled to the needle carrier assembly while the
insertion spring drives the insertion element in the distal
direction to the distal insertion position and decoupled from the
needle carrier assembly when the retraction spring drives the
insertion element in the proximal direction from the distal
insertion position. In some embodiments, the insertion element is
configured to travel in an arc when driven in the distal direction
and in the proximal direction.
[0021] In a twelfth aspect, the drive assembly includes a rotating
drive element, which includes a ridge configured to slide along a
channel in the needle carrier assembly, the ridge defining a
variable cam path around at least a portion of a circumference of
the rotating drive element, and a torsion spring configured to,
upon activation of the drive assembly, rotate the rotating drive
element thereby driving the insertion element in a distal direction
to a distal insertion position and in a proximal direction from the
distal insertion position based on the variable cam path. In some
embodiments, the torsion spring is configured to, upon activation
of the drive assembly, rotate the rotating drive element in a
single direction through an angle of greater than zero degrees and
less than 360 degrees. In some embodiments, the rotating drive
element includes a barrel cam. In some embodiments, the rotating
drive element is configured to rotate in a plane substantially
perpendicular to the proximal direction and the distal
direction.
[0022] In a thirteenth aspect, the drive assembly includes a guide
member coupled to the applicator housing, a hub configured to slide
along the guide member, the hub in contact with a reverse toggling
element through a first portion of travel along the guide member
and in contact with the needle carrier assembly through a second
portion of travel along the guide member. The reverse toggling
element includes a fulcrum, a first end in contact with the hub
through the first portion of travel along the guide member, and a
second end coupled with the needle carrier assembly. The drive
assembly further includes a spring configured to, upon activation
of the drive assembly drive the hub in a proximal direction through
the first portion of travel along the guide member, thereby driving
the insertion element in the distal direction to the distal
insertion position, and drive the hub in the proximal direction
through the second portion of travel along the guide member,
thereby driving the insertion element in the proximal direction
from the distal insertion position.
[0023] In a fourteenth aspect, the drive assembly includes a first
spring configured to, upon activation of the drive assembly, drive
the needle carrier assembly in the distal direction to a distal
insertion position, and a second spring configured to drive the
needle carrier assembly in the proximal direction from the distal
insertion position. In some embodiments, the first spring and the
second spring are precompressed before activation of the drive
assembly. In some embodiments, at least a portion of energy stored
in the first spring is transferred to the second spring as the
needle carrier assembly is driven in the distal direction to the
distal insertion position.
[0024] In some embodiments, the holder includes at least one
retention element configured to immobilize the holder to the
applicator housing upon the needle carrier assembly reaching the
distal insertion position. In some embodiments, the holder further
includes a retention element configured to releasably couple the
on-skin sensor assembly to the holder as the needle carrier
assembly travels in the distal direction to the distal insertion
position, and decouple the on-skin sensor assembly from the holder
as the needle carrier assembly travels in the proximal direction
from the distal insertion position.
[0025] In some embodiments, the holder includes a retention
element, which includes a first end and a second end. The first end
is immobilized in a guide of the needle carrier assembly thereby
releasably coupling the second end to the on-skin sensor assembly
as the needle carrier assembly travels in the distal direction to
the distal insertion position, and the first end is unseated from
the guide of the needle carrier assembly thereby decoupling the
second end from the on-skin sensor assembly as the needle carrier
assembly travels in the proximal direction from the distal
insertion position and separates from the holder.
[0026] In some embodiments, the needle carrier assembly includes a
retention element releasably coupling the on-skin sensor assembly
to the holder as the needle carrier assembly travels in the distal
direction to the distal insertion position, and the retention
element is configured to deform sufficiently to decouple from the
on-skin sensor assembly as the needle carrier assembly travels in
the proximal direction from the distal insertion position and
separates from the holder.
[0027] In some embodiments, the holder includes a deformable
retention element releasably coupling the on-skin sensor assembly
to the holder, the needle carrier assembly in contact with the
deformable retention element thereby preventing the deformable
retention element from deforming as the needle carrier assembly
travels in the distal direction to the distal insertion position.
The needle carrier assembly separates from the holder as the needle
carrier assembly travels in the proximal direction from the distal
insertion position thereby allowing the retention element to deform
sufficiently to decouple from the on-skin sensor assembly.
[0028] In some embodiments, the needle carrier assembly includes a
first retention element configured to releasably couple the holder
to the needle carrier assembly, and a second retention element
configured to releasably couple the on-skin sensor assembly to one
of the holder and the needle carrier assembly.
[0029] In some embodiments, the insertion element includes a
C-needle having flared edges. In some embodiments, the insertion
element includes a deflected-tip needle. In some embodiments, the
insertion element includes a needle having a curvilinear profile
configured to substantially track a path of insertion of the
needle. In some embodiments, the insertion element includes a
needle and the needle carrier assembly further includes a needle
hub configured as a pass through for the needle during insertion of
the sensor and is further configured to enclose a tip of the needle
after insertion of the sensor. The insertion element further
includes a needle spring configured to drive the needle hub to the
tip of the needle after insertion of the sensor.
[0030] In some embodiments, the on-skin sensor assembly includes a
fill port configured to receive a fluid or gel and a cannula
configured to deliver the fluid or gel through the skin of the
host.
[0031] In some embodiments, the applicator further includes an
elastomeric sensor retention element coupled to the applicator
housing at a first end and coupled to at least one of the insertion
element and the sensor. The elastomeric sensor retention element is
configured to retain the sensor within the insertion element prior
to activation of the drive assembly. In some embodiments upon
activation, the insertion element is configured to progress in the
proximal direction such that the elastomeric sensor retention
element decouples from the at least one of the insertion element
and the sensor.
[0032] In some embodiments, the applicator further includes a
sensor retention element, which includes a tab configured to retain
the sensor within the insertion element prior to activation of the
drive assembly.
[0033] In some embodiments, the applicator further includes a
sensor retention element disposed against at least one of the
insertion element and the sensor in a first position and configured
to rotate away from the insertion element and the sensor in a
second position.
[0034] In some embodiments, the applicator further includes a
sensor retention sleeve disposed around at least a portion of the
insertion element and the sensor. The needle carrier assembly
includes a tapered needle hub configured to split the sensor
retention sleeve during insertion of the sensor.
[0035] In some embodiments, the sensor includes a strain relief
feature configured to limit the sensor from bending at a bend
radius smaller than a predetermined bend radius. In some
embodiments, the strain relief feature includes an elastomeric
material.
[0036] In some embodiments, the on-skin sensor assembly includes an
open cavity configured to receive the sensor and provide an area
for the sensor to bend from extending in a substantially horizontal
direction to extending in a substantially vertical direction. In
some embodiments, the open cavity is configured to guide bodily
fluid released from the host as a result of insertion of the sensor
at least partially into the skin of the host. In some embodiments,
the on-skin sensor assembly includes a wicking material configured
to absorb a bodily fluid released from the host as a result of
insertion of the sensor at least partially into the skin of the
host.
[0037] In a fifteenth aspect, a method for applying an on-skin
sensor assembly to skin of a host is provided. The method includes
providing an applicator, which includes an applicator housing, a
needle carrier assembly includes an insertion element configured to
insert a sensor of the on-skin sensor assembly into the skin of the
host, a holder releasably coupled to the needle carrier assembly
and configured to guide the on-skin sensor assembly while coupled
to the needle carrier assembly and a drive assembly and an
activation element. The method includes activating the activation
element, wherein activating the activation element causes the drive
assembly to drive the insertion element in a distal direction to a
distal insertion position and in a proximal direction from the
distal insertion position to a proximal retraction position,
thereby inserting the sensor of the on-skin sensor assembly at
least partially into the skin of the host. In some embodiments, the
distal direction and the proximal direction extend along an
insertion axis of the insertion element.
[0038] In some embodiments, the applicator housing includes a
guide. The drive assembly includes a rotating drive element coupled
to the needle carrier assembly and includes a pin configured to
travel in the guide during rotation of the rotating drive element,
and a spring configured to, upon activation of the drive assembly,
rotate the rotating drive element in a single rotational direction
thereby driving the insertion element from the proximal starting
position to the distal insertion position, and from the distal
insertion position to the proximal retraction position. In some
embodiments, the rotating drive element is configured to convert
rotational motion into linear motion. In some embodiments, the
rotating drive element includes a wheel cam. In some embodiments,
the pin is radially offset from an axis of rotation of the rotating
drive element. In some embodiments, the pin is positioned
approximately 30 degrees from a bottom center orientation relative
to the axis of rotation of the rotating drive element when the
insertion element is in the proximal starting position. In some
embodiments, the pin is positioned approximately 180 degrees from a
bottom center orientation relative to the axis of rotation of the
rotating drive element when the insertion element is in the distal
insertion position. In some embodiments, the pin is positioned
approximately 330 degrees from a bottom center orientation relative
to the axis of rotation of the rotating drive element when the
needle carrier assembly is in the proximal retracted position. In
some embodiments, the guide includes a slot.
[0039] In some embodiments, the drive assembly includes a torsion
spring, the torsion spring includes a first end coupled to the
applicator housing, and a second end coupled to the needle carrier
assembly. Upon activation of the drive assembly, the first end and
the second end unwind in opposite directions, thereby driving the
insertion element from the proximal starting position to the distal
insertion position, and from the distal insertion position to the
proximal retraction position. In some embodiments, the first end
and the second end unwinding in opposite directions drives the
torsion spring in an arc. In some embodiments, the arc extends in a
direction perpendicular to the distal direction and the proximal
direction.
[0040] In some embodiments, the drive assembly includes an
insertion spring configured to, upon activation of the drive
assembly, drive the insertion element in the distal direction to
the distal insertion position, and a retraction spring in contact
with the needle carrier assembly and configured to drive the
insertion element from the distal insertion position to the
proximal retracted position. In some embodiments, the insertion
spring includes a compression spring. In some embodiments, the
retraction spring includes a leaf spring. In some embodiments, upon
activation of the drive assembly, a portion of energy stored in the
insertion spring is transferred to the retraction spring as the
insertion spring drives the insertion element in the distal
direction. In some embodiments, the insertion spring includes a
first end coupled to the applicator housing and a second end
coupled to the holder. The holder is coupled to the needle carrier
assembly while the insertion spring drives the insertion element in
the distal direction to the distal insertion position and decoupled
from the needle carrier assembly when the retraction spring drives
the insertion element in the proximal direction from the distal
insertion position. In some embodiments, the insertion element is
configured to travel in an arc when driven in the distal direction
and in the proximal direction.
[0041] In some embodiments, the drive assembly includes a rotating
drive element, which includes a ridge configured to slide along a
channel in the needle carrier assembly, the ridge defining a
variable cam path around at least a portion of a circumference of
the rotating drive element, and a torsion spring configured to,
upon activation of the drive assembly, rotate the rotating drive
element thereby driving the insertion element in a distal direction
to a distal insertion position and in a proximal direction from the
distal insertion position based on the variable cam path. In some
embodiments, the torsion spring is configured to, upon activation
of the drive assembly, rotate the rotating drive element in a
single direction through an angle of greater than zero degrees and
less than 360 degrees. In some embodiments, the rotating drive
element includes a barrel cam. In some embodiments, the rotating
drive element is configured to rotate in a plane substantially
perpendicular to the proximal direction and the distal
direction.
[0042] In some embodiments, the drive assembly includes a guide
member coupled to the applicator housing, a hub configured to slide
along the guide member, the hub in contact with a reverse toggling
element through a first portion of travel along the guide member
and in contact with the needle carrier assembly through a second
portion of travel along the guide member. The reverse toggling
element includes a fulcrum, a first end in contact with the hub
through the first portion of travel along the guide member, and a
second end coupled with the needle carrier assembly; The drive
assembly further includes a spring configured to, upon activation
of the drive assembly, drive the hub in a proximal direction
through the first portion of travel along the guide member, thereby
driving the insertion element in the distal direction to the distal
insertion position, and drive the hub in the proximal direction
through the second portion of travel along the guide member,
thereby driving the insertion element in the proximal direction
from the distal insertion position.
[0043] In some embodiments, the drive assembly includes a first
spring configured to, upon activation of the drive assembly, drive
the needle carrier assembly in the distal direction to a distal
insertion position, and a second spring configured to drive the
needle carrier assembly in the proximal direction from the distal
insertion position. In some embodiments, at least a portion of
energy stored in the first spring is transferred to the second
spring as the needle carrier assembly is driven in the distal
direction to the distal insertion position.
[0044] In a sixteenth aspect, an applicator for applying an on-skin
sensor assembly to a skin of a host is provided. The applicator
includes an insertion assembly configured to translate a needle
carrier assembly and the on-skin sensor assembly in a distal
direction from an initial proximal position to a distal insertion
position. The applicator includes a retraction assembly configured
to translate the needle carrier assembly in a proximal direction
from the distal inserted position to a proximal retracted position.
The retraction assembly is configured to activate in response to
the on-skin sensor assembly contacting the skin of the host.
[0045] In some embodiments, the insertion assembly includes a first
spring. In some embodiments, the retraction assembly includes a
second spring. In some embodiments, the insertion assembly further
includes a holder configured to guide the needle carrier assembly
at least during translation from the initial proximal position to
the distal insertion position. In some embodiments, the holder
further includes at least one retention element configured to
retain the second spring at least during insertion. In some
embodiments, the at least one retention element is disposed along
an outside of the second coil and configured to contact and retain
a coil of the second spring. In some embodiments, the needle
carrier assembly further includes at least one backstop feature
configured to prevent lateral deflection of the at least one
retention element at least during insertion. In some embodiments,
the at least one backstop feature is configured not to contact the
at least one retention element in the distal insertion position,
thereby allowing the second spring to deflect the at least one
retention element and activate the retraction assembly. In some
embodiments, the second spring is configured to exert a force
sufficient to deflect the at least one retention element in the
distal insertion position when the on-skin sensor assembly is in
contact with the skin of the host. In some embodiments, the
applicator further includes an inner housing. In some embodiments,
the applicator further includes an outer housing including an
activation element configured to activate the insertion assembly.
In some embodiments, the activation element is prevented from
activating the insertion assembly until the outer housing is
translated a predetermined distance in a distal direction with
respect to the inner housing. In some embodiments, the inner
housing further includes an engagement element and the needle
carrier assembly includes a protrusion. The engagement element is
configured to engage with the protrusion upon the needle carrier
assembly translating in a distal direction beyond a predetermined
threshold, thereby preventing the needle carrier assembly from
translating in the distal direction beyond the predetermined
threshold. In some embodiments, the engagement feature includes a
hook. In some embodiments, the needle carrier assembly further
includes a hub configured to couple an insertion element to the
needle carrier assembly. In some embodiments, the hub is further
configured to couple to the on-skin sensor assembly.
[0046] In some embodiments, the insertion assembly and the
retraction assembly both include the first spring. In some
embodiments, the first spring is configured to exert a force
between a holder and a deployment sleeve. In some embodiments, the
holder includes at least one retention element configured to
immobilize the holder to the deployment sleeve. In some
embodiments, the applicator further includes a housing and an
activation element configured to deflect the at least one retention
element, thereby enabling the first spring to translate the holder,
the needle carrier assembly and the on-skin sensor assembly from
the proximal position to the distal insertion position. In some
embodiments, the housing further includes at least one protrusion,
and the deployment sleeve includes at least one retention element
configured to contact the at least one protrusion of the housing.
In some embodiments, the first spring is configured to exert a
force sufficient to deflect the at least one retention element of
the deployment sleeve when the on-skin sensor assembly is in
contact with the skin of the host, thereby freeing the at least one
retention element of the deployment sleeve from the at least one
protrusion of the housing. In some embodiments, the first spring is
further configured to translate the deployment sleeve in the
proximal direction. In some embodiments, the needle carrier
assembly further includes a protrusion configured to contact the
deployment sleeve, thereby causing the needle carrier assembly to
translate in the proximal direction.
[0047] In a seventeenth embodiment, a needle hub for applying an
on-skin sensor assembly to a skin of a host is provided. The needle
hub includes at least one upper arm. The needle hub includes a base
comprising an anti-rotation feature. The base is configured to be
at least partially disposed in an aperture of the on-skin sensor
assembly. The needle hub is configured to couple with an insertion
element.
[0048] In some embodiments, the anti-rotation feature is configured
to prevent rotation of the base within the aperture. In some
embodiments, the anti-rotation feature includes a key having a
shape complementary to at least a portion of the aperture. In some
embodiments, the at least one upper arm is configured to be
disposed through an aperture in a needle carrier assembly of an
applicator. In some embodiments, the at least one upper arm is
configured to contact an upper surface of the needle carrier
assembly adjacent to the aperture in the needle carrier assembly.
In some embodiments, the at least one upper arm is configured to be
disposed in a groove in the upper surface of the needle carrier
assembly, thereby immobilizing the needle hub with respect to the
needle carrier assembly. In some embodiments, the at least one
upper arm is flexible. In some embodiments, the at least one upper
arm is configured to flex radially inward. In some embodiments, the
needle hub further includes at least one lower arm. In some
embodiments, the at least one lower arm is configured to contact a
lower surface of the needle carrier assembly adjacent to an
aperture in the needle carrier assembly. In some embodiments, the
insertion element includes a needle. In some embodiments, the
needle includes an open side configured to receive a sensor of the
on-skin sensor assembly. In some embodiments, the base includes a
flat surface configured to mate with a top surface of the on-skin
sensor assembly, thereby maintaining the insertion element in a
substantially perpendicular orientation to the top surface of the
on-skin sensor assembly.
[0049] In an eighteenth embodiment, a method for applying an
on-skin sensor assembly to skin of a host is provided. The method
includes providing an applicator. The applicator includes a housing
comprising an activation element. The applicator includes an
insertion assembly. The applicator includes a retraction assembly.
The method includes activating the activation element. Activating
the activation element causes the insertion assembly to translate a
needle carrier assembly and the on-skin sensor assembly in a distal
direction from a proximal position to a distal insertion position,
thereby inserting a sensor of the on-skin sensor assembly at least
partially into the skin of the host. Activating the activation
element causes the retraction assembly to translate the needle
carrier assembly in a proximal direction from the distal inserted
position to a proximal retracted position. The retraction assembly
is configured to activate in response to on-skin sensor assembly
contacting the skin of the host.
[0050] In some embodiments, the insertion assembly includes a first
spring. In some embodiments, the retraction assembly includes a
second spring. In some embodiments, the insertion assembly further
includes a holder configured to guide the needle carrier assembly
at least during translation from the proximal position to the
distal insertion position. In some embodiments, the holder further
includes at least one retention element configured to retain the
second spring at least during insertion. In some embodiments, the
at least one retention element is disposed along an outside of the
second coil and configured to contact and retain a coil of the
second spring. In some embodiments, the needle carrier assembly
further includes at least one backstop feature configured to
prevent lateral deflection of the at least one retention element at
least during insertion. In some embodiments, the at least one
backstop feature is configured not to contact the at least one
retention element in the distal insertion position, thereby
allowing the second spring to deflect the at least one retention
element and activate the retraction assembly. In some embodiments,
the second spring is configured to exert a force sufficient to
deflect the at least one retention element in the distal insertion
position when the on-skin sensor assembly is in contact with the
skin of the host. In some embodiments, the second spring includes a
tang extending along a diameter of second spring and wherein the at
least one retention element is disposed along an inside of the
second spring and configured to retain the tang of the second
spring. In some embodiments, the housing is an outer housing and
the applicator further includes an inner housing. In some
embodiments, activating the activation element includes translating
the outer housing a predetermined distance in a distal direction
with respect to the inner housing. In some embodiments, the inner
housing further includes an engagement element and the needle
carrier assembly includes a protrusion. The engagement element is
configured to engage with the protrusion upon the needle carrier
assembly translating in a distal direction beyond a predetermined
threshold, thereby preventing the needle carrier assembly from
translating in the distal direction beyond the predetermined
threshold. In some embodiments, the engagement feature includes a
hook. In some embodiments, the needle carrier assembly further
includes a needle hub configured to couple the insertion element to
the needle carrier assembly.
[0051] In some embodiments, the insertion assembly and the
retraction assembly both include the first spring. In some
embodiments, the first spring is configured to exert a force
between a holder and a deployment sleeve. In some embodiments, the
holder includes at least one retention element configured to
immobilize the holder to the deployment sleeve. In some
embodiments, activating the activation element includes deflecting
the at least one retention element of the holder, thereby enabling
the first spring to translate the holder, the needle carrier
assembly and the on-skin sensor assembly from the proximal position
to the distal insertion position. In some embodiments, the housing
further includes at least one protrusion, and the deployment sleeve
includes at least one retention element configured to contact the
at least one protrusion of the housing. In some embodiments, the
first spring is configured to exert a force sufficient to deflect
the at least one retention element of the deployment sleeve when
the on-skin sensor assembly is in contact with the skin of the
host, thereby freeing the at least one retention element of the
deployment sleeve from the at least one protrusion of the housing.
In some embodiments, the first spring is further configured to
translate the deployment sleeve in the proximal direction. In some
embodiments, the needle carrier assembly further includes a
protrusion configured to contact the deployment sleeve, thereby
causing the needle carrier assembly to translate in the proximal
direction.
[0052] In a nineteenth aspect, an applicator for applying an
on-skin sensor assembly to a skin of a host is provided. The
applicator includes a first body releasably coupled to a needle.
The applicator further includes a second body releasably coupled to
the first body by a frictional engagement. The applicator further
includes a spring configured to provide a first force to the first
body and second body. The first force can drive the first body and
second body in a distal direction. The frictional engagement can be
configured to be decoupled by a counter force applied to the
on-skin sensor assembly in an opposite direction of the first
force.
[0053] In some embodiments, the applicator further includes at
least one retention element configured to frictionally couple the
second body to the first body. In some embodiments, the at least
one retention element is formed integral with the second body. In
some embodiments, the at least one retention element is
frictionally engaged against a wall of the first body. In some
embodiments, the counter force decouples the frictional engagement
by displacing the at least one retention element from the wall of
the first body. In some embodiments, the wall is a backstop. In
some embodiments, the wall is configured to prevent the at least
one retention element from deflecting.
[0054] In some embodiments, the frictional engagement is decoupled
by the counter force exceeding a force threshold. In some
embodiments, the force threshold is determined by the frictional
force between the at least one retention element and the first
body. In some embodiments, the threshold is at least 0.5 lbf. In
some embodiments, the threshold is at least 1 lbf.
[0055] In some embodiments, the first body is configured to retract
in a proximal direction upon decoupling of the frictional
engagement. In some embodiments, the applicator further includes a
second spring. The second spring can be configured to drive the
first body in a proximal direction. In some embodiments, the second
spring is retained from release by at least one retention element
of the second body.
[0056] In some embodiments, the decoupling of the frictional
engagement is configured to be independent of a distance between
the on-skin sensor assembly and a distal end of the applicator. In
some embodiments, the first body is configured to retract
independent of the distance between the on-skin sensor assembly and
the distal end of the applicator. In some embodiments, the counter
force applied to the on-skin sensor assembly is provided by the
skin of the host opposing the first force. In some embodiments, an
interior of the applicator is configured to allow the skin of the
host to reside within the interior. In some embodiments, the needle
is configured to be inserted into the skin a predetermined depth.
In some embodiments, the frictional engagement is configured to
decouple at a range of distances between the on-skin sensor
assembly and a distal end of the applicator.
[0057] This Summary is provided to introduce a selection of
concepts further described in the Detailed Description section.
Elements or steps other than those described in this Summary are
possible, and no element or step is necessarily required. This
Summary is not intended to identify key features or essential
features of the claimed subject matter, nor is it intended for use
as an aid in determining the scope of the claimed subject matter.
The claimed subject matter is not limited to implementations that
solve any or all disadvantages noted in any part of this
disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] These and other features, aspects, and advantages are
described below with reference to the drawings, which are intended
to illustrate, but not to limit, the invention. In the drawings,
like reference characters denote corresponding features
consistently throughout similar embodiments.
[0059] FIG. 1 illustrates a schematic view of a continuous analyte
sensor system, according to some embodiments.
[0060] FIGS. 2A-2B illustrate perspective views of an on-skin
sensor assembly, according to some embodiments.
[0061] FIGS. 3A-3B illustrate perspective views of another on-skin
sensor assembly, according to some embodiments.
[0062] FIG. 4 illustrates a cross-sectional view of the on-skin
sensor assembly of FIGS. 3A-3B, according to some embodiments.
[0063] FIG. 5 illustrates an exploded perspective view of the
applicator of FIG. 5, according to some embodiments.
[0064] FIG. 6A-6H illustrate cutaway views and perspective views of
several features of the applicator of FIG. 5, according to some
embodiments.
[0065] FIGS. 7A-7F illustrate several cutaway views of the
applicator of FIG. 5 during operation, according to some
embodiments.
[0066] FIG. 8 illustrates a cutaway view of an applicator similar
to the applicator of FIG. 5, however, including an activation
element on an upper side of an applicator housing, according to
some embodiments.
[0067] FIG. 9 illustrates a cutaway view of an applicator similar
to the applicator of FIG. 5, however, including an activation
element on a medial side of an applicator housing, according to
some embodiments.
[0068] FIG. 10 illustrates a cutaway view of an applicator similar
to the applicator of FIG. 5, however, including an activation
element on a lower side of an applicator housing, according to some
embodiments.
[0069] FIGS. 11A-11D and 11J illustrate perspective views while
FIGS. 11E-11H illustrate side cutaway views of steps for assembling
the applicator of FIG. 5, according to some embodiments.
[0070] FIG. 12 illustrates an exploded perspective view of another
applicator for an on-skin sensor assembly of an analyte sensor
system, according to some embodiments.
[0071] FIG. 13A-13F illustrate perspective views and cutaway views
of several features of the applicator of FIG. 12, according to some
embodiments.
[0072] FIGS. 14A-14E illustrate several cross-sectional views of
the applicator of FIG. 12 during operation, according to some
embodiments.
[0073] FIG. 15 illustrates a perspective view of an exemplary
double torsional spring for use in an applicator for an on-skin
sensor assembly of an analyte sensor system, according to some
embodiments.
[0074] FIG. 16 illustrates a perspective view of another exemplary
double torsional spring for use in an applicator for an on-skin
sensor assembly of an analyte sensor system, according to some
embodiments.
[0075] FIG. 17 illustrates a perspective view of yet another
exemplary double torsional spring for use in an applicator for an
on-skin sensor assembly of an analyte sensor system, according to
some embodiments.
[0076] FIG. 18 illustrates a cutaway view of an alternative driving
mechanism including a torsional spring and a living hinge for the
applicator of FIG. 12, according to some embodiments.
[0077] FIG. 19 illustrates a cutaway view of another alternative
driving mechanism including a torsional spring and a living hinge
for the applicator of FIG. 12, according to some embodiments.
[0078] FIG. 20 illustrates a cutaway view of yet another
alternative driving mechanism including a torsional spring and a
living hinge for the applicator of FIG. 12, according to some
embodiments.
[0079] FIG. 21 illustrates a cutaway view of yet another
alternative driving mechanism including an extension spring and a
living hinge for the applicator of FIG. 12, according to some
embodiments.
[0080] FIG. 22 illustrates a cutaway view of yet another
alternative driving mechanism including a leaf spring for the
applicator of FIG. 12, according to some embodiments.
[0081] FIG. 23 illustrates a cutaway view of yet another
alternative driving mechanism including a leaf spring and a living
hinge for the applicator of FIG. 12, according to some
embodiments.
[0082] FIGS. 24A-24F, 24H, 24J and 24L-24M illustrate
cross-sectional views while FIGS. 24G and 24K illustrate
perspective views of steps for assembling the applicator of FIG.
12, according to some embodiments.
[0083] FIG. 25 illustrates an exploded perspective view of yet
another applicator for an on-skin sensor assembly of an analyte
sensor system, according to some embodiments.
[0084] FIG. 26A-26D illustrate several cutaway perspective views
and a bottom view of several features of the applicator of FIG. 25,
according to some embodiments.
[0085] FIGS. 27A-27E illustrate several cross-sectional views of
the applicator of FIG. 25 during operation, according to some
embodiments.
[0086] FIGS. 28A-28C and 28H illustrate several perspective views
while FIGS. 28D-28G illustrate cross-sectional views of assembling
the applicator of FIG. 25, according to some embodiments.
[0087] FIG. 29 illustrates an exploded perspective view of an
applicator for an on-skin sensor assembly of an analyte sensor
system, according to some embodiments.
[0088] FIG. 30 illustrates a cutaway view of a portion of the
applicator of FIG. 29, according to some embodiments.
[0089] FIG. 31 illustrates a cutaway view of yet another applicator
for an on-skin sensor assembly of an analyte sensor system,
according to some embodiments.
[0090] FIGS. 32A-34B illustrate exploded perspective views of yet
another applicator for an on-skin sensor assembly of an analyte
sensor system, according to some embodiments.
[0091] FIGS. 33A-33E illustrate several perspective cutaway views
of several features of the applicator of FIG. 32, according to some
embodiments.
[0092] FIG. 34A-34D illustrate several cross-sectional views of the
applicator of FIG. 32 during operation, according to some
embodiments.
[0093] FIG. 35A-35C illustrate cross-sectional views of an on-skin
sensor assembly retention mechanism of the applicator of FIG. 32,
according to some embodiments.
[0094] FIG. 36A-36C illustrate cross-sectional views of another
on-skin sensor assembly retention mechanism of the applicator of
FIG. 32, according to some embodiments.
[0095] FIG. 37A-37C illustrate cross-sectional views of yet another
on-skin sensor assembly retention mechanism of the applicator of
FIG. 32, according to some embodiments.
[0096] FIG. 38 illustrates a perspective view of an applicator
similar to those shown in FIG. 32, including an activation element
on a side of the housing, according to some embodiments.
[0097] FIG. 39 illustrates a cutaway perspective view of a portion
of the applicator of FIG. 38, according to some embodiments.
[0098] FIGS. 40A-40G illustrate several perspective views of steps
for assembling the applicator of FIG. 32, according to some
embodiments.
[0099] FIGS. 41A-41B illustrate cross-sectional views an exemplary
on-skin sensor assembly retention mechanism of an applicator for an
analyte sensor system, according to some embodiments.
[0100] FIGS. 42A-42B illustrate cross-sectional views of another
exemplary on-skin sensor assembly retention mechanism of an
applicator for an analyte sensor system, according to some
embodiments.
[0101] FIGS. 43A-43B illustrate cross-sectional views of yet
another exemplary on-skin sensor assembly retention mechanism of an
applicator for an analyte sensor system, according to some
embodiments.
[0102] FIG. 44 illustrates a perspective view of a portion of
another exemplary on-skin sensor assembly retention mechanism of an
applicator for an analyte sensor system, according to some
embodiments.
[0103] FIG. 45 illustrates a perspective view of portion of an
exemplary on-skin sensor assembly retention mechanism of an
applicator for an analyte sensor system, according to some
embodiments.
[0104] FIG. 46 illustrates a perspective view of a portion of an
exemplary on-skin sensor assembly retention mechanism of an
applicator for an analyte sensor system, according to some
embodiments.
[0105] FIG. 47 illustrates a cross-section of a kinked needle for
use in an applicator for an analyte sensor system, according to
some embodiments.
[0106] FIGS. 48A-48B illustrate a cross-section and a plan view,
respectively, of a flared C-needle for use in an applicator for an
analyte sensor system, according to some embodiments.
[0107] FIG. 49 illustrates a perspective view of a deflected-tip
needle for use in an applicator for an analyte sensor system,
according to some embodiments.
[0108] FIG. 50 illustrates a perspective view of a curved needle
for use in an applicator for an analyte sensor system, according to
some embodiments.
[0109] FIGS. 51A-51B illustrate cutaway views of a needle hub of an
applicator for an analyte sensor system, according to some
embodiments.
[0110] FIGS. 52A-52B illustrate a cross-sectional view and a plan
view, respectively, of an infusion cannula integrated into an
on-skin sensor assembly of an analyte sensor system, according to
some embodiments.
[0111] FIG. 53 illustrates a cross-sectional view of a sensor
retention mechanism for an applicator for an analyte sensor system,
according to some embodiments.
[0112] FIG. 54 illustrates a perspective view of another sensor
retention mechanism for an applicator for an analyte sensor system,
according to some embodiments.
[0113] FIG. 55 illustrates a cutaway view of another sensor
retention mechanism for an applicator for an analyte sensor system,
according to some embodiments.
[0114] FIGS. 56A-56B illustrate perspective views of another sensor
retention element for an applicator for an analyte sensor system,
according to some embodiments.
[0115] FIG. 57 illustrates a cross-sectional view of yet another
sensor retention element for an applicator for an analyte sensor
system, according to some embodiments.
[0116] FIG. 58 illustrates a cross-sectional view of yet another
sensor retention element for an applicator for an analyte sensor
system, according to some embodiments.
[0117] FIGS. 59A-59B illustrate cross-sectional views of yet
another sensor retention element for an applicator for an analyte
sensor system, according to some embodiments.
[0118] FIG. 60 illustrates a cutaway view of an on-skin sensor
assembly having at least a portion of a sensor potted in a flexible
material, according to some embodiments.
[0119] FIG. 61 illustrates a cutaway view of an on-skin sensor
assembly comprising an open cavity configured to allow a larger
bend radius in a sensor, according to some embodiments.
[0120] FIG. 62 illustrates a cutaway view of an on-skin sensor
assembly comprising an open cavity configured to allow a larger
bend radius in a sensor, according to some embodiments.
[0121] FIG. 63 illustrates a cutaway view of an on-skin sensor
assembly comprising an open cavity configured to allow a larger
bend radius in a sensor, according to some embodiments.
[0122] FIGS. 64A-64B illustrate a battery engagement feature for an
on-skin sensor assembly, according to some embodiments.
[0123] FIG. 65 illustrates a flowchart of a method for applying an
on-skin sensor assembly to skin of a host, according to some
embodiments.
[0124] FIG. 66 illustrates exemplary mechanisms for several
features of an applicator configured to apply an on-skin sensor
assembly to skin of a host, according to some embodiments.
[0125] FIG. 67 illustrates exemplary sterilization, packaging and
sealing features of an applicator configured to apply an on-skin
sensor assembly to skin of a host, according to some
embodiments.
[0126] FIG. 68 illustrates a top perspective view of an on-skin
sensor assembly, according to some embodiments.
[0127] FIG. 69 illustrates a bottom perspective view of the on-skin
sensor assembly of FIG. 68, according to some embodiments.
[0128] FIG. 70 illustrates a cross-sectional view of the on-skin
sensor assembly of FIG. 68, according to some embodiments.
[0129] FIG. 71 illustrates yet another applicator for an on-skin
sensor assembly of an analyte sensor system, according to some
embodiments.
[0130] FIG. 72 illustrates an exploded perspective view of the
applicator of FIG. 71, according to some embodiments.
[0131] FIGS. 73A-73C illustrate several cross-sectional views of
the applicator of FIGS. 71 and 72, taken along the section line
A-A' of FIG. 71, during operation, according to some
embodiments.
[0132] FIGS. 74A-74C illustrate several cross-sectional views of
the applicator of FIGS. 71 and 72, taken along the section line
B-B' of FIG. 71, during operation, according to some
embodiments.
[0133] FIGS. 75A and 75B illustrate magnified views of some
features of the applicator of FIGS. 71 and 72, according to some
embodiments.
[0134] FIGS. 76A and 76B illustrate magnified views of some
features of the applicator of FIGS. 71 and 72, according to some
embodiments.
[0135] FIG. 77 illustrates a perspective partial cutaway view of
the needle carrier assembly, hub, and on-skin sensor assembly of
the applicator of FIGS. 71 and 72, according to some
embodiments.
[0136] FIG. 78 illustrates a cross-sectional view of the hub and
on-skin sensor assembly of the applicator of FIGS. 71 and 72,
according to some embodiments.
[0137] FIG. 79 illustrates a top view of a portion of the needle
carrier assembly and hub of FIGS. 71 and 72, according to some
embodiments.
[0138] FIGS. 80A and 80B illustrate perspective views of locking
features for needles for use in an applicator for an analyte sensor
system, according to some embodiments.
[0139] FIGS. 81A-81C illustrate several cross-sectional views, and
various features and operating positions, of yet another applicator
for an on-skin sensor assembly of an analyte sensor system,
according to some embodiments.
[0140] FIG. 81D illustrates a perspective view of various features
of the applicator of FIGS. 81A-81D, according to some
embodiments.
[0141] FIGS. 82A-82D illustrate several cross-sectional views, and
various features and operating positions, of yet another applicator
for an on-skin sensor assembly of an analyte sensor system,
according to some embodiments.
[0142] FIG. 83 illustrates a cross-sectional view of an applicator
comprising a deformable layer disposed over an activation element,
according to some embodiments.
[0143] FIG. 84 illustrates a perspective view of an applicator
utilizing a twist-to-activate activation mechanism, according to
some embodiments.
[0144] FIG. 85 illustrates a cross-sectional view of an applicator
comprising a top-mounted activation element, according to some
embodiments.
[0145] FIG. 86 illustrates relationships between the axle,
insertion element, and a circular arc travelled by the insertion
element of at least FIG. 26C during insertion and retraction,
according to some embodiments.
[0146] FIG. 87 illustrates a cross-sectional view of on-skin sensor
assembly of FIGS. 3A, 3B and 4, further comprising an upper patch
328, according to some embodiments.
[0147] FIGS. 88A-88B illustrate perspective views of another
optional battery connection feature for an on-skin sensor assembly,
in accordance with some embodiments.
[0148] FIG. 89 illustrates a flowchart of another method for
applying an on-skin sensor assembly to skin of a host, according to
some embodiments.
[0149] FIG. 90 illustrates a magnified view of some features of the
applicator of FIGS. 71 and 72, according to some embodiments.
[0150] FIG. 91 illustrates a perspective view of an on-skin sensor
assembly, according to some embodiments
DETAILED DESCRIPTION
[0151] The following description and examples illustrate some
example embodiments in detail. Those of skill in the art will
recognize that there are numerous variations and modifications of
this disclosure encompassed by its scope. Accordingly, the
description of a certain example embodiment should not be deemed to
limit the scope of the present disclosure. System Introduction
[0152] FIG. 1 is a diagram depicting an example continuous analyte
monitoring system 100 including an analyte sensor system 102
comprising an on-skin sensor assembly 160 configured to be fastened
to the skin of a host via a base (not shown). Analyte sensor system
102 is operatively connected to a host and a plurality of display
devices 110-114 according to certain aspects of the present
disclosure. Example display devices 110-114 may include computers
such as smartphones, smartwatches, tablet computers, laptop
computers, and desktop computers. In some embodiments, display
devices 110-114 may be Apple Watches, iPhones, and iPads made by
Apple Inc., or Windows or Google devices. It should be noted that
display device 114 alternatively or in addition to being a display
device, may be a medicament delivery device that can act
cooperatively with analyte sensor system 102 to deliver medicaments
to the host. Analyte sensor system 102 may include a sensor
electronics module 140 and a continuous analyte sensor 138
associated with sensor electronics module 140. Sensor electronics
module 140 may be in direct wireless communication with one or more
of the plurality of display devices 110-114 via wireless
communications signals. As will be discussed in greater detail
below, display devices 110-114 may also communicate amongst each
other and/or through each other to analyte sensor system 102. For
ease of reference, wireless communications signals from analyte
sensor system 102 to display devices 110-114 can be referred to as
"uplink" signals 128. Wireless communications signals from, e.g.,
display devices 110-114 to analyte sensor system 102 can be
referred to as "downlink" signals 130. Wireless communication
signals between two or more of display devices 110-114 may be
referred to as "crosslink" signals 132. Additionally, wireless
communication signals can include data transmitted by one or more
of display devices 110-113 via "long-range" uplink signals 136
(e.g., cellular signals) to one or more remote servers 190 or
network entities, such as cloud-based servers or databases, and
receive long-range downlink signals 142 transmitted by remote
servers 190.
[0153] In embodiments shown by FIG. 1, one of the plurality of
display devices may be a custom display device 111 specially
designed for displaying certain types of displayable sensor
information associated with analyte values received from the sensor
electronics module 126 (e.g., a numerical value and an arrow, in
some embodiments). In some embodiments, one of the plurality of
display devices may be a handheld device 112, such as a mobile
phone based on the Android, iOS operating system or other operating
system, a palm-top computer and the like, where handheld device 112
may have a relatively larger display and be configured to display a
graphical representation of the continuous sensor data (e.g.,
including current and historic data). Other display devices can
include other hand-held devices, such as a tablet 113, a smart
watch 110, a medicament delivery device 114, a blood glucose meter,
and/or a desktop or laptop computer.
[0154] It should be understood that in the case of display device
134e, which may be a medicament delivery device in addition to or
instead of a display device, the alerts and/or sensor information
provided by continuous analyte sensor 122 vis-a-vis sensor
electronics module 126, can be used to initiate and/or regulate the
delivery of the medicament to host 120.
[0155] During use, a sensing portion of sensor 138 may be disposed
under the host's skin and a contact portion of sensor 138 can be
electrically connected to electronics unit 140. Electronics unit
140 can be engaged with a housing (e.g., a base) which is attached
to an adhesive patch fastened to the skin of the host. In some
embodiments, electronics unit 140 is integrally formed with the
housing. Furthermore, electronics unit 140 may be disposable and
directly coupled to the adhesive patch.
[0156] Continuous analyte sensor system 100 can include a sensor
configuration that provides an output signal indicative of a
concentration of an analyte. The output signal including (e.g.,
sensor data, such as a raw data stream, filtered data, smoothed
data, and/or otherwise transformed sensor data) is sent to the
receiver.
[0157] In some embodiments, analyte sensor system 100 includes a
transcutaneous glucose sensor, such as is described in U.S. Patent
Publication No. US-2011-0027127-A1, the entire contents of which
are hereby incorporated by reference. In some embodiments, sensor
system 100 includes a continuous glucose sensor and comprises a
transcutaneous sensor (e.g., as described in U.S. Pat. No.
6,565,509, as described in U.S. Pat. No. 6,579,690, and/or as
described in U.S. Pat. No. 6,484,046). The contents of U.S. Pat.
Nos. 6,565,509, 6,579,690, and 6,484,046 are hereby incorporated by
reference in their entirety.
[0158] Various signal processing techniques and glucose monitoring
system embodiments suitable for use with the embodiments described
herein are described in U.S. Patent Publication No.
US-2005-0203360-A1 and U.S. Patent Publication No.
US-2009-0192745-A1, the contents of which are hereby incorporated
by reference in their entirety. The sensor can extend through a
housing, which can maintain sensor 138 on, in or under the skin
and/or can provide for electrical connection of sensor 138 to
sensor electronics in electronics unit 140.
[0159] In some embodiments, description of a base, a housing, a
wearable, and/or a transmitter of on-skin sensor assembly 160 may
be interchangeable. In other embodiments, a base and a housing of
on-skin sensor assembly 160 may be different in the sense that they
may be separate components from sensor electronics module 140,
e.g., from a transmitter or receiver.
[0160] In several embodiments, sensor 138 is in a form of a wire. A
distal end of the wire can be formed, e.g., having a conical shape
(to facilitate inserting the wire into the tissue of the host).
Sensor 138 can include an elongated conductive body, such as an
elongated conductive core (e.g., a metal wire) or an elongated
conductive core coated with one, two, three, four, five, or more
layers of material, each of which may or may not be conductive. The
elongated sensor may be long and thin, yet flexible and strong. For
example, in some embodiments, the smallest dimension of the
elongated conductive body is less than 0.1 inches, less than 0.075
inches, less than 0.05 inches, less than 0.025 inches, less than
0.01 inches, less than 0.004 inches, less than 0.002 inches, less
than 0.001 inches, and/or less than 0.0005 inches.
[0161] Sensor 138 may have a circular cross section. In some
embodiments, the cross section of the elongated conductive body can
be ovoid, rectangular, triangular, polyhedral, star-shaped,
C-shaped, T-shaped, X-shaped, Y-shaped, irregular, or the like. In
some embodiments, a conductive wire electrode is employed as a
core. In other embodiments, sensor 138 may be disposed on a
substantially planar substrate. To such an electrode, one or two
additional conducting layers may be added (e.g., with intervening
insulating layers provided for electrical isolation). The
conductive layers can be comprised of any suitable material. In
certain embodiments, it may be desirable to employ a conductive
layer comprising conductive particles (i.e., particles of a
conductive material) in a polymer or other binder.
[0162] In some embodiments, the materials used to form the
elongated conductive body (e.g., stainless steel, titanium,
tantalum, platinum, platinum-iridium, iridium, certain polymers,
and/or the like) can be strong and hard, and therefore can be
resistant to breakage. For example, in several embodiments, the
ultimate tensile strength of the elongated conductive body is
greater than 80 kPsi and less than 140 kPsi, and/or the Young's
modulus of the elongated conductive body is greater than 160 GPa
and less than 220 GPa. The yield strength of the elongated
conductive body can be greater than 58 kPsi and less than 2200
kPsi.
[0163] Electronics unit 140 can be releasably or permanently
coupled to sensor 138. Electronics unit 140 can include electronic
circuitry associated with measuring and processing the continuous
analyte sensor data. Electronics unit 140 can be configured to
perform algorithms associated with processing and calibration of
the sensor data. For example, electronics unit 140 can provide
various aspects of the functionality of a sensor electronics module
as described in U.S. Patent Publication No. US-2009-0240120-A1 and
U.S. Patent Publication No. US-2012-0078071-A1, the entire contents
of which are incorporated by reference herein. Electronics unit 140
may include hardware, firmware, and/or software that enable
measurement of levels of the analyte via a glucose sensor, such as
sensor 138.
[0164] For example, electronics unit 140 can include a
potentiostat, a power source for providing power to sensor 138,
signal processing components, data storage components, and a
communication module (e.g., a telemetry module) for one-way or
two-way data communication between electronics unit 140 and one or
more receivers, repeaters, and/or display devices, such as devices
110-114. Electronic components can be affixed to a printed circuit
board (PCB), or the like, and can take a variety of forms. The
electronic components can take the form of an integrated circuit
(IC), such as an Application-Specific Integrated Circuit (ASIC), a
microcontroller, and/or a processor. The electronics unit 140 may
include sensor electronics that are configured to process sensor
information, such as storing data, analyzing data streams,
calibrating analyte sensor data, estimating analyte values,
comparing estimated analyte values with time-corresponding measured
analyte values, analyzing a variation of estimated analyte values,
and the like. Examples of systems and methods for processing sensor
analyte data are described in more detail in U.S. Pat. Nos.
7,310,544, 6,931,327, U.S. Patent Publication No. 2005-0043598-A1,
U.S. Patent Publication No. 2007-0032706-A1, U.S. Patent
Publication No. 2007-0016381-A1, U.S. Patent Publication No.
2008-0033254-A1, U.S. Patent Publication No. 2005-0203360-A1, U.S.
Patent Publication No. 2005-0154271-A1, U.S. Patent Publication No.
2005-0192557-A1, U.S. Patent Publication No. 2006-0222566-A1, U.S.
Patent Publication No. 2007-0203966-A1 and U.S. Patent Publication
No. 2007-0208245-A1, the contents of which are hereby incorporated
by reference in their entirety. Electronics unit 140 may
communicate with the devices 110-114, and/or any number of
additional devices, via any suitable communication protocol.
Example communication methods or protocols include radio frequency;
Bluetooth; universal serial bus; any of the wireless local area
network (WLAN) communication standards, including the IEEE 802.11,
802.15, 802.20, 802.22 and other 802 communication protocols;
ZigBee; wireless (e.g., cellular) telecommunication; paging network
communication; magnetic induction; satellite data communication; a
proprietary communication protocol, open source communication
protocol, and/or any suitable wireless communication method.
[0165] Additional sensor information is described in U.S. Pat. Nos.
7,497,827 and 8,828,201. The entire contents of U.S. Pat. Nos.
7,497,827 and 8,828,201 are incorporated by reference herein.
[0166] Any sensor shown or described herein can be an analyte
sensor; a glucose sensor; and/or any other suitable sensor. A
sensor described in the context of any embodiment can be any sensor
described herein or incorporated by reference. Sensors shown or
described herein can be configured to sense, measure, detect,
and/or interact with any analyte.
[0167] As used herein, the term "analyte" is a broad term, and is
to be given its ordinary and customary meaning to a person of
ordinary skill in the art (and is not to be limited to a special or
customized meaning), and refers without limitation to a substance
or chemical constituent in a biological fluid (for example, blood,
interstitial fluid, cerebral spinal fluid, lymph fluid, urine,
sweat, saliva, etc.) that can be analyzed. Analytes can include
naturally occurring substances, artificial substances, metabolites,
or reaction products.
[0168] In some embodiments, the analyte for measurement by the
sensing regions, devices, systems, and methods is glucose. However,
other analytes are contemplated as well, including, but not limited
to ketone bodies; Acetyl Co A; acarboxyprothrombin; acylcarnitine;
adenine phosphoribosyl transferase; adenosine deaminase; albumin;
alpha-fetoprotein; amino acid profiles (arginine (Krebs cycle),
histidine/urocanic acid, homocysteine, phenylalanine/tyrosine,
tryptophan); andrenostenedione; antipyrine; arabinitol enantiomers;
arginase; benzoylecgonine (cocaine); biotinidase; biopterin;
c-reactive protein; carnitine; carnosinase; CD4; ceruloplasmin;
chenodeoxycholic acid; chloroquine; cholesterol; cholinesterase;
cortisol; testosterone; choline; creatine kinase; creatine kinase
MM isoenzyme; cyclosporin A; d-penicillamine; de-ethylchloroquine;
dehydroepiandrosterone sulfate; DNA (acetylator polymorphism,
alcohol dehydrogenase, alpha 1-antitrypsin, cystic fibrosis,
Duchenne/Becker muscular dystrophy, glucose-6-phosphate
dehydrogenase, hemoglobin A, hemoglobin S, hemoglobin C, hemoglobin
D, hemoglobin E, hemoglobin F, D-Punjab, beta-thalassemia,
hepatitis B virus, HCMV, HIV-1, HTLV-1, Leber hereditary optic
neuropathy, MCAD, RNA, PKU, Plasmodium vivax, sexual
differentiation, 21-deoxycortisol); desbutylhalofantrine;
dihydropteridine reductase; diptheria/tetanus antitoxin;
erythrocyte arginase; erythrocyte protoporphyrin; esterase D; fatty
acids/acylglycines; triglycerides; glycerol; free B-human chorionic
gonadotropin; free erythrocyte porphyrin; free thyroxine (FT4);
free tri-iodothyronine (FT3); fumarylacetoacetase;
galactose/gal-1-phosphate; galactose-1-phosphate uridyltransferase;
gentamicin; glucose-6-phosphate dehydrogenase; glutathione;
glutathione perioxidase; glycocholic acid; glycosylated hemoglobin;
halofantrine; hemoglobin variants; hexosaminidase A; human
erythrocyte carbonic anhydrase I; 17-alpha-hydroxyprogesterone;
hypoxanthine phosphoribosyl transferase; immunoreactive trypsin;
lactate; lead; lipoproteins ((a), B/A-1, .beta.); lysozyme;
mefloquine; netilmicin; phenobarbitone; phenytoin;
phytanic/pristanic acid; progesterone; prolactin; prolidase; purine
nucleoside phosphorylase; quinine; reverse tri-iodothyronine (rT3);
selenium; serum pancreatic lipase; sissomicin; somatomedin C;
specific antibodies (adenovirus, anti-nuclear antibody, anti-zeta
antibody, arbovirus, Aujeszky's disease virus, dengue virus,
Dracunculus medinensis, Echinococcus granulosus, Entamoeba
histolytica, enterovirus, Giardia duodenalisa, Helicobacter pylori,
hepatitis B virus, herpes virus, HIV-1, IgE (atopic disease),
influenza virus, Leishmania donovani, leptospira,
measles/mumps/rubella, Mycobacterium leprae, Mycoplasma pneumoniae,
Myoglobin, Onchocerca volvulus, parainfluenza virus, Plasmodium
falciparum, poliovirus, Pseudomonas aeruginosa, respiratory
syncytial virus, rickettsia (scrub typhus), Schistosoma mansoni,
Toxoplasma gondii, Trepenoma pallidium, Trypanosoma cruzi/rangeli,
vesicular stomatis virus, Wuchereria bancrofti, yellow fever
virus); specific antigens (hepatitis B virus, HIV-1); acetone
(e.g., succinylacetone); acetoacetic acid; sulfadoxine;
theophylline; thyrotropin (TSH); thyroxine (T4); thyroxine-binding
globulin; trace elements; transferrin; UDP-galactose-4-epimerase;
urea; uroporphyrinogen I synthase; vitamin A; white blood cells;
and zinc protoporphyrin.
[0169] Salts, sugar, protein, fat, vitamins, and hormones naturally
occurring in blood or interstitial fluids can also constitute
analytes in certain embodiments. The analyte can be naturally
present in the biological fluid or endogenous, for example, a
metabolic product, a hormone, an antigen, an antibody, and the
like. Alternatively, the analyte can be introduced into the body or
exogenous, for example, a contrast agent for imaging, a
radioisotope, a chemical agent, a fluorocarbon-based synthetic
blood, or a drug or pharmaceutical composition, including but not
limited to insulin; glucagon; ethanol; cannabis (marijuana,
tetrahydrocannabinol, hashish); inhalants (nitrous oxide, amyl
nitrite, butyl nitrite, chlorohydrocarbons, hydrocarbons); cocaine
(crack cocaine); stimulants (amphetamines, methamphetamines,
Ritalin, Cylert, Preludin, Didrex, PreState, Voranil, Sandrex,
Plegine); depressants (barbiturates, methaqualone, tranquilizers
such as Valium, Librium, Miltown, Serax, Equanil, Tranxene);
hallucinogens (phencyclidine, lysergic acid, mescaline, peyote,
psilocybin); narcotics (heroin, codeine, morphine, opium,
meperidine, Percocet, Percodan, Tussionex, Fentanyl, Darvon,
Talwin, Lomotil); designer drugs (analogs of fentanyl, meperidine,
amphetamines, methamphetamines, and phencyclidine, for example,
Ecstasy); anabolic steroids; and nicotine. The metabolic products
of drugs and pharmaceutical compositions are also contemplated
analytes. Analytes such as neurochemicals and other chemicals
generated within the body can also be analyzed, such as, for
example, ascorbic acid, uric acid, dopamine, noradrenaline,
3-methoxytyramine (3MT), 3,4-dihydroxyphenylacetic acid (DOPAC),
homovanillic acid (HVA), 5-hydroxytryptamine (5HT),
5-hydroxyindoleacetic acid (FHIAA), and intermediaries in the
Citric Acid Cycle.
[0170] Many embodiments described herein may use an adhesive to
couple a base or housing, a sensor module, a transmitter or
electronics unit, and/or a sensor to a host (e.g., to skin of the
host). The adhesive can be configured for adhering to skin. The
adhesive can include a pad (e.g., that is located between the
adhesive and the base). Additional adhesive information, including
adhesive pad information, is described in U.S. patent application
Ser. No. 14/835,603, which was filed on Aug. 25, 2015. The entire
contents of U.S. patent application Ser. No. 14/835,603 are
incorporated by reference herein.
[0171] As noted above, systems can apply an on-skin sensor assembly
to the skin of a host. The on-skin sensor assembly may include a
base that comprises an adhesive to couple a glucose sensor to the
skin. Other methods are contemplated such as a strap, e.g., a watch
band.
[0172] Any of the features described in the context of at least
FIG. 1 can be applicable to all aspects and embodiments identified
herein. Moreover, any of the features of an embodiment is
independently combinable, partly or wholly with other embodiments
described herein in any way, e.g., one, two, or three or more
embodiments may be combinable in whole or in part. Further, any of
the features of an embodiment may be made optional to other aspects
or embodiments. Any aspect or embodiment of a method can be
performed by a system or apparatus of another aspect or embodiment,
and any aspect or embodiment of a system can be configured to
perform a method of another aspect or embodiment.
[0173] Throughout this disclosure, reference is made to an on-skin
sensor assembly, which may also be described as a wearable. Such
on-skin sensor assemblies (see FIGS. 1-4 and 68-70) may be
disposable or reusable and may (see FIGS. 68-70) or may not (see
FIGS. 2-4) comprise a base or base plate. In some embodiments,
on-skin sensor assemblies having a base plate (e.g., FIGS. 68-70)
may be reusable, whereas on-skin sensor assemblies without a base
plate (e.g., FIGS. 2-4) may be disposable. Although FIG. 1 has
already been discussed with respect to on-skin sensor assembly 160,
FIGS. 2A-4 and 68-70 describe at least some other embodiments of an
on-skin sensor assembly.
[0174] FIG. 2A illustrates a perspective view of an on-skin sensor
assembly 260, in accordance with some embodiments. On-skin sensor
assembly 260 may comprise an outer housing comprising a first, top
portion 292 and a second, lower portion 294. In some embodiments,
the outer housing may comprise a clamshell design. On-skin sensor
assembly 260 may include similar components as electronics unit 140
described above in FIG. 1 (e.g. a potentiostat, a power source for
providing power to sensor 138, signal processing components, data
storage components, and a communication module (e.g., a telemetry
module) for one-way or two-way data communication, a printed
circuit board (PCB), an integrated circuit (IC), an
Application-Specific Integrated Circuit (ASIC), a microcontroller,
and/or a processor). The outer housing may feature a large rounded
body having tapered end opposite the large rounded body. The outer
housing may further comprise an aperture 296 disposed at the
tapered end of the outer housing and adapted for sensor 238 and
needle insertion. Aperture 296 may be an opening featuring a
U-shaped channel extending through the tapered end of the outer
housing. On-skin sensor assembly 260 may further comprise an
adhesive patch 226 configured to secure on-skin sensor assembly 260
to skin of the host. As shown, adhesive patch 226 may feature an
aperture 298 having a similar shape as aperture 296 and
substantially aligned with aperture 296. Sensor 238 may be
configured to at least partially extend through apertures 296 and
298. In some embodiments, adhesive patch 226 may comprise an
adhesive suitable for skin adhesion, for example a pressure
sensitive adhesive (e.g., acrylic, rubber-based, or other suitable
type) bonded to a carrier substrate (e.g., spun lace polyester,
polyurethane film, or other suitable type) for skin attachment,
though any suitable type of adhesive is also contemplated.
[0175] On-skin sensor assembly 260 may be attached to the host with
use of an applicator adapted to provide convenient and secure
application. Such an applicator may also be used for inserting
sensor 238 through the host's skin, and/or connecting sensor 238 to
the electronics unit. Once sensor 238 has been inserted into the
skin (and is connected to the electronics unit), the sensor
assembly can detach from the applicator.
[0176] FIG. 2B illustrates a bottom perspective view of on-skin
sensor assembly 260 of FIG. 2A. FIG. 2B illustrates aperture 296
disposed to a side of the outer housing, and aperture 298, each
adapted for sensor 238 and needle insertion.
[0177] FIG. 3A illustrates a perspective view of an on-skin sensor
assembly 360, in accordance with some embodiments. On-skin sensor
assembly 360 may comprise an outer housing comprising a first, top
portion 392 and a second, lower portion 394. In some embodiments,
the outer housing may comprise a clamshell design. On-skin sensor
assembly 260 may include similar components as electronics unit 140
described above in FIG. 1 (e.g. a potentiostat, a power source for
providing power to sensor 138, signal processing components, data
storage components, and a communication module (e.g., a telemetry
module) for one-way or two-way data communication, a printed
circuit board (PCB), an integrated circuit (IC), an
Application-Specific Integrated Circuit (ASIC), a microcontroller,
and/or a processor). As shown, the outer housing may feature a
generally oblong shape. The outer housing may further comprise an
sensor assembly aperture 396 disposed substantially through a
center portion of outer housing and adapted for sensor 338 and
needle insertion through a bottom of on-skin sensor assembly 360.
In some embodiments, sensor assembly aperture 396 may be a channel
or elongated slot. On-skin sensor assembly 360 may further comprise
an adhesive patch 326 configured to secure on-skin sensor assembly
360 to skin of the host. In some embodiments, adhesive patch 326
may comprise an adhesive suitable for skin adhesion on its
underside, for example a pressure sensitive adhesive (e.g.,
acrylic, rubber-based, or other suitable type) bonded to a carrier
substrate (e.g., spun lace polyester, polyurethane film, or other
suitable type) for skin attachment, though any suitable type of
adhesive is also contemplated. In some embodiments, adhesive patch
326 may further comprise an adhesive on its topside, e.g., the
non-skin contacting side to aid adherence of adhesive patch 326 to
a portion of an associated applicator during manufacture and/or to
maintain adhesive patch 326 in a substantially flat orientation
before deployment to the skin of a host. In some embodiments, the
adhesive applied to the topside may be weaker than the adhesive
applied to the underside to ensure appropriate transfer of the
on-skin sensor assembly to the skin of the host. As shown, adhesive
patch 396 may feature an aperture 398 aligned with sensor assembly
aperture 396 such that sensor 338 may pass through a bottom of
on-skin sensor assembly 360 and through adhesive patch 396.
[0178] FIG. 3B illustrates a bottom perspective view of on-skin
sensor assembly 360 of FIG. 3A. FIG. 3B further illustrates sensor
assembly aperture 396 disposed substantially in a center portion of
a bottom of on-skin sensor assembly 360, and aperture 398, both
adapted for sensor 338 and needle insertion.
[0179] FIG. 91 illustrates a perspective view of an on-skin sensor
assembly 9160, according to some embodiments. On-skin sensor
assembly 9160 may be substantially similar to other on-skin sensor
assemblies described in this application, such as on-skin sensor
assemblies 160, 260, and 360. On-skin sensor assembly 9160 may
feature an adhesive patch 9126 and a clamshell design comprising a
top shell and a bottom shell, similar to on-skin sensor assembly
360. Further, on-skin sensor assembly 9160 may include a plurality
of attachment points 9162a and 9162b, similar to on-skin sensor
assembly 160. On-skin sensor assembly 9160 may include an aperture
9296. Aperture 9296 may be a through-hole extending through on-skin
sensor assembly 9160. Aperture 9296 may be configured to allow a
needle and/or sensor to pass through. In some embodiments, on-skin
sensor assembly 9160 may further include an aperture 9294. Aperture
9294 may extend from a top surface of on-skin sensor assembly 9150
a certain depth through on-skin sensor assembly 9160. In some
embodiments, aperture 9294 is configured to engage with an
anti-rotational feature such as base 7152 of needle hub 7150
described in FIG. 78.
[0180] In some embodiments, on-skin sensor assembly 9160 includes
an identification tag 9150. Identification tag 9150 may be located
on a top surface of on-skin sensor assembly 9150 (as shown), or on
a side surface of on-skin sensor assembly. Identification tag 9150
may be an image which resembles a logo or mark identifying the
manufacturer of the on-skin sensor assembly. Additionally,
identification tag 9150 may be configured to be scanned by a user
to pair the on-skin sensor assembly with a device, such as handheld
device 112. In some embodiments, identification tag 9150 is a code
such as, but not limited to, a QR code, a matrix code, a 2-D
barcode, or a 3-D barcode. The code may be imbedded in the image of
identification tag 9150.
[0181] FIG. 4 illustrates a cross-sectional view of on-skin sensor
assembly 360 of FIGS. 3A and 3B. FIG. 4 illustrates the first, top
portion 392 and the second, bottom portion 394 of the outer
housing, adhesive patch 326, sensor assembly aperture 396 in the
center portion of on-skin sensor assembly 360, aperture 398 in the
center portion of adhesive patch 326, and sensor 338 passing
through sensor assembly aperture 396. The electronics unit,
previously described in connection with FIG. 3A, may further
include a circuit board 404 and a battery 402 configured to provide
power to at least circuit board 404.
[0182] FIG. 87 illustrates a cross-sectional view of on-skin sensor
assembly 360 of FIGS. 3A, 3B and 4, further comprising an upper
patch 328, according to some embodiments. Upper patch 328 may
comprise an adhesive suitable for skin adhesion, device adhesion,
or a combination thereof, on its underside, for example a pressure
sensitive adhesive (e.g., acrylic, rubber-based, or other suitable
type) bonded to a carrier substrate (e.g., spun lace polyester,
polyurethane film, or other suitable type) for skin and/or device
attachment, though any suitable type of adhesive is also
contemplated. In some embodiments, such an adhesive may be the same
as the adhesive applied to the underside of patch 326. In some
other embodiments, the adhesive may be different from the adhesive
applied to the underside of patch 326. In some embodiments, upper
patch 328 may be shaped as a circle, oval, partial strip, as an X,
or as any other shape or form suitable for securing upper patch 328
to lower patch 326 and/or the skin of the host. The upper patch 328
may fully or partially cover on-skin sensor assembly 360. The upper
patch 328 may improve adhesion lifespan of on-skin sensor assembly
360 on skin 130 of the host by adding additional adhesive contact
area to the surface of the skin 130 and/or providing a single
surface covering the wearable that reduces the risk of inadvertent
mechanical removal (e.g. catching, snagging, tearing) by reducing
catch surfaces/edges on on-skin sensor assembly 360. It is
contemplated that reducing surfaces of on-skin sensor assembly 360
that are substantially perpendicular to the body surfaces may
improve catch resistance. Such increased wearable lifespan provided
by upper patch 328 may be a valuable property, especially as
systems move toward and beyond 10-14 day wearable adhesion
solutions.
[0183] In some embodiments, upper patch 328 may be assembled into
any applicator in this description, above on-skin sensor assembly
360, with underside adhesive exposed. Upon deployment of on-skin
sensor assembly 360 by the applicator, patch 326 may adhere to skin
130 of the host and upper patch 328 may be adhered over on-skin
sensor assembly 360 and onto skin 130 of the host by one or more
features of the applicator, for example, a holder and/or needle
carrier assembly as described in connection with any figure
herein.
Applicator Embodiments
[0184] FIG. 5 illustrates an exploded perspective view of an
applicator 500 for applying on-skin sensor assembly 160 to skin 130
of a host, according to some embodiments. In some embodiments,
applicator 500 may include an applicator housing 502 having an
opening at its bottom and configured to house at least one or more
mechanisms utilized to apply on-skin sensor assembly 160 to skin
130 of a host. Applicator housing 502 may be formed of any suitable
material, e.g., a polymer, polycarbonate, ABS, nylon, polyethylene,
polypropylene, etc. In some embodiments, applicator housing 502 may
be configured to cover at least one feature of applicator housing
502, for example a guide of a reciprocating or back and forth
mechanism, e.g., a scotch-yoke mechanism (see FIG. 6B).
[0185] Applicator 500 includes an activation element 504 configured
to activate a drive assembly of applicator 500. In some
embodiments, activation element 504 may be a button, a switch, a
toggle, a slide, a trigger, a knob, a rotating member, a component
that deforms and/or flexes or any other suitable mechanism for
activating a drive assembly of applicator 500.
[0186] Applicator 500 may further comprise a needle carrier
assembly 508, including an insertion element (not shown in FIG. 5)
configured to insert sensor 138 of on-skin sensor assembly 160
(e.g., FIG. 1) at least partially into skin 130 of the host. The
insertion element is further illustrated in FIG. 6H as attaching to
needle carrier assembly 508 and extending in the distal direction,
substantially along an axis of insertion. In some embodiments,
needle carrier assembly 508 comprises a needle carrier or shuttle.
In some embodiments, the insertion element comprises a needle, for
example, an open sided-needle, a deflected-tip needle with a
deflected-tip, a curved needle, a polymer-coated needle, a
hypodermic needle, or any other suitable type of needle or
structure, as will be described in more detail in connection with
at least FIGS. 47-50 and 80A-B. In yet other embodiments, insertion
element may comprise sensor 138 itself, sufficiently rigid to be
inserted partially into skin 130 of the host with minimal or no
structural support, such as described in U.S. Pat. No. 9,357,951,
which was filed on Sep. 29, 2010, U.S. Patent Publication No. US
2014/0107450, which was filed on Feb. 28, 2013, and U.S. Patent
Publication No. US 2015/0289788, which was filed on Apr. 10, 2014.
The entire contents of U.S. Pat. No. 9,357,951, U.S. Patent
Publication No. 2014/0107450, and U.S. Patent Publication No.
2015/0289788 are incorporated by reference herein.
[0187] Applicator 500 may further comprise a drive assembly 510
configured to drive the insertion element of needle carrier
assembly 508 in a distal direction to a distal insertion position
and in a proximal direction from the distal insertion position to a
proximal retraction position. A distal direction may be defined as
extending towards an open-ended side of the applicator 500 along a
path needle carrier assembly 508 is configured to travel. The
distal direction may also be defined as towards the skin of a user.
A proximal direction may be defined as a direction extending in a
substantially opposite direction from the distal direction. In some
embodiments, the distal direction and the proximal direction extend
along an insertion axis of the insertion element and of needle
carrier assembly 508.
[0188] Drive assembly 510 may include a rotating drive element 514
coupled to needle carrier assembly 508 via an axle 526. In some
embodiments, rotating drive element 514 comprises a cam feature,
e.g., a wheel cam, having a substantially circular or ovoid
circumference. Rotating drive element 514 may be configured to
rotate with respect to needle carrier assembly 508 about an axis of
rotation 518 coincident with a centerline of axle 526. Rotating
drive element 514 may further include a pin 516 disposed at a
position on a face of rotating drive element 514 displaced radially
from axis of rotation 518. Pin 516 is configured to travel in a
guide (see FIG. 6B) of applicator housing 502.
[0189] Drive assembly 510 may further include a spring 512. Spring
512 may be a torsion spring, a clock spring, a power spring, or any
other suitable type of spring. Spring 512 may be formed of any
suitable material including but not limited to plastic or metal,
e.g., stainless steel. In some embodiments, spring 512 is
pre-compressed before activation of the applicator. In some
embodiments, spring 512 is configured to be additionally loaded
during activation of the applicator. Spring 512 may have a first
end 520 coupled to needle carrier assembly 508 and a second end 522
coupled to rotating drive element 514. Spring 512 may be disposed
coaxially with axle 526. Spring 512 may be configured to, upon
activation of drive assembly 510, rotate rotating drive element 514
in a single direction with respect to needle carrier assembly 508.
In some embodiments, spring 512 is configured, upon activation of
drive assembly 510, to unwind by rotating greater than zero degrees
and less than 360 degrees. In some embodiments, spring 512 is
pre-wound between 30 and 1440 degrees.
[0190] By virtue of rotating drive element 514 being configured to
rotate with respect to needle carrier assembly 508, about axis of
rotation 518, and pin 516 being restrained to travel in the guide
of applicator housing 502, rotational motion of rotating drive
element 514, driven by spring 512, is converted into linear,
reciprocating motion of needle carrier assembly 508 along axis 590
and, therefore, of the insertion element (not shown). More
specifically, rotation of rotating drive element 514 drives
insertion element 508 in the distal direction to the distal
insertion position and in the proximal direction from the distal
insertion position to the proximal retraction position. Such
embodiments may be able to omit handoff mechanisms between aspects
of drive assembly 510 that separately drive the needle carrier
assembly 508 in the distal and proximate directions by virtue of a
single mechanism that converts rotational motion into reciprocating
linear motion.
[0191] Applicator 500 may further include a holder 524 releasably
coupled to needle carrier assembly 508 and configured to guide
on-skin sensor assembly 160 while coupled to needle carrier
assembly 508. In some embodiments, holder 524 may also be referred
to as a carrier or transport member.
[0192] FIG. 6A-6H illustrates cutaway and perspective views of
several features of applicator 500 of FIG. 5, according to some
embodiments. FIG. 6A illustrates a cutaway view of applicator 500
including applicator housing 502, activation element 504, needle
carrier assembly 508, rotating drive element 514, pin 516, and
holder 524. Each of these components may have functionality as
previously described in connection with at least FIG. 5.
[0193] FIG. 6B illustrates guide 582 in applicator housing 502. In
some embodiments, guide 582 may comprise a scotch-yoke track in
which pin 516 is configured to travel upon activation of drive
assembly 510, as rotating drive element 514 rotates.
[0194] FIG. 6C illustrates a plurality of tracks 622a, 622b, 622c
in applicator housing 502 in which a respective one of a plurality
of protrusions or ribs 624a, 624b, 624c of needle carrier assembly
508 are configured to slide. Accordingly, tracks 622a-622c in
applicator housing 502 define a path of travel for needle carrier
assembly 508. In some embodiments, this path of travel is
substantially linear and longitudinal. Although three tracks and
protrusions are shown in FIG. 6C, any number of tracks and
respective protrusions are contemplated. For ease of understanding,
FIG. 6C illustrates a partial bottom view of applicator 500, which
also shows portions of on-skin sensor assembly 160 and holder
524.
[0195] FIG. 6D illustrates an embodiment where needle carrier
assembly 508 comprises a locking element 632 configured to prevent
rotating drive element 514 from rotating. Specifically, rotating
drive element 514 comprises a protrusion 634 in contact with
retention element 632, which prevents protrusion 634 from traveling
in a path it would otherwise take as spring 512 releases at least a
portion of its stored energy in rotating drive element 514. In some
embodiments, retention element 632 comprises a deflectable tab
formed of a material such as a polymer, polycarbonate, ABS, nylon,
polyethylene, polypropylene, or any other suitable material.
Activation element 504 comprises a protrusion 640 configured to
deflect retention element 632 such that protrusion 634 is no longer
held by retention element 632, thereby allowing rotating drive
element 514 to rotate and activating drive assembly 510. Rotating
drive element 514 further comprises a ridge 636 configured to limit
rotation of rotating drive element 514 as rotating drive element
514 rotates and ridge 636 comes in contact with retention element
632.
[0196] FIG. 6E illustrates a retention element 642 of holder 524
and a stop element 644 of applicator housing 502 configured to
immobilize holder 524 to applicator housing 502 upon needle carrier
assembly 508 reaching the distal insertion position. In some
embodiments, retention element 642 is a deflectable arm, or any
other type of protrusion or snap. For example, as needle carrier
assembly 508 travels in the distal direction, as a result of spring
512 turning rotating drive element 514, retention element 642
slides along an inside surface of applicator housing 502 until
retention element 642 is slightly deflected by stop element 644,
then snapping in an outward direction under stop element 644. At
this point, needle carrier assembly 508 may be free to progress in
the proximal direction as a result of spring 512 further turning
rotating drive element 514. Stop element 644 will prevent retention
element 642, and so holder 524, from traveling in the proximal
direction. In this way, movement of needle carrier assembly 508 in
the proximal direction, after reaching the distal insertion
position, releases holder 524 from needle carrier assembly 508
and/or on-skin sensor assembly 160.
[0197] FIG. 6F illustrates a protrusion 652 of holder 524 and a
protrusion 654 of applicator housing 502 configured to prevent
holder 524 from travelling beyond the distal insertion position in
the distal direction. For example, as holder 524 is driven in the
distal direction by needle carrier assembly 508, protrusion 652
travels along an inside surface of the applicator housing 502 until
protrusion 652 comes in contact with protrusion 654, at which point
holder 524 is prevented from further travel in the distal
direction.
[0198] FIG. 6G illustrates on-skin sensor assembly 160 including a
plurality of attachment points 662a-662f configured to mate with
respective retention elements on needle carrier assembly 508 and/or
holder 524 while traveling at least partially toward the distal
insertion position, in the distal direction, during applicator
activation. In some embodiments, attachment points 662a-662f are
small grooves or indentations. Although a plurality of attachment
points 662a-662f are illustrated, any number of attachment points
are contemplated. In some embodiments, the respective retention
elements may comprise snap fits, friction fits, interference
features, elastomeric grips and/or adhesives configured to couple
on-skin sensor assembly 160 with needle carrier assembly 508 and/or
holder 524.
[0199] Moreover, during pressure fluctuations, such as at high
altitude or vacuum during sterilization processes for example, air
present within on-skin sensor assembly 160 may exert a deforming
force from within the cavity of on-skin sensor assembly 160.
Although not shown in FIG. 6G, in some embodiments, on-skin sensor
assembly 160 may have at least a portion formed with a reduced
thickness or a second material (e.g. an elastomer) and, therefore,
reduced strength and rigidity, such that when applicator 500 is
exposed to such pressure fluctuations, the portions having the
reduced thickness or second material deform in a controlled manner,
thereby reducing or eliminating damage that would otherwise occur
to on-skin sensor assembly 160 due to undesirable uncontrolled
expansion of on-skin sensor assembly 160. The portion formed with
reduced thickness or a second material may be selected to direct
controlled expansion away from datum and/or retention features
securing the on-skin sensor assembly to applicator assembly. Such a
feature may be present in any applicator described herein.
[0200] FIG. 6H illustrates retention elements 672a, 672b of holder
528 configured to releasably couple on-skin sensor assembly 160 to
holder 528 as needle carrier assembly 508 travels in the distal
direction to the distal insertion position, and to decouple on-skin
sensor assembly 160 from holder 528 as needle carrier assembly 508
travels in the proximal direction from the distal insertion
position towards the proximal retraction position. Specifically,
retention elements 672a, 672b may each comprise a first end 676a,
676b, a second end 678a, 678b, and a pivot point 680a, 680b. As
needle carrier assembly 508 travels in the distal direction to the
distal insertion position, first end 676a, 676b of each of
retention elements 672a, 672b is immobilized in a respective guide
674a, 674b of needle carrier assembly 508 and each of retention
elements 672a, 672b is immobilized against interference points
682a, 682b of needle carrier assembly 508, thereby releasably
coupling second ends 678a, 678b to attachment points 662a, 662b of
on-skin sensor assembly 160. In some embodiments, guides 674a, 674b
comprise a slot or a stop element. Since retention elements 642,
644 and/or protrusions 652, 654 immobilize holder 524 at the distal
insertion position (as described in FIG. 6E), as needle carrier
assembly 508 travels back in the proximal direction, needle carrier
assembly 508 separates from holder 524, thereby separating first
ends 676a, 676b of retention elements 672a, 672b from respective
slots 674a, 674b, allowing first ends 676a, 676b to deflect inward
and second ends 678a, 678b to deflect outward from attachment
points 662a, 662b of on-skin sensor assembly 160 as retention
elements 672a, 672b rotate about pivot points 680a, 680b. Although
two retention elements are illustrated, any number of retention
elements are contemplated. Moreover, some alternative mechanisms
that may perform such retention and release actions are further
described in connection with at least FIGS. 35A-37C below. Any of
these alternative mechanisms are contemplated for use with
applicator 500.
[0201] A brief description of the operation of applicator 500
follows with respect to FIGS. 7A-7F, which illustrate several
perspective views of the applicator of FIG. 5 in sequence, during
operation, according to some embodiments.
[0202] FIG. 7A illustrates a pre-activated state of applicator 500.
Applicator housing 502 and slot 582 remain stationary with respect
to the skin of the host during activation. Activation element 504
is in a pre-activation position. Insertion assembly 508 is also in
a pre-activation position, coupled to holder 524, which is
releasably coupled to on-skin sensor assembly 160, as described in
connection with at least FIGS. 6A-61I. At least a portion of
insertion element 674 of needle carrier assembly 508 is illustrated
as protruding, in a distal direction, below on-skin sensor assembly
160. Insertion element 674 may comprises a needle, for example, an
open sided-needle, a needle with a deflected-tip, a curved needle,
a polymer-coated needle, a hypodermic needle, deflected-tip or any
other suitable type of needle or structure, as will be described in
more detail in connection with at least FIGS. 47-50 and 80A-B.
Insertion element 674 may be configured to guide at least a portion
of sensor 138 of on-skin sensor assembly 160. rotating drive
element 514 of drive assembly 510 is shown in a pre-activation
position, having pin 516 located at a first position within guide
582 of applicator housing 502, and having protrusion 634 in contact
with retention element 632. In FIG. 7A, pin 516 is positioned
approximately 30 degrees (illustrated as clockwise, though
counterclockwise is also contemplated) from a bottom dead center
orientation relative to an axis of rotation of rotating drive
element 514 that passes through a center of the face on which pin
516 is disposed.
[0203] FIG. 7B illustrates a state of applicator 500 at activation.
Activation element 504 is illustrated in an activated position,
having been pushed longitudinally in the distal direction by a
user, for example. In the activated position, activation element
504 deflects retention element 632 such that protrusion 634 of
rotating drive element 514 is unimpeded from moving, thus allowing
rotating drive element 514 to rotate by the unwinding of spring
512. Since FIG. 7B illustrates applicator 500 just at activation,
rotating drive element 514, pin 516, needle carrier assembly 508,
insertion element 674, holder 524 and on-skin sensor assembly 160
are still shown in their pre-activation orientations and locations
as in FIG. 7A. However, rotating drive element 514 will rotate in
the direction of the circular arrow, and needle carrier assembly
508, insertion element 674, holder 524 and on-skin sensor assembly
160 will be driven, by pin 516 under rotating drive element 514
rotation, in the distal direction to the distal insertion position.
However, the present disclosure is not so limited, and rotating
drive element 514 may be configured to rotate in a direction
opposite of the direction of the circular arrow.
[0204] FIG. 7C illustrates a state of applicator 500 during
activation. Activation element 504 is illustrated in the activated
position of FIG. 7B. Rotating drive element 514 is shown as having
rotated a portion of a revolution, indicated by the circular arrow,
protrusion 634 having advanced beyond retention element 632. Pin
516 is shown as having moved to a second position within guide 582.
This second position is shown as being to the left of the first,
pre-activation position. Insertion assembly 508, insertion element
674, holder 524 and on-skin sensor assembly 160 are driven in the
distal direction toward the distal insertion position when rotating
drive element 514 is rotated by a force generated by spring
512.
[0205] FIG. 7D illustrates applicator 500 during activation, in the
distal insertion position. Activation element 504 is illustrated in
the activated position of FIGS. 7B and 7C. Rotating drive element
514 is shown as having rotated clockwise further compared to FIG.
7C, indicated by the circular arrow, protrusion 634 having advanced
yet further beyond retention element 632. Pin 516 is shown as
having moved to a third position within guide 582, shown as being
to the right of the first, pre-activation position and the second,
activation position of FIG. 7C. Insertion assembly 508, insertion
element 674, holder 524 and on-skin sensor assembly 160 are driven
in the distal direction to the distal insertion position as
rotating drive element 514 is further rotated by the force
generated by spring 512. In this distal insertion position, at
least a portion of insertion element 674 as well as at least a
portion of sensor 138 of on-skin sensor assembly 160 may be
inserted into skin 130 of the host. At this position, retention
elements 642, 644 (see FIG. 6) may be engaged and protrusions 652
and 654 (see FIG. 6) may be in contact with one another. In FIG.
7D, pin 516 is positioned approximately 180 degrees (illustrated as
clockwise, though counterclockwise is also contemplated) from the
bottom dead center orientation relative to the axis of rotation of
rotating drive element 514.
[0206] FIG. 7E illustrates applicator 500 during activation.
Activation element 504 is illustrated in the activated position of
FIGS. 7B-7D. Rotating drive element 514 is shown as having rotated
further compared to FIG. 7D, indicated by the circular arrow. Pin
516 is shown as having moved to a fourth position within guide 582.
This fourth position is shown as being to the right of the first
through third positions previously discussed. Insertion assembly
508 and insertion element 674 are now shown as being driven in the
proximal direction from the distal insertion position as rotating
drive element 514 is further rotated by the force generated by
spring 512. Since retention elements 642, 644 (see FIG. 6) are
engaged and protrusions 652 and 654 (see FIG. 6) may be in contact
with one another, holder 524 and on-skin sensor assembly 160 are
shown as separated from needle carrier assembly 508. In the
position shown by FIG. 7E, on-skin sensor assembly 160 may also be
decoupled from holder 524, as previously described in connection
with FIG. 6H.
[0207] FIG. 7F illustrates applicator 500 post-activation.
Activation element 504 is illustrated in the activated position of
FIGS. 7B-7E. Rotating drive element 514 is shown as having rotated
further compared to FIG. 7E, indicated by the circular arrow, such
that ridge 636 is in contact with retention element 632, thereby
restricting further rotation of rotating drive element 514. Pin 516
is shown as having moved to a fifth position within guide 582,
which is shown as being to the left of the fourth, right-most
position, as pin 516 travels back along guide 582. Insertion
assembly 508 and insertion element 674 are shown in the proximal
retraction position. Holder 524 and on-skin sensor assembly 160 are
shown as separated from needle carrier assembly 508. In the
position shown by FIG. 7F, on-skin sensor assembly 160 may also be
decoupled from holder 524, as previously described in connection
with FIG. 6H. In FIG. 7F, pin 516 is positioned approximately 330
degrees (illustrated as clockwise, though counterclockwise is also
contemplated) from the bottom center orientation relative to the
axis of rotation of rotating drive element 514.
[0208] FIGS. 8-10 illustrate cutaway views of applicators 800, 900,
1000 similar to applicator 500 of FIG. 5, however, alternatively
having activation elements 804, 904, 1004 disposed on an upper,
medial, and lower side of, rather than on a top of, an applicator
housing 802, 902, 1002, respectively. Applicators 800, 900, 1000
may comprise substantially all features of applicator 500 and have
substantially the same operation. For example, applicator housing
802, 902, 1002, activation element 804, 904, 1004, a needle carrier
assembly 808, 908, 1008, a rotating drive element 814, 914, 1014,
including a pin 816, 916, 1016 and a protrusion 834, 934, 1034 and
a retention element 832, 932, 1032 may correspond substantially to
applicator housing 502, activation element 504, needle carrier
assembly 508, rotating drive element 514 including pin 516 and
protrusion 504, and retention element 502 of applicator 500,
respectively.
[0209] However, in FIG. 8, activation element 804 is disposed on an
upper side, rather than on a top, of applicator housing 802 and may
be configured to, upon activation, deflect retention element 832
such that protrusion 834 no longer restrains rotating drive element
814 from rotating under force of a spring (not shown in FIG. 8)
similar to spring 512 of applicator 500. In FIG. 9, activation
element 904 is disposed on a medial side, rather than on a top, of
applicator housing 902 and may be configured to, upon activation,
deflect retention element 932 such that protrusion 934 no longer
restrains rotating drive element 914 from rotating under force of a
spring (not shown in FIG. 9) similar to spring 512 of applicator
500. As shown, due to the medial side location of activation
element 904, retention element 932 may be located substantially on
a side of rotating drive element 914.
[0210] In FIG. 10, activation element 1004 is disposed on a lower
side, rather than on a top, of applicator housing 1002 and may be
configured to, upon activation, deflect retention element 1032 such
that protrusion 1034 no longer restrains rotating drive element
1014 from rotating under force of a spring (not shown in FIG. 10)
similar to spring 512 of applicator 500. As shown, due to the lower
side location of activation element 1004, retention element 1032
may be located substantially on a side of rotating drive element
1014. 50
[0211] An example of steps for assembling an applicator such as
applicators 500, 800, 900, 1000 of FIGS. 5 and 8-10 will now be
discussed in connection with FIGS. 11A-11H.
[0212] FIG. 11A illustrates coupling first end 520 of spring 512 to
needle carrier assembly 508. First end 520 may be coupled to, or
disposed against, a protrusion 1102 of needle carrier assembly 508
and spring 512 may be inserted around a hub 1104 of needle carrier
assembly 508 such that spring 512 and hub 1104 are disposed
coaxially with one another.
[0213] FIG. 11B illustrates coupling second end 522 of spring 512
with rotating drive element 514 and inserting axle 526 into hub
1104 of needle carrier assembly 508 within which axle 526 may
rotate. Axle 526, hub 1104, and spring 512 may be disposed
coaxially with respect to one another. As shown by the circular
arrow, rotating drive element 514 may be rotated about axle 526 in
a circular direction opposite of a direction that rotating drive
element 514 rotates during activation, thereby pre-storing energy
in spring 512. Axle 524 may be fully inserted into the portion of
needle carrier assembly 508 such that protrusion 634 is in contact
with retention element 632, thereby preventing rotating drive
element 514 from rotating until activation. In some embodiments,
rotating drive element 514 may be rotated about axle 504 such that
spring 512 is only partially wound. In such embodiments, spring 512
may be fully wound at a later stage of assembly. Although FIG. 11B
illustrates rotating drive element 514 as having a male-type aspect
configured to mate with a female-type aspect of hub 1104, the
present disclosure also contemplates rotating drive element 514 as
having a female-type aspect configured to mate with a male-type
aspect of hub 1104.
[0214] FIG. 11C illustrates pushing retention elements 672a, 672b
toward a center of holder 524 and coupling holder 524 to needle
carrier assembly 508 by seating first ends 676a, 676b of retention
elements 672a, 672b into respective slots 674a, 674b of needle
carrier assembly 508.
[0215] FIG. 11D illustrates coupling on-skin sensor assembly 160 to
holder 524 by snapping second ends 678a, 678b (not shown in FIG.
11D) of retention elements 672a, 672b into attachment points 662a,
662b of on-skin sensor assembly 160. In some embodiments, retention
elements 672a, 672b may comprise snap fits, friction fits,
interference features, elastomeric grips and/or adhesives.
[0216] FIG. 11E illustrates inserting the assembled needle carrier
assembly 508, rotating drive element 514, holder 524, and on-skin
sensor assembly 160 into applicator housing 502 through the opening
in the bottom of applicator housing 502 and through a vertical
portion of guide 582 (see FIG. 11F). During such insertion, pin 516
of rotating drive element 514 is inserted along at least the
vertical portion of guide 582 in applicator housing 502, as shown
in FIG. 11F. Accordingly, spring 512 (not shown in FIGS. 11E, 11F)
may not be fully wound at this point, instead being partially wound
to the extent that pin 516 of rotating drive element 514 is
positioned to be inserted along guide 582 in applicator housing
502.
[0217] FIG. 11G illustrates positioning the assembled needle
carrier assembly 508, rotating drive element 514, holder 524, and
on-skin sensor assembly 160 further in the proximal direction into
applicator housing 502 such that pin 516 of rotating drive element
514 follows guide 582 of applicator housing 502, thereby turning
rotating drive element 514 fully winding spring 512 (not shown in
FIG. 11G) and positioning protrusion 634 in contact with retention
element 632 such that the drive assembly, comprising at least
rotating drive element 514, having pin 516, and spring 512, are
loaded for activation.
[0218] FIG. 11H illustrates a magnified cutaway view of area 1106
of FIG. 11G illustrating the relationship between rotating drive
element 514, pin 516, guide 582, protrusion 634 and retention
element 632.
[0219] FIG. 11J illustrates inserting activation element 504 into
applicator housing 502.
[0220] FIG. 12 illustrates an exploded perspective view of another
applicator 1200 for applying an on-skin sensor assembly to a skin
of a host, according to some embodiments. Applicator 1200 may
include an applicator housing 1202 having an opening in its bottom
and configured to house at least one or more mechanisms utilized to
apply on-skin sensor assembly 160 to skin 130 (see FIG. 2) of a
host.
[0221] Applicator 1200 includes an activation element 1204
configured to activate a drive assembly of applicator 1200. In some
embodiments, activation element 1204 may be a button, a switch, a
toggle, a slide, a trigger, a knob, a rotating member, a component
that deforms and/or flexes or any other suitable mechanism for
activating a drive assembly of applicator 1200.Applicator 1200 may
further comprise a needle carrier assembly 1208, including an
insertion element (not shown in FIG. 12) configured to insert
sensor 138 of on-skin sensor assembly 160 (e.g., FIG. 1) into skin
130 of the host. In some embodiments, the insertion element
comprises a needle, for example a C-needle, as will be described in
more detail in connection with at least FIGS. 47-50 and 80A-B.
[0222] Applicator 1200 may further comprise a drive assembly 1210
configured to drive the insertion element of needle carrier
assembly 1208 in the distal direction to a distal insertion
position and in the proximal direction from the distal insertion
position to a proximal retraction position. A distal direction may
be defined as extending towards an open-ended side of the
applicator 1200 along a path needle carrier assembly 1208 is
configured to travel. The distal direction may also be defined as
towards the skin of a user. A proximal direction may be defined as
a direction extending in a substantially opposite direction from
the distal direction. In some embodiments, the distal direction and
the proximal direction extend along an insertion axis of the
insertion element and of needle carrier assembly 1208.
[0223] Drive assembly 1210 may include a spring 1212 having a first
tang 1220 (e.g., end) and a second tang 1222 (e.g., end). Spring
1212 may be a torsion spring, a double torsion spring, or any other
suitable type of spring. Spring 1212 may be supported by a spring
spool 1250 comprising a first portion 1250a and an optional second
portion 1250b. In some embodiments, spring 1212 is self-supporting
and is not supported by a spring spool. First portion 1250a may be
configured to couple with second portion 1250b such that spring
spool 1250 is disposed coaxially with spring 1212 and provides
support for spring 1212 along an axis of rotation 1218 of spring
1212. As will be shown in more detail in connection with FIG. 13,
first tang 1220 of spring 1212 may be coupled to applicator housing
1202, e.g., to a hook or protrusion of applicator housing 1202.
Second tang 1222 may be coupled to needle carrier assembly 1208,
e.g., a hook or protrusion of needle carrier assembly 1208. Upon
activation of drive assembly 1210, first tang 1220 and second tang
1222 of spring 1212 unwind in opposite clockwise or
counterclockwise directions, thereby driving spring 1212 in an arc
and insertion element 1208 in the distal direction to the distal
insertion position and in the proximal direction from the distal
insertion position. The arc through which drive assembly 1210
travels may extend in a direction approximately perpendicular to
the distal direction and the proximal direction, or in an arc
defined by the tangs of the spring and the rotation points.
[0224] Applicator 1200 may further include a holder 1224 releasably
coupled to needle carrier assembly 1208 and configured to guide
on-skin sensor assembly 160 while coupled to needle carrier
assembly 1208. In some embodiments, holder 1224 may comprise a
stripper plate. As will be described in more detail below, on-skin
sensor assembly 160 may be stripped from holder 1224 and needle
carrier assembly 1208 once on-skin sensor assembly 160 is disposed
on skin 130 of the host.
[0225] FIG. 13A-13F illustrate perspective and cutaway views of
several features of applicator 1200 of FIG. 12, according to some
embodiments. FIG. 13A illustrates a cross-sectional view of
applicator 1200, including applicator housing 1202 having retention
element 1334, activation element 1204, spring spool 1250, spring
1212 having first tang 1220 and second tang 1222, needle carrier
assembly 1208 having retention element 1332, holder 1224, and
on-skin sensor assembly 160. In some embodiments, retention element
1332 may comprise snap fits, friction fits, interference features,
elastomeric grips and/or adhesives configured to couple on-skin
sensor assembly 160 with needle carrier assembly 1208 and/or holder
1224. Each of these components may have functionality as previously
described in connection with at least FIG. 12. Moreover, first tang
1220 is configured to, upon activation of the drive assembly,
rotate about a rotation point 1336. Second tang 1222 is similarly
configured.
[0226] FIG. 13F illustrates a magnified perspective view of a
retention element 1342 of holder 1224 and a stop element 1344 of
applicator housing 1202 configured to immobilize holder 1228 to
applicator housing 1202 upon needle carrier assembly 1208 reaching
the distal insertion position. In some embodiments, retention
element 1342 is a deflectable arm. For example, as needle carrier
assembly 1208 travels in the distal direction, as a result of
spring 1212 partially unwinding, retention element 1342 slides
along an inside surface of applicator housing 1202 and is deflected
by stop element 1344 until retention element 1342 snaps under stop
element 1344. In some embodiments, the functionality between
retention element 1342 and stop element 1344 may be swapped, e.g.,
stop element 1344 may be configured to be deflected by and snap
over retention element 1342. At this point, though needle carrier
assembly 1208 may be free to progress in the proximal direction, as
a result of spring 1212 unwinding further, stop element 1344 will
prevent retention element 1342, and so holder 1224, from traveling
back in the proximal direction. In this way, movement of needle
carrier assembly 1208 in the proximal direction after reaching the
distal insertion position allows holder 1224 and/or needle carrier
assembly 1208 to be released from on-skin sensor assembly 160.
[0227] FIG. 13B illustrates a magnified cutaway view of a portion
of needle carrier assembly 1208 comprising a retention element 1332
configured to interlock with a retention element 1334 of applicator
housing 1202 and prevent needle carrier assembly 1208 from
separating from applicator housing 1202 in the loaded,
pre-activated position. Activation element 1204 is configured to
deflect retention element 1332 such that retention element 1334 no
longer holds retention element 1332, thereby allowing spring 1212
to separate needle carrier assembly 1208 from applicator housing
1202 and activating drive assembly 1210.
[0228] FIG. 13C illustrates a magnified view of second tang 1222 of
a spring coupled to needle carrier assembly 1208, for example, via
a hook 1348 configured to immobilize second tang 1222 to needle
carrier assembly 1208. The fastening concept described for second
tang 1222 in FIG. 13C may also be utilized for first tang 1220.
[0229] FIG. 13D illustrates on-skin sensor assembly 160 including a
plurality of attachment points 662a-662c configured to mate with
respective retention elements 1372a-1372c on needle carrier
assembly 1208 and/or holder 1224 while traveling in the distal
direction at least partially toward the distal insertion position
during applicator activation. In some embodiments, where holder
1224 comprises a stripper plate, holder 1224 may function similarly
to a stripper plate in punch and die manufacturing or injection
molding processes. Although a plurality of attachment points
662a-662c are illustrated, any number of attachment points are
contemplated. In some embodiments, retention elements 1372a-1372c
may comprise snap fits, friction fits, interference features,
elastomeric grips and/or adhesives.
[0230] Retention elements 1372a-1372c of needle carrier assembly
1208 and/or holder 1224 are configured to releasably couple on-skin
sensor assembly 160 to holder 1228 as needle carrier assembly 1208
travels in the distal direction to the distal insertion position,
and to decouple on-skin sensor assembly 160 from needle carrier
assembly 1208 and/or holder 1228 as needle carrier assembly 1208
travels in the proximal direction from the distal insertion
position towards the proximal retraction position. Specifically,
since retention elements 1342, 1344 immobilize holder 1224 from
traveling in the proximal direction at the distal insertion
position, as needle carrier assembly 1208 travels back in the
proximal direction. This causes needle carrier assembly 1208 to
separate from holder 1224 and on-skin sensor assembly 160, thereby
decoupling retention elements 1372a-1372c from attachment points
662a-662c of on-skin sensor assembly 160. Although two retention
elements are illustrated, any number of retention elements are
contemplated. Moreover, alternative mechanisms that may perform
such retention and release actions are further described in
connection with at least FIGS. 35A-37C below. Any of these
alternative mechanisms are contemplated for use with applicator
1200.
[0231] FIG. 13E illustrates a perspective view of a plurality of
tracks 1322a, 1322b, 1322c in applicator housing 1202 in which a
respective plurality of protrusions 1324a, 1324b, 1324c of needle
carrier assembly 1208 are configured to slide. Accordingly, tracks
1322a-1322c in applicator housing 1202 define a path of travel for
needle carrier assembly 1208. In some embodiments, this path of
travel is substantially linear and longitudinal. Although three
tracks and protrusions are shown in FIG. 13E, a single track or a
plurality of tracks and respective protrusions are
contemplated.
[0232] A brief description of the operation of applicator 1200
follows with respect to FIGS. 14A-14E, which illustrate several
cross-sectional views of the applicator of FIG. 12 during
operation, according to some embodiments.
[0233] FIG. 14A illustrates a state of applicator 1200 at
activation. Activation element 1204 is illustrated in an activated
position, having been pushed longitudinally in the distal direction
by a user, for example. In the activated position, activation
element 1204 deflects retention element 1332 such that retention
element 1334 of applicator housing 1202 does not prevent needle
carrier assembly 1208 from moving when spring 1212 unwinds from a
pre-wound state. Since FIG. 14A illustrates applicator 1200 just at
activation, spring 1212, needle carrier assembly 1208, holder 1224
and on-skin sensor assembly 160 are shown in their pre-activation
orientations and locations. However, spring 1212 will unwind
partially and needle carrier assembly 1208, holder 1224 and on-skin
sensor assembly 160 will be driven, by such unwinding, in the
distal direction to the distal insertion position.
[0234] FIG. 14B illustrates a state of applicator 1200 during
activation. Activation element 1204 is illustrated in the activated
position of FIG. 14A. Spring 1212 has partially unwound such that
first tang 1220 unwinds in a first arc-direction and second tang
1222 unwinds in a second arc-direction opposite of the first
arc-direction. Spring 1212 travels through an arc-direction
approximately perpendicular to the distal direction and the
proximal direction, or in an arc defined by the tangs of spring
1212 and their associated rotation points. As a result, needle
carrier assembly 1208, insertion element 1374, holder 1224 and
on-skin sensor assembly 160 are driven in the distal direction
toward the distal insertion position by a force generated by spring
1212.
[0235] FIG. 14C illustrates applicator 1200 during activation, in a
distal insertion position. Activation element 1204 is illustrated
in the activated position of FIGS. 14A and 14B. Spring 1212 has
unwound further, relative to its position as illustrated in FIGS.
14A and 14B, substantially in the direction of the horizontal
arrow. Insertion assembly 1208, holder 1224 and on-skin sensor
assembly 160 are driven in the distal direction to the distal
insertion position by the force generated by spring 1212. In this
distal insertion position, at least a portion of an insertion
element coupled to needle carrier assembly 1208 similarly to that
shown in FIG. 6 (not shown in FIGS. 14A-14E) as well as at least a
portion of sensor 138 of on-skin sensor assembly 160 (e.g., FIG. 1)
may be inserted into skin 130 of the host. At this position,
although not shown, retention elements 1342, 1344 (see FIG. 13) may
be engaged with one another.
[0236] FIG. 14D illustrates applicator 1200 during activation.
Activation element 1204 is illustrated in the activated position of
FIGS. 14A-14C. Spring 1212 has further unwound and travelled in
substantially the same direction as shown by the arrow. Where
unwinding of spring 1212 in FIGS. 14A-14C caused movement of the
needle carrier assembly 1208 in the distal direction, because
spring 1212 is now on an opposite side of the points at which the
first tang 1220 and the second tang 1222 are anchored, further
unwinding of spring 1212 results in movement of the needle carrier
assembly 1208 in the proximal direction toward the proximal
retraction position. Since the retention elements (see FIG. 13) are
engaged, holder 1224 and on-skin sensor assembly 160 are shown as
separated from needle carrier assembly 1208. In the position shown
by FIG. 14D, on-skin sensor assembly 160 may also be decoupled from
holder 1224, as previously described in connection with call-out
1330 of FIG. 13.
[0237] FIG. 14E illustrates applicator 1200 post-activation.
Activation element 1204 is illustrated in the activated position of
FIGS. 14A-14D. Spring 1212 is illustrated as having unwound further
compared to its position as illustrated in FIG. 14D and having
travelled substantially in the direction indicated by the arrow.
Insertion assembly 1208 has travelled in the proximal direction
indicated by the vertical arrow to the proximal retraction
position. Holder 1224 and on-skin sensor assembly 160 are shown as
separated from needle carrier assembly 1208.
[0238] FIGS. 15-17 illustrate perspective views of several
exemplary double torsional springs that support different
configurations of applicator 1200, according to some embodiments.
Accordingly, any of the springs described by FIGS. 15-17 may be
utilized for spring 1212 previously discussed in connection with
FIGS. 12-14E. As shown in FIGS. 15-17, different shaped and/or
sized cross-bridges 1522c, 1622c, 1722c of springs 1512, 1612, 1712
may be provided by flaring one or more tangs in a particular
direction.
[0239] For example, FIGS. 15-17 illustrate double torsional springs
1512, 1612, 1712, each comprising a first winding 1512a, 1612a,
1712a and a second winding 1512b, 1612b, 1712b. Double torsional
springs 1512, 1612, 1712 may be formed from a single segment of
suitable material, e.g., metal or plastic. First windings 1512a,
1612a, 1712a each comprise a first tang 1520a, 1620a, 1720a and a
second tang 1522a, 1622a, 1722a. Second windings 1512b, 1612b,
1712b each comprise a first tang 1520b, 1620b, 1720b and a second
tang 1522b, 1622b, 1722b. For each spring 1512, 1612, 1712, second
tangs 1522a, 1522b; 1622a, 1622b; 1722a, 1722b may be coupled to
one another by a cross-bridge 1522c, 1622c, 1722c. Cross-bridge
1522c of FIG. 15 may have a length substantially equal to a spacing
1530 between first winding 1512a and second winding 1512b defined
by the extension of second tangs 1522a, 1522b from first winding
1512a and second winding 1512b, respectively. Cross-bridge 1622c of
FIG. 16 may have a length exceeding a spacing 1630 between first
winding 1612a and second winding 1612b defined by the extension of
second tangs 1622a, 1622b from first winding 1612a and second
winding 1612b, respectively, due to second tang 1622b of second
winding 1612b being flared toward first tang 1620b of second
winding 1612b. Cross-bridge 1722c of FIG. 17 may have a length
exceeding a spacing 1730 between first winding 1712a and second
winding 1712b defined by the extension of second tangs 1722a, 1722b
from first winding 1712a and second winding 1712b, respectively,
due to second tang 1722a of first winding 1712a being flared toward
first tang 1720a of first winding 1712a and second tang 1722b of
second winding 1712b being flared toward first tang 1720b of second
winding 1712b to provide the increased length of cross-bridge 1722c
compared to either cross-bridge 1522c shown in FIG. 15 or
cross-bridge 1622c shown in of FIG. 16.
[0240] FIGS. 18-23 illustrate alternative drive assemblies for
utilization in applicators, such as applicator 1200 of FIG. 12,
according to some embodiments. FIG. 18 illustrates a drive assembly
comprising a linkage element 1850. In some embodiments, linkage
element 1850 may comprise a flex linkage. The flex linkage may
contain one or more living hinge(s). In other embodiments, linkage
element 1850 may comprise at least two discrete sections configured
to pivot about a hinge coupling the at least two discrete
sections.
[0241] A flex linkage is a type of hinge assembly formed from an
extension of a parent material (e.g., polypropylene plastic). The
hinge flex linkage is a thin section of the parent material that
acts as a bending connection with two larger sections of the parent
material. Typically, the larger sections of the parent material as
well as the hinge will be made of one continuous piece of the
parent material. Since it is relatively thin and typically made
from flexible materials, the flex linkage is also able to rotate
about one axis by 180 degrees or more--potentially for many
thousands or even millions of cycles. Contrary to most hinges,
which involve multiple parts assembled in a traditional pivoting
mechanism, flex linkages are not a separate entity. They may be
described as a purposeful fault line at a predetermined point in
the material which is designed such that it does not fail after
repeated bending.
[0242] Linkage element 1850 has a first end 1852 coupled to an
applicator housing 1802, a second end 1854 coupled to a needle
carrier assembly 1808, and a hinge 1856 disposed between first end
1852 and second end 1854.
[0243] The drive assembly further comprises a spring 1812, which in
some embodiments may be a single or double torsion spring. Spring
1812 comprises a first tang 1820 coupled to applicator housing 1802
and/or to linkage element 1850 at first end 1852 or at a position
between first end 1852 and hinge 1856. Spring 1812 further
comprises a second tang 1822 coupled to needle carrier assembly
1808 and/or to linkage element 1850 at second end 1854 or at a
position between second end 1854 and hinge 1856. In some
embodiments, hinge 1856 may be aligned with an axis of rotation
1818 of spring 1812 to provide smooth operation as well as to
reduce any stresses caused by incompatible movement between linkage
element 1850 and spring 1812.
[0244] Applicator 1200, utilizing drive assembly 1810, may function
substantially as described for applicator 1200 of FIG. 12, however,
further including that first end 1852, second end 1854 and hinge
1856 of linkage element 150 move substantially in alignment with
first tang 1820, second tang 1822 and axis of rotation 1818 of
spring 1812, respectively, during activation.
[0245] FIG. 19 illustrates another drive assembly comprising a
linkage element 1950. Linkage element 1950 has a first end 1952
coupled to an applicator housing 1902, a second end 1954 coupled to
a needle carrier assembly 1908, and a hinge 1956 disposed between
first end 1952 and second end 1954. The drive assembly further
comprises a spring 1912, which in some embodiments may be a single
or double torsion spring. Spring 1912 comprises a first tang 1920
coupled to linkage element 1950 between second end 1954 and hinge
1956. Spring 1912 further comprises a second tang 1922 coupled to
needle carrier assembly 1908. Upon activation, spring 1912 unwinds
and first tang 1952 sweeps an arc while second tang 1954 is held
substantially stationary against needle carrier assembly 1908. As
first tang 1952 sweeps its arc, first tang 1952 drives linkage
element 1950 from the bent position shown, hinge 1956 pivoting,
until linkage element 1950 is substantially vertical, and then
continuing pivoting until linkage element 1950 is in a
substantially mirror orientation from that shown in FIG. 19. This
motion drives needle carrier assembly 1908 in the distal direction,
reaching the distal insertion position when linkage element 1950 is
substantially vertical, and then increasingly in the proximal
direction as linkage element 1950 is further driven from the
substantially vertical orientation to the substantially mirrored
orientation to that shown in FIG. 19.
[0246] FIG. 20 illustrates another drive assembly comprising a
linkage element 2050. Linkage element 2050 has a first end 2052
coupled to an applicator housing 2002, a second end 2054 coupled to
a needle carrier assembly 2008, and a hinge 2056 disposed between
first end 2052 and second end 2054. The drive assembly further
comprises a spring 2012, which in some embodiments may be a single
or double torsion spring. Spring 2012 comprises a first tang 2020
coupled to linkage element 2050 between first end 2052 and hinge
2056. Spring 2012 further comprises a second tang 2022 coupled to
applicator body 2002. Upon activation, spring 2012 unwinds and
first tang 2052 sweeps an arc while second tang 2054 is held
substantially stationary against applicator body 2002. As first
tang 2052 sweeps its arc, first tang 2052 drives linkage element
2050 from the bent position shown, hinge 2056 pivoting, until
linkage element 2050 is substantially vertical, and then continuing
pivoting until linkage element 2050 is in a substantially mirror
orientation from that shown in FIG. 20. This motion drives needle
carrier assembly 2008 in the distal direction, reaching the distal
insertion position when linkage element 2050 is substantially
vertical, and then increasingly in the proximal direction as
linkage element 2050 is further driven from the substantially
vertical orientation to the substantially mirrored orientation to
that shown in FIG. 20.
[0247] FIG. 21 illustrates another drive assembly comprising a
linkage element 2150. Linkage element 2150 has a first end 2152
coupled to an applicator housing 2102, a second end 2154 coupled to
a needle carrier assembly 2108, and a hinge 2156 disposed between
first end 2152 and second end 2154. The drive assembly further
comprises a spring 2112, which in some embodiments may be an
extension spring. A compression spring is also contemplated.
However, a compression spring may be coupled between hinge 2156 and
the closer side of applicator housing 2102. Spring 2112 comprises a
first end 2120 coupled to linkage element 2150 and a second end
2122 coupled to applicator body 2102. In some embodiments, first
end 2120 is coupled to linkage element 2150 between first end 2152
and hinge 2156. In other embodiments first end 2120 is coupled to
linkage element 2150 at hinge 2156. In yet other embodiments first
end 2120 is coupled to linkage element 2150 between hinge 2156 and
second end 2154. Upon activation, spring 2112 unwinds through an
arc that extends in a direction approximately perpendicular to the
distal direction and the proximal direction, or in an arc defined
by the tangs of the spring and their respective rotation points,
driving linkage element 2150 from the bent position shown, hinge
2156 pivoting, until linkage element 2150 is substantially
vertical, and then continuing pivoting until linkage element 2150
is in a substantially mirror orientation from that shown in FIG.
21. This motion drives needle carrier assembly 2108 in the distal
direction, reaching the distal insertion position when linkage
element 2150 is substantially vertical, and then increasingly in
the proximal direction as linkage element 2150 is further driven
from the substantially vertical orientation to the substantially
mirrored orientation to that shown in FIG. 21.
[0248] FIG. 22 illustrates another drive assembly comprising a leaf
spring 2212. Leaf spring 2212 comprises a first end 2220 coupled to
an applicator housing 2202 and a second end 2222 coupled to a
needle carrier assembly 2208. Upon activation, leaf spring 2212
unloads in a direction substantially parallel to the axis of
insertion, driving needle carrier assembly 2208 to the distal
insertion position when leaf spring 2212 is unloaded.
[0249] FIG. 23 illustrates another drive assembly comprising a
linkage element 2350. Drive assembly 2310 is substantially the same
as drive assembly 1910 except replacing torsion spring 1912 with
leaf spring 2312. Linkage element 2350 has a first end 2352 coupled
to an applicator housing 2302, a second end 2354 coupled to a
needle carrier assembly 2308, and a hinge 2356 disposed between
first end 2352 and second end 2354. The rive assembly further
comprises leaf spring 2312 having a first end 2320 coupled to
linkage element 2350 between second end 2354 and hinge 2356, and a
second end 2322 coupled to needle carrier assembly 2308. Upon
activation, spring 2312 unloads and first end 2320 sweeps an arc
while second end 2322 is held substantially stationary against
needle carrier assembly 2308. As first end 2320 sweeps its arc,
first end 2320 drives linkage element 2350 from the bent position
shown, hinge 2356 pivoting, until linkage element 2350 is
substantially vertical, and then continuing pivoting until linkage
element 2350 is in a substantially mirror orientation from that
shown in FIG. 23. This motion drives needle carrier assembly 2308
in the distal direction, reaching the distal insertion position
when linkage element 2350 is substantially vertical, and then
increasingly in the proximal direction as linkage element 2350 is
further driven from the substantially vertical orientation to the
substantially mirrored orientation to that shown in FIG. 23.
[0250] An example of steps for assembling an applicator such as
applicator 1200 of FIG. 12 will now be discussed in connection with
FIGS. 24A-24M. To the extent any step is compatible, the assembly
steps of FIGS. 24A-24M may also apply to any applicator utilizing
the drive assemblies described in connection with FIGS. 18-23.
[0251] FIG. 24A illustrates coupling first portion 1250a and second
portion 1250b of spring spool 1250 together inside the windings of
spring 1212. FIG. 24B illustrates the assembled spring spool 1250
and spring 1212. Spring spool 1250 and spring 1212 are disposed
coaxially with one another. FIG. 24C illustrates spring 1212 before
winding in the direction indicated by the circular arrow, having
first tang 1220 and second tang 1222 in the illustrated positions.
FIG. 24D illustrates spring 1212 after winding, having first tang
1220 and second tang 1222 in the illustrated positions.
[0252] FIG. 24E illustrates coupling wound spring 1212 to needle
carrier assembly 1208. In some embodiments, this includes coupling
first tang 1220 to a hook 1348 of needle carrier assembly 1208 and
coupling second tang 1222 to or disposing second tang 1222 against
needle carrier assembly 1208. FIG. 24F illustrates a side view of
wound spring 1212 coupled to needle carrier assembly 1208, while
FIG. 24G illustrates a perspective view of the arrangement shown in
FIG. 24F.
[0253] FIG. 2411 illustrates coupling holder 1224 to needle carrier
assembly 1208 and on-skin sensor assembly 160 to holder 1224. FIG.
24J illustrates a side view of on-skin sensor assembly 160, holder
1224, and needle carrier assembly 1208 assembled, while FIG. 24K
illustrates a perspective view of the arrangement shown in FIG.
24J.
[0254] FIG. 24L illustrates assembling the complex including
on-skin sensor assembly 160, holder 1224, needle carrier assembly
1208, and spring 1212 into applicator housing 1202 through the
opening in the bottom of applicator housing 1202, and insertion of
activation element 1204 into applicator housing 1202. FIG. 24M
illustrates the result of the assembly shown in FIG. 24L.
[0255] FIG. 25 illustrates an exploded perspective view of yet
another applicator 2500 for on-skin sensor assembly 160 of an
analyte sensor system, according to some embodiments. Applicator
2500 may include an applicator housing 2502 configured to house one
or more mechanisms for applying on-skin sensor assembly 160 to skin
130 of a host. Applicator housing 2502 may be formed of any
suitable material, e.g., a polymer, polycarbonate, ABS, nylon,
polyethylene, polypropylene, etc.
[0256] Applicator 2500 includes an activation element 2504
configured to activate a drive assembly of applicator 2500. In some
embodiments, activation element 2504 may be a button, a switch, a
toggle, a slide, a trigger, a knob, a rotating member, a component
that deforms and/or flexes or any other suitable mechanism for
activating a drive assembly of applicator 2500.Applicator 2500 may
further comprise a needle carrier assembly 2508, including an
insertion element 2574 configured to insert sensor 138 (e.g., FIG.
1) of on-skin sensor assembly 160 (e.g., FIG. 1) into skin 130
(e.g., FIG. 1) of the host. In some embodiments, insertion element
2574 comprises a needle, for example, an open sided-needle, a
needle with a deflected-tip, a curved needle, a polymer-coated
needle, a hypodermic needle, or any other suitable type of needle
or structure, as will be described in more detail in connection
with at least FIGS. 47-50 and 80A-B. In yet other embodiments,
insertion element may comprise sensor 138, sufficiently rigid to be
inserted partially into skin 130 of the host with minimal or no
structural support.
[0257] Applicator 2500 may further comprise a drive assembly 2510
configured to drive insertion element 2574 of needle carrier
assembly 2508 in a distal direction to a distal insertion position
and in a proximal direction from the distal insertion position to a
proximal retraction position.
[0258] Applicator 2500 may further include a holder 2524 releasably
coupled to needle carrier assembly 2508 and configured to guide
on-skin sensor assembly 160 while coupled to needle carrier
assembly 2508. As will be described in more detail below, on-skin
sensor assembly 160 may be stripped from holder 2524 and needle
carrier assembly 2508 once on-skin sensor assembly 160 is disposed
on skin 130 of the host.
[0259] Drive assembly 2510 may include a spring 2512, which may be
any suitable type of spring, e.g., a compression spring, extension
spring, leaf spring, flex arm spring, etc. Spring 2512 may have a
first end 2520 coupled to applicator housing 2502 and a second end
coupled to needle carrier assembly 2508. Spring 2520 may be
configured to, upon activation of drive assembly 2510, drive needle
carrier assembly 2508 in the distal direction. In some embodiments,
spring 2512 may be pre-loaded, e.g., at the factory. In some other
embodiments, spring 2512 may be loaded by an action of the user of
applicator 2500.
[0260] Drive assembly 2510 further includes a spring 2528 that may
be coupled to an applicator base 2530 of applicator 2500. In some
embodiments, spring 2528 may be a compression spring, extension
spring, leaf spring, flex arm spring, etc. In some embodiments,
spring 2528 may be pre-loaded, e.g., at the factory. In some other
embodiments, spring 2528 may be loaded by an action of the user. In
yet other embodiments, spring 2528 may be loaded by unloading of
spring 2512. Spring 2528 may comprise one or more portions
configured to drive needle carrier assembly 2508 in the proximal
direction from the distal insertion position, as will be described
in more detail below.
[0261] FIG. 26A-26D illustrate several cutaway views and a bottom
view of several features of applicator 2500 of FIG. 25, according
to some embodiments. FIG. 26A illustrates a perspective cutaway
view of applicator 2500 including applicator housing 2502,
activation element 2504, applicator base 2530 including protrusion
2602, spring 2512, leaf spring(s) 2528, needle carrier assembly
2508, holder 2524, and on-skin sensor assembly 160. Each of these
components may have functionality as previously described in
connection with at least FIG. 25.
[0262] FIG. 26B illustrates a perspective view of several features
of holder 2524, applicator base 2530 and activation element 2504.
Spring 2512 is configured to be coupled to applicator housing 2502
at a first end and to holder 2524 at a second end. In a
pre-activation state, spring 2512 may be configured to store energy
for driving holder 2512 (and needle carrier assembly 2508) in the
distal direction to the distal insertion position upon activation.
Holder 2524 comprises an axle 2614 configured to snap into
applicator base 2530 such that holder 2524 is configured to pivot
in a substantially circular arc about axle 2614. In FIG. 26B,
activation element 2504 is illustrated as comprising a protrusion
2612 configured to guide holder 2524 in the pre-activation position
shown until activation element 2504 is activated, thereby
displacing protrusion 2612 from its pre-activation orientation
relative to holder 2524 and releasing holder 2524. FIG. 26B further
illustrates that leaf spring(s) 2528 are not coupled to holder
2524. Instead, leaf spring(s) 2528 are coupled to needle carrier
assembly 2508 and are configured to drive needle carrier assembly
2508 in the proximal direction from the distal insertion position.
Although activation element 2504 is shown as a button, the present
disclosure further contemplates activation element 2504 as a
switch, a toggle, a slide, a trigger, a knob, a rotating member, a
component that deforms and/or flexes or any other suitable
mechanism for activating a drive assembly of applicator 2500.
Moreover, although activation element 2504 is illustrated as being
disposed on a side of applicator housing 2502, the present
disclosure contemplates any other location, e.g., on a top, bottom,
or other side location of applicator housing 2502, and/or any other
angle of disposition with respect to applicator housing 2502.
[0263] FIG. 26C illustrates an exploded perspective view of needle
carrier assembly 2508, insertion element 2674, and holder 2524.
Insertion element 2674 is coupled to needle carrier assembly 2508.
In some embodiments, insertion element 2674 comprises an open-sided
needle configured to guide and insert sensor 138 of on-skin sensor
assembly 160 (e.g., FIG. 1) into skin 130 of the host. Insertion
assembly 2508 is coupled at a first end to axle 2614 of holder
2524. Insertion assembly 2508 further comprises a retention element
2622 configured to releasably couple a second end of needle carrier
assembly 2508 to holder 2524. Insertion assembly 2508 further
comprises a retention element 2604 configured to releasably couple
on-skin sensor assembly 160 to needle carrier assembly 2508 and
holder 2524. In some embodiments, retention element 2604 may
comprise a snap fit, friction fit, interference feature,
elastomeric grip and/or adhesive configured to couple on-skin
sensor assembly 160 with needle carrier assembly 2508 and/or holder
2524. Spring 2512 is configured to, upon activation of applicator
2500, drive needle carrier assembly 2508 and holder 2524 in the
distal direction along a circular arc defined by axle 2614 to the
distal insertion position. Spring 2512 transfers at least a portion
of its stored energy to leaf spring(s) 2528 as needle carrier
assembly 2508 is driven in the distal direction along the circular
arc. In some other embodiments, leaf spring(s) 2528 may be
pre-loaded such that spring 2512 does not transfer stored energy to
leaf spring(s) 2528. As needle carrier assembly 2508 is driven in
the distal direction, a protrusion 2602 of applicator base 2530 is
configured to deflect retention element 2622 sufficiently to
separate needle carrier assembly 2508 from holder 2524
substantially at the distal insertion position, thereby uncoupling
the second end of needle carrier assembly 2508 from holder 2524.
Accordingly, from the distal insertion position, leaf spring(s)
2528, now loaded, are configured to drive needle carrier assembly
2508 in the proximal direction from the distal insertion position,
along the circular arc, to the proximal retraction position.
[0264] FIG. 26D illustrates a portion 2632 of activation element
2504 coupled to applicator housing 2502 and configured to act as a
return spring, returning activation element 2504 to its
pre-activation position after activation. For example, as
activation element 2504 is pressed to the right as shown in FIG.
26D, portion 2632 is deformed against applicator housing 2502,
thereby functioning substantially as a spring, which when unloaded,
returns activation element 2504 to its pre-activation position.
[0265] FIGS. 27A-27E illustrate several cross-sectional views of
applicator 2500 of FIG. 25 during operation, according to some
embodiments. FIG. 86 illustrates relationships between axle 2614,
insertion element 2674, and a circular arc 8602 travelled by
insertion element 2674 during insertion and retraction, according
to some embodiments. FIG. 27A illustrates applicator 2500 at the
time of activation. For example, activation element 2504 is
illustrated in an activated position, e.g., pushed inwardly, which
releases holder 2524 from its immobilized, pre-activation state.
Spring 2512, needle carrier assembly 2508, insertion element 2674,
holder 2524, and on-skin sensor assembly 160 are all shown in their
pre-activation positions.
[0266] FIG. 27B illustrates applicator 2500 during activation.
Spring 2512 is driving holder 2524, and so releasably coupled
needle carrier assembly 2508, insertion element 2674, and on-skin
sensor assembly 160, in the distal direction along the circular arc
8602 (see FIG. 86) defined by axle 2614. In some embodiments, a
radius 8604 (see FIG. 86) of the circular arc 8602 may be between
20 millimeters (mm) and 80mm, inclusive, although radiuses larger
or smaller than this range are also contemplated.
[0267] With respect to FIG. 86, the radius 8604 of this circular
arc 8602 may depend on one or more of a distance 8606 from the skin
130 of the host to axle 2614, a height 8608 of the on-skin sensor
assembly 160 from a bottom opening or surface of applicator 2500 or
from axle 2614, and/or a location of sensor 138 within on-skin
sensor assembly 160. Selection of a radius 8604 may be made at
least in part to minimize tissue trauma, optimize deployment of
sensor 138, and to minimize insertion and/or retraction friction
between the insertion member and the tissue of the host.
[0268] For example, with respect to FIGS. 27A and 86, an angle 2710
between a needle axis and a bottom plane of on-skin sensor assembly
may be calculated such that a minimum offset is achieved between
the straight needle path and the ideal curved profile 8602. In some
embodiments, it has been determined that an approximately 71 degree
angle between the needle axis and the bottom plane of on-skin
sensor assembly produces less lateral motion of the tip of the
insertion element 2674 within the skin of the host compared to an
approximately 90 degree angle between the needle axis and the
bottom plane of on-skin sensor assembly. However, this angle may
depend on at least some of the same factors affecting an ideal
radius of the circular arc.
[0269] Moreover, various needle geometries may be utilized,
including, but not limited to, straight needle geometries, kinked
needle geometries (e.g., two or more substantially straight
portions with one or more bends disposed therebetween), and fully
or partially curved needle geometries (e.g., a curved distal
portion configured to at least partially pierce the skin of the
host with or without a straight proximal portion), as described in
more detail in connection with at least FIGS. 47-50 and 80A-B.
[0270] FIG. 27C illustrates applicator 2500 in the distal insertion
position. Spring 2512 has driven holder 2524, and so releasably
coupled needle carrier assembly 2508, insertion element 2674, and
on-skin sensor assembly 160, in the distal direction to the distal
insertion position. In addition, protrusion 2602 of applicator base
2530 has deflected retention arm 2622 sufficiently to release the
second end of needle carrier assembly 2508 from holder 2524 in
preparation for movement in the proximal direction from the distal
insertion position.
[0271] FIG. 27D illustrates applicator 2500 during retraction.
Spring 2512 remains unloaded, pinning holder 2524 in the distal
insertion position. However, leaf spring(s) 2528, still in contact
with now-released needle carrier assembly 2508, drive needle
carrier assembly 2508 and coupled insertion element 2674 in the
proximal direction from the distal insertion position to the
proximal retraction position. Retention element(s) 2604 are
released from on-skin sensor assembly 160 by virtue of spring 2512
pinning holder 2524, and so on-skin sensor assembly 160 disposed
thereunder, in the distal insertion position. In some embodiments,
retention element(s) 2604 may comprise snap fits, friction fits,
interference features, elastomeric grips and/or adhesives.
[0272] FIG. 27E illustrates applicator 2500 in the proximal
retraction position. Leaf spring(s) 2528 have driven needle carrier
assembly 2508 and insertion element 2674 in the proximal direction
to the proximal retraction position. Applicator 2500 may then be
released from the skin of the host, whereby all portions of the
applicator 2500 will be removed from the skin of the host except
the on-skin sensor assembly 160 and the sensor 138 (e.g., FIG. 1)
which is now at least partially inserted into the skin of the
host.
[0273] FIGS. 28A-28H illustrate steps to assemble applicator 2500
of FIG. 25, according to some embodiments. FIG. 28A illustrates
coupling insertion element 2674 to needle carrier assembly 2508. In
some embodiments, insertion element 2674 may be coupled to needle
carrier assembly 2508 at an angle that substantially coincides with
the circular path insertion element 2674 and needle carrier
assembly 2508 traverse during activation. FIG. 28B illustrates
coupling holder 2524 to needle carrier assembly 2508 by coupling
needle carrier assembly 2508 to axle 2614 of holder 2524 and
retention element 2622 to holder 2524. FIG. 28C illustrates
coupling on-skin sensor assembly 160 to holder 2524 and needle
carrier assembly 2508 by engaging retention element(s) 2604 of
needle carrier assembly 25089 with on-skin sensor assembly 160.
[0274] FIG. 28D illustrates inserting activation element 2504 into
applicator housing 2502. FIG. 28E illustrates coupling a first end
of spring 2512 with applicator housing 2502 through an opening in
the bottom of applicator housing 2502. FIG. 28F illustrates
inserting the assembly 2800c resulting from the step(s) illustrated
by FIG. 28C into applicator housing 2502. In assembly 2800c, shown
in FIG. 28F, spring 2512 is placed in contact with holder 2524 and
holder 2524 is secured by protrusion 2612 of activation element
2504.
[0275] FIG. 28G illustrates coupling applicator base 2530 to
applicator housing 2502. Axle 2614 of holder 2524 is coupled to
applicator base 2530 and leaf spring(s) 2528 are placed in contact
with needle carrier assembly 2508. FIG. 28H illustrates applicator
2500 in assembled form. At this step, applicator base 2530 may be
coupled to applicator housing 2502, for example, via sonic welding,
press-fit, snap-fit, adhesive, or any other suitable method of
securing plastic materials together.
[0276] FIG. 29 illustrates an exploded perspective view of yet
another applicator 2900 for applying an on-skin sensor assembly to
skin 130 of a host, according to some embodiments. Applicator 2900
may include an applicator housing 2902 having an opening at its
bottom and configured to house at least one or more mechanisms
utilized to apply on-skin sensor assembly 160 to skin 130 of a
host.
[0277] Applicator 2900 includes an activation element 2904
configured to activate a drive assembly of applicator 2900. In some
embodiments, activation element 2904 may be a button, a switch, a
toggle, a slide, a trigger, a knob, a rotating member, a component
that deforms and/or flexes or any other suitable mechanism for
activating a drive assembly of applicator 2900. Applicator 2900 may
further comprise a needle carrier assembly 2908, including an
insertion element (see FIG. 30) configured to insert sensor 138 of
on-skin sensor assembly 160 (e.g., FIG. 1) into skin 130 of the
host. In some embodiments, the insertion element comprises a
needle, for example, an open sided-needle, a needle with a
deflected-tip, a curved needle, a polymer-coated needle, a
hypodermic needle, or any other suitable type of needle or
structure, as will be described in more detail in connection with
at least FIGS. 47-50 and 80A-B. In yet other embodiments, insertion
element may comprise sensor 138 itself, sufficiently rigid to be
inserted partially into skin 130 of the host with minimal or no
structural support.
[0278] Applicator 2900 may further comprise a drive assembly 2910
configured to drive the insertion element of needle carrier
assembly 2908 in a distal direction to a distal insertion position
and in a proximal direction from the distal insertion position to a
proximal retraction position. A distal direction may be defined as
extending towards an open-ended side of applicator 2900 along a
path needle carrier assembly 2908 is configured to travel. The
distal direction may also be defined as towards the skin of a user.
A proximal direction may be defined as a direction extending in a
substantially opposite direction from the distal direction. In some
embodiments, the distal direction and the proximal direction extend
along an insertion axis of the insertion element and of needle
carrier assembly 2908.
[0279] Drive assembly 2910 may include a rotating drive element
2914 disposed within needle carrier assembly 2908 and configured to
rotate with respect to needle carrier assembly 2908 about an axis
of rotation 2918 parallel with a centerline of needle carrier
assembly 2908. In some embodiments, rotating drive element 2914 is
configured to rotate in a plane substantially perpendicular to the
proximal direction and the distal direction. In some embodiments,
rotating drive element 2914 may comprise a barrel cam. Rotating
drive element 2914 comprises a ridge 2916 that defines a variable
cam path around at least a portion of a circumference of the
rotating drive element. Ridge 2916 is configured to slide along a
channel (see FIG. 30) on an inside surface of needle carrier
assembly 2908 as rotating drive element 2914 rotates, thereby
driving needle carrier assembly 2908 in the distal direction to the
distal insertion position and then in the proximal direction to the
proximal retraction position as defined by the variable cam path of
ridge 2916.
[0280] Drive assembly 2910 may further include a spring 2912
disposed within rotating drive element 2914. Spring 2912 may be a
torsion spring, or any suitable type of spring. Spring 2912 may
have a first end 2920 coupled to applicator housing 2902 and a
second end 2922 coupled to rotating drive element 2914. Spring 2912
may be disposed coaxially with rotating drive element 2914 and
needle carrier assembly 2908. Spring 2920 may be configured to,
upon activation of drive assembly 2910, rotate rotating drive
element 2914 in a single direction with respect to needle carrier
assembly 2908.
[0281] By virtue of rotating drive element 2914 being configured to
rotate with respect to needle carrier assembly 2908, about axis of
rotation 2918, and ridge 2916 being restrained to travel in the
channel of needle carrier assembly 2908, rotational motion of
rotating drive element 2914, caused by spring 2912, is converted
into linear, reciprocating motion of needle carrier assembly 2908
and, therefore, insertion element (see FIG. 30). More specifically,
rotation of rotating drive element 2914 drives insertion element
2908 in the distal direction to the distal insertion position and
in the proximal direction from the distal insertion position to the
proximal retraction position.
[0282] Applicator 2900 may further include a holder 2924 releasably
coupled to needle carrier assembly 2908 via retention element(s)
2980 and configured to guide on-skin sensor assembly 160 while
coupled to needle carrier assembly 2908. In some embodiments,
retention element(s) 2980 may comprise snap fits, friction fits,
interference features, elastomeric grips and/or adhesives
configured to couple on-skin sensor assembly 160 with needle
carrier assembly 2908 and/or holder 2924. On-skin sensor assembly
160 may be stripped from holder 2924 and/or needle carrier assembly
2908 once on-skin sensor assembly 160 is disposed on skin 130 of
the host.
[0283] FIG. 30 illustrates a perspective cutaway view of a portion
of applicator 2900 of FIG. 29, according to some embodiments. FIG.
30 illustrates at least one protrusion 3024 of needle carrier
assembly 2908 configured to slide within tracks (not shown in FIG.
30) on an inside surface of applicator housing 2902 (similar to
tracks 622a-622c in FIG. 6) that define a linear path of travel for
needle carrier assembly 2908. FIG. 30 further illustrates channel
3002 in which ridge 2916 of rotating drive element 2914 is
configured to slide as spring 2912 rotates rotating drive element
2914 with respect to needle carrier assembly 2908. FIG. 30 further
illustrates insertion element 3074 coupled to needle carrier
assembly 2908.
[0284] In some embodiments, holder 2924 further includes a
retention element 3042 configured to engage with a retention
element (not shown in FIG. 30) of applicator housing 2902, similar
to stop element 644 of applicator housing 462 of FIG. 6, and
immobilize holder 2924 to applicator housing 2902 upon needle
carrier assembly 2908 reaching the distal insertion position.
Although not shown in FIG. 30, holder 2928 may further comprise a
protrusion and applicator housing 2902 may further comprise a
protrusion configured to prevent holder 2924 from travelling beyond
the distal insertion position in the distal direction, similar to
protrusion 652 and protrusion 654 as previously described in
connection with FIG. 6F.
[0285] FIG. 31 illustrates a cutaway view of yet another applicator
3100 for an on-skin sensor assembly of an analyte sensor system,
according to some embodiments. In some embodiments, applicator 3100
may include an applicator housing 3102 configured to house one or
more mechanisms for applying on-skin sensor assembly 160 to skin
130 of a host. Applicator 3100 may further comprise a base 3130
coupled to applicator housing 3102 and configured to form a bottom
of applicator 3100.
[0286] Applicator 3100 further includes an activation element (not
shown in FIG. 31) configured to activate a drive assembly 3110 of
applicator 3100. In some embodiments, the activation element may be
a button, a switch, a toggle, a slide, a trigger, a knob, a
rotating member, a component that deforms and/or flexes or any
other suitable mechanism for activating a drive assembly of
applicator 3100. In addition, the activation element of applicator
3100 may be disposed in any location and orientation with respect
to applicator housing 3102, e.g., a top, any portion of a side, or
bottom of applicator housing 3102 and/or at any angle with respect
to the portion of applicator housing 2102 in which the activation
element is disposed. Applicator 3100 may further comprise a needle
carrier assembly 3108, including an insertion element 3174
releasably coupled to on-skin sensor assembly 160 and configured to
insert sensor 138 of on-skin sensor assembly 160 (e.g., FIG. 1)
into skin 130 of the host. In some embodiments, the insertion
element comprises a needle, for example, an open sided-needle, a
needle with a deflected-tip, a curved needle, a polymer-coated
needle, a hypodermic needle, deflected-tip or any other suitable
type of needle or structure, as will be described in more detail in
connection with at least FIGS. 47-50 and 80A-B. In yet other
embodiments, insertion element may comprise sensor 138 itself,
sufficiently rigid to be inserted partially into skin 130 of the
host with minimal or no structural support,
[0287] Drive assembly 3110 may be configured to drive insertion
element 3174 of needle carrier assembly 3108 in a distal direction
to a distal insertion position and in a proximal direction from the
distal insertion position to a proximal retraction position. Drive
assembly 3110 may include a guide member 3138, a spring 3112, a hub
3132 and a reverse toggling element 3136. guide member 3138 may be
coupled to at least one of applicator housing 3102 and base 3130 at
a first end and/or a second end, respectively. Spring 3112 may be
disposed around guide member 3138 such that guide member 3138
extends substantially along a centerline of spring 3112. Spring
3112 may be any suitable type of spring, e.g., a compression
spring, and may have a first end coupled to base 3130 and a second
end coupled to a hub 3132, which is disposed on and configured to
travel along guide member 3138. Spring 3120 may be configured to,
upon activation of drive assembly 3110, drive hub 3132 in the
proximal direction along guide member 3138, as shown by the arrow.
Reverse toggling element 3136 may function substantially as a lever
with a fulcrum at or near its midpoint, rotatably coupled to base
3130 or applicator housing 3102. A first end of reverse toggling
element 3136 may be in contact with a protrusion 3134 of hub 3132
for at least a first portion of travel of hub 3132 in the proximal
direction and a second end of reverse toggling element 3136 may be
in contact with needle carrier assembly 3108. Insertion assembly
3108 may be slideably coupled to guide member 3138 on the side of
hub 3132 opposite spring 3112.
[0288] In operation, upon activation of drive assembly 3110, spring
3112 drives hub 3132 along guide member 3138 in the proximal
direction. For a first portion of travel along guide member 3138,
protrusion 3134 of hub 3132 is in contact with the first end of
reverse toggling element 3136, causing the second end of reverse
toggling element 3136 to drive needle carrier assembly 3138, and so
insertion element 3174 and on-skin sensor assembly 160, in the
distal direction. After the first portion of travel along guide
member 3138, protrusion 3134 of hub 3132 will clear the first end
of reverse toggling element 3136 and make contact with the portion
of needle carrier assembly 3138 slideably coupled with guide member
3138. At this point, needle carrier assembly 3108, insertion
element 3174 and on-skin sensor assembly 160 are in the distal
insertion position. For a second portion of travel along guide
member 3138 in the proximal direction, hub 3132, still driven by
spring 3112, drives needle carrier assembly 3108, and so insertion
element 3174, in the proximal direction from the distal insertion
position to the proximal retraction position. In this way, drive
assembly 3110 converts linear motion of spring 3112 in a single
direction, e.g., the proximal direction, into reciprocating linear
motion in the distal direction and then the proximal direction.
[0289] FIG. 32A illustrates an exploded perspective view of yet
another applicator 3200 for an on-skin sensor assembly of an
analyte sensor system, according to some embodiments. Applicator
3200 may include an applicator housing 3202 configured to house at
least one or more mechanisms utilized to apply the on-skin sensor
assembly 160 to skin 130 of a host. Applicator 3200 may further
include a base 3230 coupled to a bottom opening of applicator
housing 3202. Base 3230 defines a bottom surface of applicator 3200
and a plane for application of on-skin sensor assembly 160 to skin
130 of a host.
[0290] Applicator 3200 includes an activation element 3204
configured to activate a drive assembly of applicator 3200. In some
embodiments, activation element 3204 may be a button, a switch, a
toggle, a slide, a trigger, a knob, a rotating member, a component
that deforms and/or flexes or any other suitable mechanism for
activating a drive assembly of applicator 460.
[0291] Applicator 3200 may further comprise a needle carrier
assembly 3208, including an insertion element 3274 configured to
insert sensor 138 of on-skin sensor assembly 160 into skin 130 of
the host (e.g., FIG. 1). In some embodiments, the insertion element
comprises a needle, for example, an open sided-needle, a needle
with a deflected-tip, a curved needle, a polymer-coated needle, a
hypodermic needle, or any other suitable type of needle or
structure, as will be described in more detail in connection with
at least FIGS. 47-50 and 80A-B. In yet other embodiments, insertion
element may comprise sensor 138, sufficiently rigid to be inserted
partially into skin 130 of the host with minimal or no structural
support.
[0292] Applicator 3200 may further include a holder 3224 releasably
coupled to needle carrier assembly 3208 and configured to guide
on-skin sensor assembly 160 while coupled to needle carrier
assembly 3208. As will be described in more detail below, on-skin
sensor assembly 160 may be stripped from holder 3224 and needle
carrier assembly 3208 once on-skin sensor assembly 160 is disposed
on skin 130 of the host.
[0293] Applicator 3200 may further comprise a drive assembly
configured to drive insertion element 3274 and needle carrier
assembly 3208 in the distal direction to the distal insertion
position and in the proximal direction from the distal insertion
position to the proximal retraction position. Drive assembly 3210
may include a first spring 3212 and a second spring 3228. First
spring 3212 may be a compression spring, or any suitable type of
spring, and may have a first end coupled to applicator housing 3202
and a second end coupled to holder 3224. First spring 3212 is
configured to, upon activation of drive assembly 3210, drive holder
3224, and also coupled needle carrier assembly 3208, insertion
element 3274 and on-skin sensor assembly 160, in the distal
direction to the distal insertion position. Substantially at the
distal insertion position, needle carrier assembly 3208 may
decouple from holder 3224 and on-skin sensor assembly 160.
[0294] Second spring 3228 may be a compression spring, or any
suitable type of spring, and may have a first end coupled to holder
3224 and a second end coupled to needle carrier assembly 3208.
Second spring 3228 is configured to drive needle carrier assembly
3208, and also insertion element 3274, in the proximal direction
from the distal insertion position to the proximal retraction
position. In some embodiments, first spring and/or second spring
can be preloaded, partially loaded, or unloaded.
[0295] FIG. 32B illustrates an exploded perspective view 3250 of
needle carrier assembly 3208 coupled to insertion element 3274,
second spring 3228, holder 3224 and on-skin sensor assembly
160.
[0296] FIG. 33A-33E illustrate perspective cutaway views of several
features of applicator 3200 of FIGS. 32A-32B, according to some
embodiments. FIG. 33A illustrates a perspective cutaway view of the
entire applicator 3200, including applicator housing 3202,
activation element 3204, first spring 3212, needle carrier assembly
3208 coupled to insertion element 3274, holder 3224 coupled to
on-skin sensor assembly 160, and base 3230. Each of these
components may have functionality as previously described in
connection with at least FIGS. 32A-32B.
[0297] FIG. 33B illustrates a magnified perspective cutaway view of
a retention element 3312 of holder 3224 releasably coupled to
application housing 3202. Retention element 3312 is configured to
prevent holder 3224 from traveling in the distal direction and,
therefore, spring 3212 from unloading. Activation mechanism 3204,
when activated, is configured to deflect retention element 3312
sufficiently to decouple it from applicator housing 3202, thereby
freeing holder 3224 to travel in the distal direction, driven by
spring 3212.
[0298] FIG. 33C illustrates a magnified perspective cutaway view of
a retention element 3342 of needle carrier assembly 3208 configured
to releasably couple needle carrier assembly 3208 to holder 3224.
As shown, retention element 3342 may have a sloped surface
configured to come in contact with a protrusion (not shown in FIG.
33) of the applicator housing 3202 or base 3230 (not shown in FIG.
33) that is configured to deflect retention element 3342
sufficiently to decouple needle carrier assembly 3208 from holder
3224 when needle carrier assembly 3208 is at or near the distal
insertion position.
[0299] FIG. 33D illustrates a perspective view of a plurality of
retention elements 3372a, 3372b of needle carrier assembly 3208
configured to pass through holder 3224 and releasably couple
on-skin sensor assembly 160 to holder 3224 and to needle carrier
assembly 3208. As previously described, at the distal insertion
position, deflected retention element 3342 decouples needle carrier
assembly 3208 from holder 3224, allowing second spring 3228 to
drive needle carrier assembly 3208 in the proximal direction. As
needle carrier assembly 3208 is driven in the proximal direction,
retention elements 3372a, 3372b detach from on-skin sensor assembly
160. Although two retention elements are illustrated, any number of
retention elements are contemplated. In some embodiments, retention
element(s) 3372a, 3372b may comprise snap fits, friction fits,
interference features, elastomeric grips and/or adhesives
configured to couple on-skin sensor assembly 160 with needle
carrier assembly 3208 and/or holder 3224. Moreover, alternative
mechanisms that may perform such retention and release actions are
further described in connection with at least FIGS. 35A-37C
below.
[0300] FIG. 33E illustrates a perspective cutaway view of a
retention element 3346 of holder 3224 and a retention element 3348
of applicator housing 3202 configured to immobilize needle carrier
assembly 3208 to holder 3346 upon needle carrier assembly 3208
reaching the distal insertion position. This interaction
immobilizes insertion element 3274 in the proximal retraction
position, thereby ensuring the end of insertion element 3274 is not
exposed out the bottom of applicator 3200.
[0301] A brief description of the operation of applicator 3200
follows with respect to FIGS. 34A-34F, which illustrate several
perspective views of the applicator of FIG. 32 during operation,
according to some embodiments.
[0302] FIG. 34A illustrates a state of applicator 3200 at
activation. Activation element 3204 is illustrated in the process
of being activated, having been pushed down by a user, for example.
Activation element 3204 deflects retention element 3312 such that
holder 3224 is not prevented from traveling in the distal
direction. Holder 3224, needle carrier assembly 3208, insertion
element 3274, first spring 3212 and second spring 3228 are all
shown in pre-activation positions.
[0303] FIG. 34B illustrates applicator 3200 during activation.
Activation element 3204 is illustrated in the activated position.
Spring 3212 is driving holder 3224, and also needle carrier
assembly 3208, insertion element 3274, and on-skin sensor assembly
160, in the distal direction toward the distal insertion
position.
[0304] FIG. 34C illustrates applicator 3200 during activation, as
needle carrier assembly 3208 approaches the distal insertion
position. Activation element 3204 is illustrated in the activated
position. Insertion assembly 3208, insertion element 3274, holder
3224 and on-skin sensor assembly 160 are driven in the distal
direction to the distal insertion position. At or near this distal
insertion position, at least a portion of insertion element 3274 as
well as at least a portion of sensor 138 of on-skin sensor assembly
160 may be inserted into the skin of the host. At this position,
retention element 3342 is deflected by a portion of applicator
housing 3302 or base 3230, thereby decoupling needle carrier
assembly 3208 from holder 3224.
[0305] FIG. 34D illustrates applicator 3200 during activation.
Activation element 3204 is illustrated in the activated position.
Second spring 3228 drives needle carrier assembly 3208 and
insertion element 3274 in the proximal direction from the distal
insertion position. Although not shown in FIG. 34D, once needle
carrier assembly reaches the proximal retraction position,
retention elements 3346 and 3348 may be engaged with one another
immobilizing needle carrier assembly 3208 and insertion element
3274 in the proximal retraction position, thereby maintaining
insertion element 3274 in a locked, retracted position.
[0306] FIG. 35A-35C illustrate several cross-sectional views of an
on-skin sensor assembly retention mechanism of applicator 3200 of
FIG. 32, according to some embodiments. The retention mechanism
described in connection with FIGS. 35A-35C is similar to the
retention mechanism previously described in connection with FIGS.
6A-61I. FIG. 35A illustrates the retention mechanism while
applicator 3200 is in the pre-activated state. Retention element
3372a is illustrated as a portion of holder 3224 and configured to
releasably couple on-skin sensor assembly 160 to holder 3224 as
needle carrier assembly 3208 travels in the distal direction to the
distal insertion position, and to decouple on-skin sensor assembly
160 from holder 3224 as needle carrier assembly 3208 travels in the
proximal direction from the distal insertion position towards the
proximal retraction position. Specifically, retention element 3372a
may comprise a first end 3376a and a second end 3378a. The second
end may be releasably coupled to on-skin sensor assembly 160 in the
pre-activation state. As previously stated, retention element(s)
3372a, 3372b may comprise snap fits, friction fits, interference
features, elastomeric grips and/or adhesives configured to couple
on-skin sensor assembly 160 with needle carrier assembly 3208
and/or holder 3224. FIG. 35A further illustrates applicator housing
3202 comprising an optional reinforcing element 3510 configured to
prevent lateral motion of retention element 3372a in the proximal
starting position, thereby supporting releasable coupling of second
end 3378a of retention element 3372a with on-skin sensor assembly
160.
[0307] FIG. 35B illustrates applicator 3200 in the distal insertion
position after activation. As needle carrier assembly 3208 travels
in the distal direction to the distal insertion position, retention
element 3342 of needle carrier assembly 3208 is released from
holder 3224. The second end of retention element 3372a may still be
releasably coupled to on-skin sensor assembly 160. FIG. 35B further
illustrates optional reinforcing element 3510 as no longer being in
physical contact with retention element 3372a in the distal
insertion position, thereby allowing for the uncoupling of second
end 3378a of retention element 3372a from on-skin sensor assembly
160.
[0308] FIG. 35C illustrates applicator 3200 where needle carrier
assembly 3208 is moving in the proximal direction from the distal
insertion position. Since retention element 3342 of needle carrier
assembly 3208 was uncoupled from holder 3224 at the distal
insertion position, as needle carrier assembly 3208 travels back in
the proximal direction, needle carrier assembly 3208 separates from
holder 3224. As needle carrier assembly 3208 travels in the
proximal direction, first end 3376a of retention element 3372a is
deflected by needle carrier assembly 3208, thereby decoupling
second end 3378a of retention element 3372a from on-skin sensor
assembly 160. FIG. 35C further illustrates optional reinforcing
element 3510 as no longer being in physical contact with retention
element 3372a in the distal insertion position.
[0309] FIG. 36A-36C illustrate several cross-sectional views of
another on-skin sensor assembly retention mechanism of applicator
3200 of FIG. 32, according to some embodiments. FIG. 36A
illustrates the retention mechanism while applicator 3200 is in the
pre-activated state. Retention element 3372a is illustrated as a
portion of needle carrier assembly 3208 and is configured to
releasably couple on-skin sensor assembly 160 to holder 3224 as
needle carrier assembly 3208 travels in the distal direction to the
distal insertion position, and to decouple on-skin sensor assembly
160 from holder 3224 as needle carrier assembly 3208 travels in the
proximal direction from the distal insertion position towards the
proximal retraction position. Specifically, retention element 3372a
may releasably couple on-skin sensor assembly 160 as needle carrier
assembly 3208 travels in the distal direction to the distal
insertion position. FIG. 36A further illustrates applicator housing
3202 comprising an optional reinforcing element 3610 configured to
prevent lateral motion of retention element 3372a and/or retention
element 3342 in the proximal starting position, thereby supporting
releasable coupling of retention element 3372a with on-skin sensor
assembly 160.
[0310] FIG. 36B illustrates applicator 3200 at the distal insertion
position. Retention element 3342 of needle carrier assembly 3208 is
uncoupled from holder 3224 at the distal insertion position,
retention element 3224 being deflected by a portion of applicator
housing 3202 or an applicator base of applicator housing 3202
sufficient for retention element 3224 to clear a stop element of
needle carrier assembly. Accordingly, needle carrier assembly 3208
separates from holder 3224 as needle carrier assembly 3208 travels
back in the proximal direction by a force provided by spring 3228.
Rather than being physically deflected in orientation as needle
carrier assembly 3208 travels in the proximal direction, retention
element 3372a is formed to be easily deflected or deformed simply
by the separation of holder 3224 from needle carrier assembly 3208.
FIG. 36B further illustrates optional reinforcing element 3610 as
no longer being in physical contact with retention element 3372a
and/or retention element 3342 in the distal insertion position,
thereby allowing for the uncoupling of retention element 3372a from
on-skin sensor assembly 160 and/or the uncoupling of holder 3224
from needle carrier assembly 3208.
[0311] FIG. 36C illustrates needle carrier assembly 3208 moving in
the proximal direction from the distal insertion position of FIG.
36B. As shown, retention element 3372a has been released from
on-skin sensor assembly 160 by separation of needle carrier
assembly 3208 from holder 3224, and needle carrier assembly 3208 is
driven in the proximal direction by a force provided by spring
3228. FIG. 36C further illustrates optional reinforcing element
3610 as no longer being in physical contact with retention element
3372a and/or retention element 3342 in the proximal retracted
position.
[0312] FIG. 37A-37C illustrate several cross-sectional views of yet
another on-skin sensor assembly retention mechanism of applicator
3200 of FIG. 32, according to some embodiments. FIG. 37A
illustrates applicator 3200 in the pre-activated position.
Retention element 3372a is illustrated in FIG. 37A as an integral
portion of holder 3208 and is configured to releasably couple
on-skin sensor assembly 160 to holder 3224 as needle carrier
assembly 3208 travels in the distal direction to the distal
insertion position, and to decouple on-skin sensor assembly 160
from holder 3224 as needle carrier assembly 3208 travels in the
proximal direction from the distal insertion position towards the
proximal retraction position. Specifically, retention element 3372a
may releasably couple on-skin sensor assembly 160 as needle carrier
assembly 3208 travels in the distal direction to the distal
insertion position. FIG. 37A further illustrates applicator housing
3202 comprising an optional first reinforcing element 3710
configured to prevent lateral motion of retention element 3342 in
the proximal retracted position. FIG. 37A further illustrates
needle carrier 3208 comprising an optional second reinforcing
element 3712 configured to prevent lateral motion of retention
element 3372a, thereby supporting releasable coupling of retention
element 3372a with on-skin sensor assembly 160.
[0313] FIG. 37B illustrates needle carrier assembly 3208 in the
distal insertion position. Retention element 3342 of needle carrier
assembly 3208 is uncoupled from holder 3224 at the distal insertion
position. Accordingly, needle carrier assembly 3208 separates from
holder 3224 as needle carrier assembly 3208 travels back in the
proximal direction under influence of a force provided by spring
3228 as spring 3228 unloads, pushing against holder 3224 and needle
carrier assembly 3208. FIG. 37B further illustrates optional first
reinforcing element 3710 as no longer being in physical contact
with retention element 3342 in the distal insertion position,
thereby allowing for the uncoupling of holder 3224 from needle
carrier assembly 3208. Optional second reinforcing element 3712 is
still illustrated as being in physical contact with retention
element 3372a in the distal insertion position.
[0314] FIG. 37C illustrates needle carrier assembly as it begins to
travel in the proximal direction, after retention element 3372a of
needle carrier assembly 3208 is uncoupled from holder 3224. Rather
than being physically deflected in orientation as needle carrier
assembly 3208 travels in the proximal direction, as in FIGS.
35A-35C, retention element 3372a detaches from on-skin sensor
assembly 160 simply by the user removing applicator 3200 from the
skin. In some embodiments, an adhesive patch that holds on-skin
sensor assembly 160 to the skin of the host provides sufficient
bonding strength to decouple on-skin sensor assembly 160 from the
skin of the host when applicator 3200 is removed from the skin.
FIG. 37C further illustrates optional first reinforcing element
3710 as no longer being in physical contact with retention element
3372a in the proximal retracted position, thereby supporting
uncoupling of retention element 3372a from on-skin sensor assembly
160.
[0315] FIG. 38 illustrates a perspective view of an applicator 3800
similar to those shown in FIG. 32, including an activation element
3804 on a side of an applicator housing 3802, according to some
embodiments. Applicator 3800 may have substantially the same
features as either applicator 3200 of FIG. 32, except that
activation element 3804 is located on a side of applicator housing
3802, rather than on a top of the applicator housing. Such an
arrangement may provide for an applicator having a reduced height
compared to top-activated applicators, though potentially having an
increased width or diameter compared to the top-activated
applicators.
[0316] FIG. 39 illustrates a cutaway view of a portion of
applicator 3800 of FIG. 38, according to some embodiments.
Activation element 3804 may be configured to, upon activation,
deflect a retention element 3902 of holder 3824 configured to
prevent holder 3824 from traveling in the distal direction. All
other features of applicator 3800 not discussed may be
substantially as previously described for either applicator 3200 of
FIG. 32.
[0317] FIGS. 40A-40G illustrate several perspective views of an
assembly process for the applicator of FIG. 32, according to some
embodiments. FIG. 40A illustrates inserting second spring 3228 into
holder 3224. FIG. 40B illustrates next inserting insertion element
3274 into needle carrier assembly 3208 and then inserting insertion
element 3274 into needle carrier assembly 3208 into holder 3224. In
some embodiments, inserting insertion element 3274 into needle
carrier assembly 3208 into holder 3224 pre-compresses second spring
3228. FIG. 40C illustrates coupling on-skin sensor assembly 160 to
at least one of holder 3224 and needle carrier assembly 3208 by
coupling retention elements (not shown in FIG. 40C) of holder 3224
or of needle carrier assembly 3208 to attachment points (not shown
in FIG. 40C) of on-skin sensor assembly 160.
[0318] FIG. 40D illustrates coupling activation element 3204 to
applicator housing 3202. In FIG. 40D, activation element 3204 is
coupled on a top of applicator housing 3202. In some embodiments,
activation element 3204 may be pressed into an opening of
applicator housing 3202 configured to receive activation element
3204. However, in other embodiments, applicator housing 3202 may
accommodate activation element 3204 in other locations, for
example, an upper, medial or lower side of applicator housing. FIG.
40E illustrates inserting first spring 3212 into applicator housing
3202. FIG. 40F illustrates inserting the assembly described in FIG.
40C (comprising holder 3224, second spring 3228, needle carrier
assembly 3208, insertion element 3274 and on-skin sensor assembly
160) into applicator housing 3202. In some embodiments, the act of
inserting the assembly described in FIG. 40C pre-compresses first
spring 3212. FIG. 40G illustrates coupling base 3230 to applicator
housing 3202. On-Skin Sensor Assembly Retention Mechanisms
[0319] In some embodiments of applicators described herein, on-skin
sensor assembly 160 is held in place during at least travel in the
distal direction to the distal insertion position. In some such
embodiments, on-skin sensor assembly 160 is then released or
decoupled from a portion of the applicator during application to
the skin of the host so that a needle carrier assembly and
insertion element may travel back in the proximal direction. FIGS.
41A-45 illustrate several alternative retention mechanisms that may
be utilized in any of the applicators described herein.
[0320] FIGS. 41A-41B illustrate an exemplary on-skin sensor
assembly retention mechanism of an applicator for an analyte sensor
system, according to some embodiments. The retention mechanism
illustrated by FIGS. 41A-41B may be considered a first on-skin
sensor assembly retention configuration, and is similar to the
retention mechanism previously described in connection with FIG.
5.
[0321] FIG. 41A illustrates a retention mechanism in a state where
on-skin sensor assembly 160 is retained, while FIG. 41B illustrates
the retention mechanism in a state where on-skin sensor assembly
160 is decoupled.
[0322] FIG. 41A illustrates retention elements 4172a, 4172b of a
holder 4124 configured to releasably couple on-skin sensor assembly
160 to holder 4124 as needle carrier assembly 4108 (and so
insertion element 4172, holder 4124, and on-skin sensor assembly
160) travels in the distal direction to the distal insertion
position. Specifically, retention elements 4172a, 4172b may each
comprise a first end 4176a, 4176b, a second end 4178a, 4178b, and a
pivot point 4180a, 4180b. First end 4176a, 4176b is immobilized in
a respective guide 4174a, 4174b of needle carrier assembly 4108 and
each of retention elements 4172a, 4172b is immobilized against
interference points 4182a, 4182b of needle carrier assembly 4108,
thereby releasably coupling and immobilizing second end 4178a,
4178b to attachment points 4162a, 4162b of on-skin sensor assembly
160 as needle carrier assembly 4108 travels in the distal direction
to the distal insertion position. In some embodiments, the profile
of slots 4174a, 4174b may be such that the sides of slots 4174a,
4174b exert a force on first ends 4176a, 4176b of retention
elements 4172a, 4172b sufficient to hold second ends 4178a, 4178b
of retention elements 4172a, 4172b in engagement with attachment
points 4162a, 4162b of on-skin sensor assembly 160. Although two
retention elements are illustrated, any number of retention
elements are contemplated.
[0323] FIG. 41B illustrates the retention mechanism as needle
carrier assembly 4108 and insertion element 4174 travel in the
proximal direction from the distal insertion position to the
proximal retraction position. As needle carrier assembly 4108
travels back in the proximal direction, needle carrier assembly
4108 separates from holder 4124, thereby removing first ends 4176a,
4176b of retention elements 4172a, 4172b from respective slots
4174a, 4174b, allowing first ends 4176a, 4176b to deflect inward
and second ends 4178a, 4178b of retention elements 4172a, 4172b to
deflect outward from attachment points 4162a, 4162b of on-skin
sensor assembly 160 as retention elements 4172a, 4172b rotate about
pivot points 4180a, 4180b.
[0324] FIGS. 42A-42B illustrate an exemplary on-skin sensor
assembly retention mechanism of an applicator for an analyte sensor
system, according to some embodiments. The retention mechanism
illustrated by FIGS. 42A-42B may be considered a second on-skin
sensor assembly retention configuration, and is similar to the
retention mechanism previously described in connection with FIG.
36. FIG. 42A illustrates a retention mechanism in a state where
on-skin sensor assembly 160 is retained, while FIG. 42B illustrates
the retention mechanism in a state where on-skin sensor assembly
160 is decoupled.
[0325] FIG. 42A illustrates retention elements 4272a, 4272b as
portions of needle carrier assembly 4208 that pass through or
around needle carrier assembly 4208, rather than as portions of
holder 4224. Retention elements 4272a, 4272b are configured to
releasably couple on-skin sensor assembly 160 to holder 4228 as
needle carrier assembly 4208 (and so an insertion element, holder
4224, and on-skin sensor assembly 4224) travels in the distal
direction to the distal insertion position.
[0326] FIG. 42B illustrates the retention mechanism as needle
carrier assembly 4208 and insertion element 4274 travel in the
proximal direction from the distal insertion position to the
proximal retraction position. As needle carrier assembly 4208
travels in the proximal direction, needle carrier assembly 2508
separates from holder 4224 and retention elements 4272a, 4272b are
uncoupled from respective attachment points 4262a, 4262b of on-skin
sensor assembly 160. Rather than being physically deflected in
orientation as needle carrier assembly 4208 travels in the proximal
direction, as described for retention elements 4172a, 4172b of
FIGS. 41A-41B, retention elements 4272a, 4272b are pulled out of
attachment points 4262a, 4262b by the energy of the retraction.
[0327] FIGS. 43A-43B illustrate an exemplary on-skin sensor
assembly retention mechanism of an applicator for an analyte sensor
system, according to some embodiments. The retention mechanism
illustrated by FIGS. 43A-43B may be considered a passive snap
design. FIG. 43A illustrates a retention mechanism in a state where
on-skin sensor assembly 160 is retained, while FIG. 43B illustrates
the retention mechanism in a state where on-skin sensor assembly
160 is decoupled.
[0328] FIG. 43A illustrates retention elements 4372a, 4372b as
portions of a holder 4324. Retention elements 4372a, 4372b are
configured to releasably couple on-skin sensor assembly 160 to
holder 4324 as needle carrier assembly 4308 (and so an insertion
element, holder 4324, and on-skin sensor assembly 4324) travels in
the distal direction to the distal insertion position. FIG. 43A
further illustrates protrusions 4380a, 4380b of needle carrier
assembly 4308 configured to physically contact retention elements
4372a, 4372b of holder 4324 thereby preventing retention elements
4372a, 4372b from disengaging from on-skin sensor assembly 4324
while needle carrier assembly 4308 is in contact with holder
4324.
[0329] FIG. 43B illustrates the retention mechanism as needle
carrier assembly 4308 travels in the proximal direction from the
distal insertion position to the proximal retraction position. As
needle carrier assembly 4308 travels in the proximal direction,
needle carrier assembly 4308 separates from holder 4324. Although
not shown in FIGS. 43A-43B, holder 4324 may be immobilized to an
applicator housing or base by one or more retention elements,
similar to retention elements 642, 644 of FIG. 6E. Accordingly,
retention elements 4372a, 4372b may be uncoupled from respective
attachment points 4362a, 4362b of on-skin sensor assembly 160 as
the applicator is removed from the skin of the host. In some
embodiments, an adhesive patch that holds on-skin sensor assembly
160 to the skin of the host provides sufficient bonding strength to
decouple on-skin sensor assembly 160 from the skin of the host when
the applicator is removed from the skin.
[0330] FIG. 44 illustrates another portion of an exemplary on-skin
sensor assembly retention mechanism of an applicator for an analyte
sensor system, according to some embodiments. FIG. 44 illustrates a
needle carrier assembly 4408, a holder 4424, and on-skin sensor
assembly 160. Contrary to several previous embodiments of retention
mechanisms for on-skin sensor assembly 160, needle carrier assembly
4408 comprises at least one retention element 4472a and holder 4424
comprises at least one alignment element 4473 a, in which retention
element 4472a is configured to releasably couple to on-skin sensor
assembly 160, and alignment element 4473a is configured to align
on-skin sensor assembly 160 within the applicator. This
distribution of retention elements between both a needle carrier
assembly and a holder may be implemented for any on-skin sensor
assembly retention mechanism described herein.
[0331] FIGS. 45 and 46 illustrate portions of exemplary on-skin
sensor assembly retention mechanisms of an applicator for an
analyte sensor system, according to some embodiments. FIGS. 45 and
46 illustrate a needle carrier assembly 4508, 4608, a rotating
drive element 4514, 4614 similar to that previously described in
connection with FIG. 5, and on-skin sensor assembly 160.
Accordingly, the retention mechanisms of FIGS. 45 and 46 may
function similarly to that described in FIG. 5. Rotating drive
element 4514, 4614 may be a wheel cam and may comprise a cam lobe
4518 (e.g., a ramp or protrusion, not shown in FIG. 46, see FIG.
45) disposed along at least a portion of a circumference of
rotating drive element 4514, 4614. In FIG. 45, as rotating drive
element 4514 is rotated, protrusion 4518 may travel alongside
needle carrier assembly 4508 and come into contact with and
increasingly apply a force to on-skin sensor assembly 160 such that
on-skin sensor assembly 160 decouples from needle carrier assembly
4508. In FIG. 46, as rotating drive element 4614 is rotated, the
protrusion may travel at least partially through a guide or slot
4620 in needle carrier assembly 4608 and come into contact with and
increasingly apply a force to on-skin sensor assembly 160 such that
on-skin sensor assembly 160 decouples from needle carrier assembly
4608. In this way, rotating drive element 4514, 4614 may serve both
to drive needle carrier assembly 4508, 4608 in the distal and
proximal directions, as previously described in connection with
FIG. 5, and to release on-skin sensor assembly 160 upon deposition
to the skin of the host.
[0332] In some embodiments, on-skin sensor assembly retention
mechanisms may incorporate features to couple an on-skin sensor
assembly to the needle carrier assembly and/or the holder. Methods
of coupling on-skin sensor assembly are described in U.S. Patent
Application No. 15/387088, which is incorporated herein by
reference it its entirety. For non-limiting example, on-skin sensor
assembly retention mechanisms may include a frangible release (e.g.
FIGS. 137-140), a frangible elastomer (e.g. FIGS. 134-136), a
releasable adhesive (e.g. FIG. 123-125), or a releasable
friction-fit coupling (e.g. FIG. 126-133).
[0333] For example, a frangible release can be implemented in the
current embodiments by a structure attached between an on-skin
sensor assembly (e.g. 160), a holder (e.g. 524), a needle carrier
(e.g. 508), and/or an applicator housing (e.g. 502). The frangible
component may include features such has a weakened portion or a
portion designated to fracture during release of the on-skin sensor
assembly from the applicator. Frangible components configured to
fracture may include patch material (e.g. spun lace) or molded
components (e.g. ABS, PC, polymer, elastomeric polymer, etc.).
[0334] For example, a releasable adhesive can be implemented in the
current embodiments by a releasable adhesive releasably attached
between an on-skin sensor assembly (e.g. 160), a holder (e.g. 524),
a needle carrier (e.g. 508), and/or an applicator housing (e.g.
502). The releasable adhesive may consist of a double sided
adhesive tape, a glue, or a hot melt polymer. The releasable
adhesive is configured to detach during release of the on-skin
sensor assembly from the applicator via an applicator mechanism
(e.g. retraction mechanism) or user force.
[0335] For example, a releasable friction-fit coupling can be
implemented in the current embodiments by a surface contact between
an on-skin sensor assembly (e.g. 160), a holder (e.g. 524), a
needle carrier (e.g. 508), and/or an applicator housing (e.g. 502).
The releasable friction-fit coupling may consist of a rigid or
elastomeric material (e.g. silicone, TPE, TPU, rubber, etc.) or a
combination thereof. The coupled components (e.g. on-skin sensor
assembly 160 and holder 524) have a frictional material interaction
(e.g. interference fit, deformable fit, etc.). The releasable
friction-fit coupling is configured to detach during release of the
on-skin sensor assembly from the applicator via an applicator
mechanism (e.g. retraction mechanism) or user force.
[0336] Discussion with respect to FIGS. 71-89 below may be directed
to, among other aspects, applicators that account for skin tenting
(e.g., the skin bowing in a substantially convex fashion as the
host pushes the applicator against the skin). FIGS. 71-89 may be
further directed to preventing an insertion mechanism, assembly or
spring from stalling due to such skin tenting by, among other
aspects, initiating retraction, after insertion, based on an
on-skin sensor assembly and/or other features of the applicator
pushing against the skin of the host with a force sufficient to
initiate the retraction, as opposed to retraction being triggered
by the on-skin sensor assembly and/or other features of the
applicators reaching a predetermined physical displacement in the
distal direction. It is contemplated that such force-based
retraction trigger allows the transition from insertion to
retraction at a variety of distally displaced positions based at
least in part on the location of the surface of the skin of the
host during application.
[0337] FIG. 71 illustrates an applicator 7100 for an on-skin sensor
assembly of an analyte sensor system, according to some
embodiments. As will be described below, applicator 7100 may
comprise an activation element 7104 disposed on a side of
applicator 7100, for example, on a side of an outer housing 7101 of
applicator 7100. In some embodiments, activation element 7104 may
be a button, a switch, a toggle, a slide, a trigger, a knob, a
rotating member, a portion of applicator 7100 that deforms and/or
flexes or any other suitable mechanism for activating an insertion
and/or retraction assembly of applicator 7100. In some embodiments,
activation element 7104 may be disposed in any location, e.g., a
top, upper side, lower side, or any other location of applicator
7100. Applicator 7100 may be large enough for a host to grasp with
a hand and push, or otherwise activate, activation element 7104
with, for example, a thumb, or with an index finger and/or a middle
finger.
[0338] Applicator 7100 may be configured with one or more safety
features such that applicator 7100 is prevented from activating
until the safety feature is deactivated. In one example, the one or
more safety features prevents applicator 7100 from activating
unless applicator 7100 is pressed against the skin of a host with
sufficient force. Moreover, as will be described in more detail in
connection with one or more of FIGS. 72-80B below, applicator 7100
may be further configured such that one or more components therein
retract based at least in part on the one or more components
pushing against the skin of the host with a force exceeding a
predetermined threshold, rather than based on the one or more
components translating beyond a predetermined and static distal
position. In other words, applicator 7100 may implement force-based
retraction triggering rather than being limited to
displacement-based retraction triggering.
[0339] FIG. 72 illustrates an exploded perspective view of
applicator 7100 of FIG. 71, according to some embodiments.
Applicator 7100 may include outer applicator housing 7101
comprising activation element 7104. Outer applicator housing 7101
may be configured to translate in a distal direction by a force
applied by a host to applicator 7100, specifically to inner housing
7102, thereby aligning activation element 7104 in a position that
allows applicator 7100 to fire. Further explanation of the
alignment process will be explained below.
[0340] Applicator 7100 further comprises inner housing 7102,
configured to house at least one or more mechanisms utilized to
apply on-skin sensor assembly 360 to skin 130 of a host. A distal
surface 7130 of a bottom opening of inner housing 7102 may define a
bottom surface of applicator 7100. In some embodiments, upon
pressing applicator 7100 against skin 130 of the host, skin 130 may
deform in a substantially convex shape at distal surface 7130 such
that at least a portion of a surface of skin 130 disposed at the
bottom opening of applicator housing 7102 extends into the bottom
opening of inner housing 7102 beyond a plane defined by distal
surface 7130 in a proximal direction.
[0341] In some embodiments, a first barrier layer 7192 may be
disposed over one or more apertures in inner housing 7102, for
example, an aperture 7106 through which at least a portion of
activation element 7104 may be configured to extend through during
activation of applicator 7100. In such embodiments, a portion of
activation element 7104 may be configured to pierce or deform first
barrier layer 7192 upon activation of applicator 7100. First
barrier layer 7192 may comprise a gas permeable material such as
Tyvek, or a non-gas permeable material such as metallic foil,
polymer film, elastomer, or any other suitable material.
[0342] Applicator 7100 may further comprise a needle carrier
assembly 7108, including a needle hub 7150 configured to couple an
insertion element 7174 to needle carrier assembly 7108. In some
other embodiments, insertion element 7174 may be directly coupled
to needle carrier assembly 7108. Insertion element 7174 is
configured to insert sensor 338 of on-skin sensor assembly 360 (see
FIGS. 3A-4) into skin 130 of the host (e.g., FIG. 1). In some
embodiments, the insertion element comprises a needle, for example,
an open sided-needle, a needle with a deflected-tip, a curved
needle, a polymer-coated needle, a hypodermic needle, or any other
suitable type of needle or structure, as described in connection
with at least FIGS. 47-50 and 80A-B. In yet other embodiments,
insertion element 7174 may be integrally formed with sensor 338 and
may be sufficiently rigid to be inserted partially into skin 130 of
the host with minimal or no structural support.
[0343] Applicator 7100 may further include a holder 7124 releasably
coupled to needle carrier assembly 7108 and configured to guide
needle carrier assembly 7108 and on-skin sensor assembly 360 while
coupled to needle carrier assembly 7108, e.g., at least during
translation from a proximal position to a distal insertion
position. As will be described in more detail below, on-skin sensor
assembly 360 may be stripped or released from holder 7124 and/or
needle carrier assembly 7108 once on-skin sensor assembly 360 is
disposed on skin 130 of the host.
[0344] Applicator 7100 may further comprise an insertion assembly
configured to translate insertion element 7174, needle hub 7150,
needle carrier assembly 7108, and on-skin sensor assembly 360 from
a proximal position, in the distal direction, to a distal insertion
position. Such an insertion assembly may include a first spring
7112. First spring 7112 may be a compression spring, or any
suitable type of spring, and may have a first end in contact with
or coupled to inner applicator housing 7102 and a second end in
contact with or coupled to holder 7124. First spring 7112 is
configured to, upon activation of the insertion assembly, translate
holder 7124, needle carrier assembly 7108, needle hub 7150,
insertion element 7174 and on-skin sensor assembly 360, in the
distal direction to the distal insertion position. Substantially at
the distal insertion position, needle carrier assembly 7108 may
decouple from holder 7124 and on-skin sensor assembly 360.
[0345] Applicator 7100 may further comprise a retraction assembly
configured to translate needle carrier assembly 7108, needle hub
7150 and insertion element 7174, in the proximal direction, from
the distal insertion position to a proximal retracted position. In
some embodiments the initial proximal position may be the same as
the proximal retracted position. In other embodiments, the initial
proximal position may be different from the proximal retracted
position. Such a retraction assembly may include a second spring
7128. Second spring 7128 may be a compression spring, or any
suitable type of spring, and may have a first end contacting or
coupled to holder 7124 and a second end in contact with or coupled
to at least one spring retention element (e.g., 7442a, 7442b in
FIGS. 74A-75B), at least until retraction. Second spring 7128 is
configured to translate needle carrier assembly 7108, needle hub
7150, and insertion element 7174 in the proximal direction from the
distal insertion position to the proximal retracted position in
response to on-skin sensor assembly 360 contacting skin 130 of the
host, and/or reaching a limit of travel with a force exceeding a
predetermined threshold sufficient to cause first end of second
spring 7128 to overcome the at least one spring retention element
(e.g., 7442a, 7442b in FIGS. 74A-75B). In some embodiments, a stop
feature (not shown) may be disposed at a bottom of applicator 7100,
e.g., on a distal portion of inner housing 7102. Such a stop
feature may be configured to contact one or more of on-skin sensor
assembly 360, needle carrier 7108, or holder 7124 in the distal
insertion position.
[0346] In some embodiments, transfer of on-skin sensor assembly 360
between insertion and retraction may occur as previously described
in connection with, for example, any of FIGS. 35A-37C.
[0347] In some embodiments, a second barrier layer 7194 may be
disposed over the bottom opening of inner housing 7102. Second
barrier layer 7194 may comprise a gas permeable material such as
Tyvek, or a non-gas permeable material such as metallic foil, film.
In some embodiments, second barrier layer 7194 may be removed by
the host prior to use of applicator 7100. In embodiments comprising
one or both of first and second barrier layers 7192, 7194, such
layers may provide a sterile environment between applicator 7100
and the outside environment and/or may allow ingress and egress of
gas such as during sterilization.
[0348] Although not shown in FIGS. 71-72, in some embodiments,
applicator 7100 may comprise a cap configured to be secured to
distal surface 7130 of inner housing 7102 and that may be removed
before use. In some embodiments, such a cap may also function as a
sterile barrier, as previously described in U.S. patent application
Ser. No. 16/011527, hereby incorporated by reference in its
entirety.
[0349] A brief description of some aspects of the operation of
applicator 7100 follows with respect to FIGS. 73A-73C, which
illustrate several cross-sectional views of applicator 7100 of
FIGS. 71 and 72 during operation, according to some embodiments.
FIGS. 73A-73C may correspond to applicator 7100 cut along the
section line A-A' shown in FIG. 71, for example.
[0350] FIG. 73A illustrates a state of applicator 7100 prior to
activation. Holder 7124 comprises an insertion assembly retention
element 7332 configured to contact inner housing 7102, thereby
immobilizing holder 7124, needle carrier assembly 7108, needle hub
7150, insertion element 7174 and on-skin sensor assembly 360, in
the pre-activated state.
[0351] Needle carrier assembly 7108 comprises a plurality of
wearable retention and/or alignment elements 7372a, 7372b
configured to extend through holder 7124 and releasably couple
on-skin sensor assembly 360 to holder 7124 and/or to needle carrier
assembly 7108. Wearable retention elements 7372a, 7372b may
comprise, e.g., arms, deflection element, tabs, detents, snaps or
any other features capable of a retaining function. In some
embodiments, wearable retention elements 7372a, 7372b may extend
around rather than through holder 7124. Although two wearable
retention elements are illustrated, any number of wearable
retention elements are contemplated. In some embodiments, wearable
retention element(s) 7372a, 7372b may comprise snap fits, friction
fits, interference features, elastomeric grips and/or adhesives
configured to couple on-skin sensor assembly 360 with needle
carrier assembly 7108 and/or holder 7124.
[0352] Inner housing 7102 may comprise a spring 7320 configured to
contact outer housing 7101 and maintain a predetermined spacing
between outer housing 7101 and inner housing 7102 in the
pre-activation orientation of FIG. 73A. Spring 7320 may be a
compression spring, leaf spring, flex arm spring, a piece of foam
or rubber, etc. In some other embodiments, outer housing 7101 may
comprise spring 7320 and spring 7320 may be configured to contact
inner housing 7102, in a reverse fashion from that shown in FIG.
73A.
[0353] Activation of applicator 7100 may include a host pressing
applicator 7100 against their skin with sufficient force to
translate outer housing 7101 in a distal direction, as shown by
arrow 7302, toward and with respect to inner housing 7102 until
activation element 7104 is aligned with aperture 7106 of inner
housing 7102 and insertion assembly retention element 7332 of
holder 7124. Insertion assembly retention element 7332 may
comprise, e.g., an arm, a deflection element, a tab, a detent, a
snap or any other feature capable of a retaining function. Once
such an alignment is achieved, a host may initiate (e.g. pushing)
activation element 7104, as shown by arrow 7304, thereby deflecting
insertion assembly retention element 7332 sufficiently to release
holder 7124 from inner housing 7102. In some other embodiments,
applicator 7100 may be configured such that activation element 7104
may be activated first, but that actual insertion is not triggered
until outer housing 7101 is translated sufficiently in the distal
direction toward and with respect to inner housing 7102. In yet
other embodiments, activation element 7104 may be biased toward a
center of applicator 7100 such that activation element 7104 need
not be explicitly activated by the host but, instead, activation
element 7104 may be configured to automatically initiate insertion
upon outer housing 7101 being translated sufficiently in the distal
direction toward and with respect to inner housing 7102.
[0354] Such configurations provide several benefits. First,
translation of outer housing 7101 with respect to inner housing
7102 before activation provides a measure of drop protection such
that if applicator 7100 is accidentally dropped, it may not
prematurely fire. Second, spring 7320 provides a force bias that
the host has to affirmatively overcome by pressing applicator 7100
into their skin prior to firing, thereby reducing the probability
of activating applicator 7100 before it is properly positioned.
Further, the host may decide to not fire applicator 7100 and
discontinue pressing applicator 7100 against their skin, in which
spring 7320 will bias against outer housing 7101 and allow outer
housing 7101 to return to its initial state.
[0355] Holder 7124, needle carrier assembly 7108, needle hub 7150,
insertion element 7174, on-skin sensor assembly 360, first spring
7112 and second spring 7128 are all shown in pre-activation
positions in FIG. 73A.
[0356] FIG. 73B illustrates applicator 7100 during insertion of
on-skin sensor assembly 360 but before retraction of needle carrier
assembly 7108. First spring 7112 drives holder 7124, needle carrier
assembly 7108, needle hub 7150, insertion element 7174, and on-skin
sensor assembly 360, in the distal direction toward the distal
insertion position. FIG. 73B illustrates a position where on-skin
sensor assembly 360 is in contact with skin 130 of the host but
where holder 7124 is not yet fully driven, by first spring 7112,
into contact with on-skin sensor assembly 360 or skin 130 of the
host.
[0357] In some embodiments, masses of each of holder 7124, needle
carrier assembly 7108, needle hub 7150, insertion element 7174, and
on-skin sensor assembly 360 may be specifically designed to reduce
or substantially eliminate a tendency of needle carrier assembly
7108, needle hub 7150, insertion element 7174, and on-skin sensor
assembly 360 to detach due to inertial forces from holder 7124
while being driven in the distal direction during insertion. In
some embodiments, a force exerted by first spring 7112 may be
selected to be sufficient for proper operation of applicator 7100,
while not so large as to further exacerbate such above-described
inertially triggered detachment. In some embodiments, a spring (not
shown) may be configured to exert a force against a portion of
needle carrier assembly 7108, for example in a distal direction,
sufficient to prevent needle carrier assembly 7108 from inertially
triggered detaching from holder 7124 during insertion.
[0358] FIG. 73C illustrates applicator 7100 during activation, as
needle carrier assembly 7108, needle hub 7150 and insertion element
7174 are retracted in the proximal direction by second spring 7128.
In FIG. 73C, first spring 7112 has fully driven on-skin sensor
assembly 360 to the skin of the host. In this position, second
spring 7128 is released from spring retention elements (e.g.,
7442a, 7442b in FIGS. 74A-75B) and drives needle carrier assembly
7108, needle hub 7150, and insertion element 7174 in the proximal
direction from the distal insertion position. Upon needle carrier
assembly 7108 reaching the proximal retraction position, needle
carrier retention element 7334 of holder 7124 engages with needle
carrier assembly 7108, thereby maintaining needle carrier assembly
7108, needle hub 7150 and insertion element 7174 in a locked,
retracted position limiting access to insertion element 7174.
Needle carrier retention element 7334 may comprise, e.g., an arm, a
deflection element, a tab, a detent, a snap or any other feature
capable of a retaining function. In this retracted position, needle
carrier assembly 7108, needle hub 7150, and insertion element 7174
is prevented from travelling in a distal direction.
[0359] A further description of some aspects of the operation of
applicator 7100 follows with respect to FIGS. 74A-74C, which
illustrate several cross-sectional views of applicator 7100 of
FIGS. 71 and 72 during operation, according to some embodiments.
FIGS. 74A-74C may correspond to applicator 7100 cut along the
section line B-B' shown in FIG. 71, for example. For ease of
illustration, needle hub 7150 and insertion element 7174 are not
shown in FIGS. 74A-74C.
[0360] FIG. 74A illustrates a state of applicator 7100 prior to
activation. For ease of illustration, on-skin sensor assembly 360
is not illustrated in FIG. 74A. Holder 7124 comprises spring
retention elements 7442a, 7442b configured to contact and retain a
first end of second spring 7128 in the pre-activated state, e.g.,
during insertion, while a second end of spring 7128 is in contact
with needle carrier assembly 7108. Spring retention elements 7442a,
7442b may comprise, e.g., arms, deflection element, tabs, detents,
snaps or any other features capable of a retaining function.
Although two spring retention elements 7442a, 7442b are shown, at
least one spring retention element is contemplated. In some
embodiments, applicator 7100 may include one spring retention
element, as shown in FIGS. 81A-81D. In some embodiments, applicator
7100 may include three spring retention elements. In some
embodiments, applicator 7100 may include four spring retention
elements. In some embodiments, spring retention elements 7442a,
7442b are deflectable arms, rigid arms, deformable features, snaps,
catches, or hooks. In some embodiments, spring retention elements
7442a, 7442b may be actively deflected by one or more features
within applicator 7100.
[0361] Needle carrier assembly 7108 comprises backstop features
7444a, 7444b, configured to prevent lateral deflection of spring
retention elements 7442a, 7442b in the proximal starting position,
e.g., at least during insertion, thereby supporting retention of
second spring 7128 between spring retention elements 7442a, 7442b
and holder 7124 until retraction. Although two backstop features
are illustrated, any number of backstop features are contemplated.
The number of backstop features may equal the number of spring
retention elements.
[0362] FIG. 75A illustrates a magnified view of spring retention
element 7442b and backstop feature 7444b. In FIG. 75A, first spring
7112 is driving holder 7124, needle carrier assembly 7108 and
on-skin sensor assembly 360, in the distal direction toward the
distal inserted position. Backstop feature 7444b is shown engaged
to spring retention element 7442b, preventing spring retention
element 7442b from deflecting laterally, thereby preventing second
spring 7128 from releasing. As shown in FIG. 75A, a proximal end of
spring retention element 7442b may be offset from a distal end of
backstop feature 7444b by a distance a. In some embodiments,
distance a is the length required for spring retention element
7442b to traverse along backstop feature 7444b such that spring
retention element 7442b clears past backstop feature 7444b.
Backstop feature 7444b may feature a ramp to guide spring retention
element 7442b. A distal end of needle carrier assembly 7108 and a
distal end of holder 7124 may be offset from each other at least
the same distance a to allow for spring retention element 7442b to
traverse distally past backstop feature 7444b.
[0363] It may be appreciated that the frictional force between
corresponding contacting surfaces of backstop feature 7444b and
spring retention element 7442b may at least partly determine an
amount of force to release spring retention element 7442b from
backstop feature 7444b. This force may allow for lateral deflection
of spring retention element 7442b and thus allow the expansion of
second spring 7128. In some embodiments, the amount of force is at
least 0.1 pounds. In some embodiments, the amount of force is at
least 0.5 pounds. In some embodiments, the amount of force is at
least 1 pound. In some embodiments, the amount of force is at least
2 pounds. In some embodiments, the amount of force is at least 3
pounds. In some embodiments, the amount of force is at least 4
pounds. In some embodiments, the amount of force is at least 5
pounds.
[0364] Although the figure shows backstop feature 7444b preventing
lateral deflection of spring retention element 7442b in a radially
outward direction, it is contemplated that an inverse structural
relationship can be achieved. For instance, the ramped surface of
spring retention element 7442b can be reversed to face the opposite
direction as shown in FIG. 75A. Further, the ramped surface of
spring retention element 7442b may be biased in a radially inward
direction by second spring 7128 against backstop feature 7444b. In
such embodiments, backstop feature 7444b may be located radially
inward of spring retention element 7442b.
[0365] Accordingly, in some embodiments, materials utilized to form
holder 7124 and needle carrier assembly 7108 may be selected based
on a desired amount of force to release spring retention element
7442b for lateral deflection. Examples of such materials may
include Polycarbonate, ABS, PC/ABS, Polypropylene, HIPS (High
impact polystyrene), Polybutylene Terephthalate (PBT),
Polyoxymethylene (POM), Acetal, polyacetal, polyformaldehyde, PTFE,
High density polyethylene (HDPE), Nylon, Polyethylene terephthalate
(PET), Thermoplastic elastomer (TPE), Thermoplastic polyurethane
(TPU), TPSiv, Cyclo olefin polymer (COP), Cyclo olefin copolymer
(COC), and/or Liquid-crystal polymer (LCP).
[0366] An angle .theta. of a portion of spring retention element
7442b in contact with second spring 7128 may also affect the amount
of frictional force to laterally deflect spring retention element
7442b and so to release second spring 7128. Accordingly, the angle
.theta. may be selected based on a desired amount of force to
laterally deflect spring retention element 7442b sufficiently to
release second spring 7128. In some embodiments, the angle .theta.
is at least 1 degree with respect to a vertical axis of the spring
retention element 7442b. In some embodiments, the angle .theta. is
at least 5 degrees. In some embodiments, the angle .theta. is at
least 10 degrees. In some embodiments, the angle .theta. is at
least 15 degrees. In some embodiments, the angle .theta. is at
least 20 degrees. In some embodiments, the angle .theta. is about
30 to 45 degrees. In addition, the force profile of second spring
7128 may affect a target amount of frictional force to laterally
deflect spring retention element 7442b. Accordingly, in some
embodiments, the force profile of second spring 7128 may be taken
into account when selecting one or both of the materials for
forming holder 7124 and needle carrier assembly 7108 and the angle
.theta. of the portion of spring retention element 7442b in contact
with second spring 7128.
[0367] An angle B of spring retention element 7442b with respect to
a vertical axis may also affect the amount of frictional force to
laterally deflect spring retention element 7442b and so to release
second spring 7128. By contacting spring retention element 7442b,
second spring 7128 may exert a force on spring retention element
7442b at a distance d from a bottom of spring retention element
7442b that causes a torque moment sufficient to induce a lateral
deflection of spring retention element 7442b.
[0368] FIG. 75A further illustrates needle carrier assembly 7108
comprising a deflecting element 7522 configured to contact spring
retention element 7442b and maintain spring retention element 7442b
in a laterally deflected orientation once second spring 7128 has
initially deflected spring retention element 7442b and sufficiently
driven needle carrier assembly 7108 in the proximal direction, as
will be shown in more detail in FIG. 75B. Deflecting element 7522
may prevent spring retention element 7442b from contacting the
windings of second spring 7128 while second spring 7128 is
extending, smoothing the operation of applicator 7100 and
preventing energy released by second spring 7128 and designed for
driving needle carrier assembly 7128 in the proximal direction from
being absorbed by undesired contact with spring retention element
7442b during the release of second spring 7128.
[0369] In some embodiments, the angle .theta. of the portion of
spring retention element 7442b in contact with second spring 7128
may be substantially 90.degree. (e.g., flat) and deflecting element
7522 may have a ramped or angled surface in contact with spring
retention element 7442b in the position illustrated in FIG. 75A. In
such embodiments, deflecting element 7522, in addition to the
above-described functionality, may be configured to initially
deflect spring retention element 7442b as first spring 7112 drives
holder 7124 from the position illustrated in FIG. 75A to the
position illustrated in FIG. 75B.
[0370] In some embodiments, inner housing 7102 may comprise a
protrusion 7546 extending from inner housing 7102 in the distal
direction. Protrusion 7546 may be configured to contact at least
one of spring retention elements 7442a, 7442b and backstop features
7444a, 7444b in the pre-activation state such that spring retention
elements 7442a, 7442b are prevented from laterally deflecting until
holder 7124 and needle carrier assembly 7108 have translated at
least a predetermined minimum distance in the distal direction.
Accordingly, protrusion 7546 may provide a measure of drop
protection such that applicator 7100 may not prematurely fire in
response to a concussive shock from being dropped before
intentional activation.
[0371] Turning back to FIG. 74A, inner housing 7102 may further
comprise an engagement element 7448 configured to engage with a
protrusion 7449 of needle carrier assembly 7108 upon needle carrier
assembly 7108 translating in the distal direction beyond a
predetermined threshold, thereby preventing needle carrier assembly
7108 from translating in the distal direction beyond the
predetermined threshold. It is contemplated that this may ensure
needle carrier assembly retraction in the event of an air firing or
dry firing in which applicator 7100 is somehow activated when not
held against the skin of the host. In some embodiments, the
predetermined threshold may correspond to the distal end of needle
carrier assembly 7108 extending beyond a point proximal to the
distal end of inner housing 7102, to a point substantially in line
with the distal end of inner housing 7102 or to a point distal of
the distal end of inner housing 7102. In some embodiments,
engagement element 7448 comprises a hook, a U-shaped structure, a
loop, a protrusion, or any other structure capable of engaging with
protrusion 7449 as described above.
[0372] FIG. 74B illustrates applicator 7100 after activation, at a
beginning of a force retraction feature process at or near the
distal insertion position where on-skin sensor assembly 360 may be
in contact with the skin of the host. First spring 7112 has driven
holder 7124, needle carrier assembly 7108, needle hub 7150,
insertion element, and on-skin sensor assembly 360, in the distal
direction toward the distal insertion position. During proper
operation, holder 7124 and on-skin sensor assembly 360 should be
pressing against the skin of the host. However, FIG. 74B may also
illustrate a dry fire condition, where applicator 7100 is not
properly pressed against the skin of the host before triggering
applicator 7100. Accordingly, upon first spring 7112 driving holder
7124 and needle carrier assembly 7108 in the distal direction
beyond the predetermined threshold, engagement element 7448
contacts protrusion 7449, which prevents needle carrier assembly
7108 from traveling further in the distal direction, while holder
7124 is driven sufficiently further in the distal direction such
that backstop features 7444a, 7444b of needle carrier assembly 7108
no longer contact spring retention elements 7442a, 7442b in the
distal insertion position, thereby releasing the first end of
second spring 7128 and initiating retraction even when applicator
7100 is dry fired. The insertion force provided by first spring
7112 may be sufficient to additionally overcome the frictional
force between corresponding contacting surfaces of backstop feature
7444b and spring retention element 7442b.
[0373] Turning to FIG. 75B, first spring 7112 has driven holder
7124, needle carrier assembly 7108 and on-skin sensor assembly 360
in the distal direction to the skin of the host. As first spring
7112 drives holder 7124, needle carrier assembly 7108 and on-skin
sensor assembly 360 against the skin of the host, the skin provides
a counter force to the force generated by first spring 7112. The
skin may oppose the force of first spring 7112 and bias against the
distal end of on-skin sensor assembly 360. Because the distal end
of holder 7124 is offset from the distal end of on-skin sensor
assembly 360 as shown in FIG. 75A, the counter force provided by
the skin is transferred to holder 7124 as first spring 7112
continues to drive holder 7124 towards the skin while on-skin
sensor assembly 360 is pressed against the skin. The counter force
provided by the skin allows spring retention element 7442b to
displace past backstop feature 7444b. Once spring retention element
7442b has cleared distance a past backstop feature 7444b, second
spring 7128 can laterally deflect spring retention element 7442b,
thereby releasing second spring 7128, which drives needle carrier
assembly 7108 in the proximal direction. Alternatively, as
described above in connection with FIG. 75A, where the angle
.theta. of the portion of spring retention element 7442b in contact
with second spring 7128 is substantially 90.degree. (e.g., flat),
the ramped or angled surface of deflecting element 7522 in contact
with spring retention element 7444b deflects spring retention
element 7442b sufficiently to release second spring 7128, which
drives needle carrier assembly 7108 in the proximal direction.
[0374] In some embodiments, engagement element 7448 may engage
protrusion 7449 even when applicator 7100 is pressed against the
skin of a user. In such embodiments, engagement element 7448
engages protrusion 7449 as first spring 7112 drives holder 7124,
needle carrier assembly 7108, and on-skin sensor assembly 360
against the skin of the host. As explained above, engagement
element 7448 prevents needle carrier assembly 7108 from moving
distally when engagement element 7448 engages protrusion 7449. This
allows spring retention elements 7442a, 7442b to separate away from
backstop features 7444a, 7444b and allow for release of second
spring 7128. The engagement of engagement element 7448 and
protrusion 7449 may add additional force to the counter force
provided by the skin, thus increasing the energy needed to overcome
the frictional engagement of spring retention elements 7442a, 7442b
and backstop features 7444a, 7444b. In some instances, the
engagement of engagement element 7448 and protrusion 7449 provides
an immediate impulse force that converts at least some of the
initial energy of first spring 7112 into energy needed to overcome
the frictional engagement of spring retention elements 7442a, 7442b
and backstop features 7444a, 7444b. It is contemplated that such
embodiments may benefit users with soft skin or higher body fat
percentage.
[0375] Turning back to FIG. 74C, which illustrates applicator 7100
during activation, needle carrier assembly 7108 is retracted in the
proximal direction by second spring 7128, as indicated by arrow
7402. In FIG. 74C, with backstop features 7444a, 7444b no longer
immobilizing spring retention elements 7442a, 7442b, first end of
second spring 7128 pushes against spring retention elements 7442a,
7442b with sufficient force to deflect spring retention elements
7442a, 7442b in the distal insertion position when on-skin sensor
assembly 360 is in contact with skin 130 of the host, allowing
second spring 7128 to clear spring retention elements 7442a, 7442b
and drive needle carrier assembly 7108 in the proximal direction,
thereby maintaining needle carrier assembly 7108, needle hub 7150
(see FIGS. 73A-73C) and insertion element 7174 (see FIGS. 73A-73C)
in a locked, retracted position even in the event of a dry
fire.
[0376] FIGS. 76A and 76B illustrate magnified views of some
features of an applicator, such as applicator 7100, according to
some embodiments.
[0377] In FIG. 76A, first spring 7112 (see FIGS. 72-74C) is driving
holder 7124, as well as the needle carrier assembly and on-skin
sensor assembly 360 in the distal direction, illustrated by arrow
7602, toward the distal insertion position. Retention element 7372b
of the needle carrier assembly is releasably coupled to on-skin
sensor assembly 360. As illustrated, during insertion and near the
distal inserted position, holder 7124 is in contact with spring
retention element 7372b, preventing spring retention element 7372b
from deflecting laterally and thereby rigidly securing on-skin
sensor assembly 360 to the needle carrier assembly.
[0378] In FIG. 76B, second spring 7128 (see FIGS. 72-74C) is
driving needle carrier assembly 7108 in the proximal direction from
the distal insertion position. Because holder 7124 has been driven
sufficiently in the distal direction, at the distal insertion
position, holder 7124 is no longer in contact with wearable
retention element 7372b. Accordingly, wearable retention element
7372b is free to deflect laterally, thereby releasing on-skin
sensor assembly 360 from wearable retention element 7372b and thus
from the needle carrier assembly 7108. Needle carrier assembly 7108
is now driven in the proximal direction by second spring 7128,
while on-skin sensor assembly 360 is secured to the skin of the
host. Moreover, in some embodiments, because holder 7124 is driven
to the distal inserted position and substantially held in that
position by first spring 7112, holder 7124 may press against one or
both of on-skin sensor assembly 360 or an adhesive patch of on-skin
sensor assembly 360, supporting one or both during attachment to
the skin of the host.
[0379] FIG. 90 illustrates a magnified view of some features of the
applicator of FIGS. 71 and 72, according to some embodiments. As
shown, applicator 7100 is in a pre-activation state. In this state,
spring retention elements 7442a, 7442b may be retained against
backstop features 7444a, 7444b. Second spring 7128 may be biasing
spring retention elements 7442a, 7442b against backstop features
7444a, 7444b. As described above, sufficient force is needed to
deflect spring retention elements 7442a, 7442b past backstop
features 7444a, 7444b. The sufficient force may be determined or at
least partly determined by the frictional force between spring
retention elements 7442a, 7442b and backstop features 7444a, 7444b.
It may be appreciated that backstop features 7444a and 7444b may
feature a groove 7446a and a groove 7446b, respectively, to engage
with spring retention elements 7442a, 7442b. Grooves 7446a, 7446b
may increase a drag force between spring retention elements 7442a,
7442b and backstop features 7444a, 7444b. In such embodiments,
grooves 7446a, 7446b can increase the force required to deflect
spring retention elements 7442a, 7442b from backstop features
7444a, 7444b while the materials of spring retention elements
7442a, 7442b and/or backstop features 7444a, 7444b have low or
lower coefficient of friction. Further, grooves 7446a, 7446b can
increase the force required to deflect spring retention elements
7442a, 7442b from backstop features 7444a, 7444b while second
spring 7128 has a small or smaller diameter or has a low or lower
spring constant. In some embodiments, grooves 7446a, 7446b may each
feature a concave channel. The concave shape of the channel may
feature angled surfaces configured to drag against multiple edges
of spring retention elements 7442a, 7442b. In such embodiments,
spring retention element 7442a, 7442b can be wedges configured to
drag within grooves 7446a, 7446b. In some embodiments, applicator
7100 may include as many grooves 7446 as backstop features
7444.
[0380] FIG. 77 illustrates a perspective partial cutaway view of
needle carrier assembly 7108, needle hub 7150, and on-skin sensor
assembly 360 of applicator 7100 of FIGS. 71 and 72, according to
some embodiments. FIG. 78 illustrates a cross-sectional view of
needle hub 7150 and on-skin sensor assembly 360, according to some
embodiments. FIG. 79 illustrates a top view of a portion of needle
carrier assembly 7108 and needle hub 7150, according to some
embodiments. The following is a description of these features with
reference to FIGS. 77-79.
[0381] On-skin sensor assembly 360 comprises sensor assembly
aperture 396. Hub 7150 is configured to couple insertion element
7174 to needle carrier assembly 7108 and to substantially maintain
a desired orientation of insertion element 7174 during insertion of
the sensor of on-skin sensor assembly 360 into the skin of the
host.
[0382] Needle hub 7150 comprises a plurality of upper arms 7156a,
7156b, a plurality of lower arms 7154a, 7154b, and a base 7152.
Although two upper arms and two lower arms are illustrated, any
number of arms, including a single upper and lower arm, are
contemplated. In some embodiments, upper arms 7156a, 7156b and
lower arms 7154a, 7154b may be flexible such that, when needle hub
7150 is coupled to needle carrier assembly 7108, upper arms 7156a,
7156b and lower arms 7154a, 7154b secure needle hub 7150 in a
desired orientation with respect to needle carrier assembly 7108.
For example, upper arms 7156a, 7156b may be configured to flex
radially inward, such that when disposed through a carrier aperture
7712 in needle carrier assembly 7108, upper arms 7156a, 7156b are
in contact with an upper surface of needle carrier assembly 7108
adjacent to carrier aperture 7712 and lower arms 7154a, 7154b are
in contact with a lower surface of needle carrier assembly 7108
adjacent to carrier aperture 7712. Such an arrangement allows a
compliant fit between needle carrier assembly 7108 and needle hub
7150 where lower arms 7154a, 7154b deflect to allow upper arms
7156a, 7156b to expand after clearing surface of carrier aperture
7712. The lower arms 7154a, 7154b can partially or fully relax to
bias the needle hub in a distal direction and decrease the
clearance between the needle hub and the needle carrier that would
otherwise exist with a non-compliant fit. In addition, upper arms
7156a, 7156b and lower arms 7154a, 7154b also help to maintain
contact between base 7152 and a top surface of on-skin sensor
assembly 360.
[0383] Base 7152 comprises an anti-rotation feature. The
anti-rotation feature may comprise a key having a shape
complementary to at least a portion of sensor assembly aperture 396
of on-skin sensor assembly 360 and may be configured to
substantially prevent needle hub 7150 from rotating about an axis
7702 parallel to insertion element 7174 with respect to on-skin
sensor assembly 360, e.g., to prevent rotation of base 7152 within
sensor assembly aperture 396. In addition, or the alternative, the
upper surface of needle carrier assembly 7108 adjacent to carrier
aperture 7712 may comprise a groove 7910 configured to accept upper
arms 7156a, 7156b when upper arms 7156a, 7156b are disposed through
carrier aperture 7712 in an orientation complementary to an
orientation of groove 7910, as illustrated in FIG. 79, thereby
immobilizing needle hub 7150 with respect to needle carrier
assembly 7108.
[0384] In some embodiments, base 7152 further comprises a
substantially flat surface configured to mate with a top surface of
on-skin sensor assembly 360 and maintain insertion element 7174 in
a substantially perpendicular orientation to the top surface of
on-skin sensor assembly 360, in some cases, when the anti-rotation
feature of base 7152 is engaged within sensor assembly aperture 396
of on-skin sensor assembly 360.
[0385] Based at least upon the above-described features of needle
hub 7150, on-skin sensor assembly 360, and/or needle carrier
assembly 7108, base 7152 allows easy assembly during manufacture,
including but not limited to proper alignment and preassembly of
insertion element 7174 onto on-skin sensor assembly 360, and/or the
ability to easily engage an assembly of needle hub 7150, insertion
element 7174, sensor 338 and on-skin sensor assembly 360 to other
portions of assembled applicator 7100.
[0386] FIGS. 80A and 80B illustrate perspective views of locking
features for needles 8074a, 8074b for use in an applicator for an
analyte sensor system, according to some embodiments. For example,
needle 8074a of FIG. 80A comprises a locking feature comprising a
ridge 8076 configured to mate with a complementary-shaped feature
within needle hub 7150, for example. In the alternative, needle
8074b of FIG. 80B comprises a locking feature comprising a groove
8078 configured to mate with a complementary-shaped feature within
needle hub 7150, for example.
[0387] In yet another alternative, any insertion element described
in this disclosure may comprise a locking feature that heat stakes
the selected insertion element to needle hub 7150, for example. In
yet another alternative, any insertion element described in this
disclosure may comprise a locking feature comprising one or more
friction-fit or snap-fit elements securing the selected insertion
element to needle hub 7150, for example. In yet another
alternative, any insertion element described in this disclosure may
comprise a locking feature comprising complementary clamshell
elements on the selected insertion element and needle hub 7150, for
example, configured to mate with one another. In yet another
alternative, any insertion element described in this disclosure may
comprise a locking element comprising one or more inserted molded
elements configured to couple the selected insertion element to
needle hub 7150, for example.
[0388] During manufacture, applicator 7100 may be assembled in
stages. For example, and not limitation, if present, first barrier
layer 7192may be affixed to inner housing 7102. Insertion element
7174 may be coupled to needle hub 7150, which may then be coupled
to on-skin sensor assembly 360. Second spring 7128 may be placed
into holder 7124 or needle carrier assembly 7108 and then needle
carrier assembly 7108 may be disposed into holder 7124 and attached
to needle hub 7150 and to on-skin sensor assembly 360 via wearable
retention elements 7372a, 7372b. First spring 7112 may be disposed
in holder 7124, which may then be installed into inner housing
7102. Inner housing 7102 may be inserted into and secured to outer
housing 7102. If present, second barrier layer 7194 may be affixed
to inner housing 7102. If a separate element, activation element
7104 may then be disposed into outer housing 7101. Any labeling,
sterilizing and/or packaging may then be applied to applicator
7100.
[0389] FIGS. 81A-81C illustrate several cross-sectional views, and
various features and operating positions, of yet another applicator
8100 for an on-skin sensor assembly of an analyte sensor system,
according to some embodiments.
[0390] Applicator 8100 may include outer applicator housing 7101
comprising activation element 7104. Outer applicator housing 7101
may be configured to translate in a distal direction under force
applied by a host of applicator 8100, thereby aligning activation
element 7104 in a position that allows applicator 8100 to fire, an
alignment illustrated by FIG. 81A. As previously described in
connection with applicator 7100, in some embodiments, activation
element 7104 may be disposed in any location, e.g., a top, upper
side, lower side, or any other location of applicator 8100.
[0391] Applicator 8100 further comprises inner housing 7102,
configured to house one or more mechanisms utilized to apply
on-skin sensor assembly 360 to skin of a host. Distal surface 7130
of a bottom opening of inner housing 7102 may define a bottom
surface of applicator 8100.
[0392] In some embodiments, upon pressing applicator 8100 against
the skin of the host, the skin may deform in a substantially convex
shape at distal surface 7130 such that at least a portion of a
surface of the skin disposed at the bottom opening of applicator
housing 7102 extends into the bottom opening of inner housing 7102,
in a proximal direction, beyond a plane defined by distal surface
7130.
[0393] Although not illustrated in FIGS. 81A-81C, inner housing
7102 may comprise a spring 7320 configured to contact outer housing
7101 and maintain a predetermined spacing between outer housing
7101 and inner housing 7102 in the pre-activation orientation (see
FIG. 73A). Spring 7320 may be a compression spring, leaf spring,
flex arm spring, a piece of foam or rubber, etc. In some other
embodiments, outer housing 7101 may comprise spring 7320 and spring
7320 may be configured to contact inner housing 7102.
[0394] Applicator 8100 may further comprise a needle carrier
assembly 8108. Needle carrier assembly 8108 comprises wearable
retention and/or alignment elements 7372a, 7372b configured to pass
through holder 8124 and releasably couple on-skin sensor assembly
360 to holder 8124 and/or to needle carrier assembly 8108. Although
two wearable retention and/or alignment elements are illustrated,
any number of wearable retention and/or alignment elements are
contemplated.
[0395] Applicator 8100 further comprises needle hub 7150 configured
to couple insertion element 7174 to needle carrier assembly 8108.
Insertion element 7174 is configured to insert sensor 338 of
on-skin sensor assembly 360 into skin 130 of the host (e.g., FIGS.
3A-4). In some embodiments, insertion element 7174 comprises a
needle, for example, an open sided-needle, a needle with a
deflected-tip, a curved needle, a polymer-coated needle, a
hypodermic needle, or any other suitable type of needle or
structure, as described in connection with at least FIGS. 47-50 and
80A-B. In yet other embodiments, insertion element 7174 may be
integrally formed with sensor 338, in which insertion element 7174
may be sufficiently rigid to be inserted partially into skin 130 of
the host with minimal or no structural support.
[0396] Applicator 8100 may further include holder 8124 releasably
coupled to needle carrier assembly 8108 and configured to guide
on-skin sensor assembly 360 while coupled to needle carrier
assembly 8108, e.g., at least during translation from a proximal
position to a distal insertion position. As previously described in
connection with applicator 7100, on-skin sensor assembly 360 may be
stripped or released from holder 8124 and/or needle carrier
assembly 8108 once on-skin sensor assembly 360 is disposed on the
skin of the host.
[0397] Applicator 8100 may further comprise an insertion assembly
configured to translate insertion element 7174, needle hub 7150,
and needle carrier assembly 8108 from a proximal position, in the
distal direction, to a distal insertion position. Such an insertion
assembly may include first spring 7112. First spring 7112 may be a
compression spring, or any suitable type of spring, and may have
its first end in contact with or coupled to inner applicator
housing 7102 and its second end in contact with or coupled to
holder 8124. First spring 7112 is configured to, upon activation of
the insertion assembly, translate holder 8124, needle carrier
assembly 8108, needle hub 7150, insertion element 7174 and on-skin
sensor assembly 360, in the distal direction to the distal
insertion position. Substantially at the distal insertion position,
needle carrier assembly 8108 may decouple from holder 8124 and
on-skin sensor assembly 360.
[0398] Applicator 8100 may further comprise a retraction assembly
configured to translate needle carrier assembly 8108, needle hub
7150 and insertion element 7174, in the proximal direction, from
the distal insertion position to a proximal retracted position. In
some embodiments the initial proximal position may be the same as
the proximal retracted position. In other embodiments, the initial
proximal position may be different from the proximal retracted
position. Such a retraction assembly may include a second spring
8128. Second spring 8128 may be a compression spring, or any
suitable type of spring, and may have a first end contacting or
coupled to holder 8124 and a second end, comprising a tang 8129
(e.g., a spring portion or spring end) disposed substantially along
a diameter of second spring 8128, in contact with or coupled to a
spring retention element 8142 of holder 8124, at least until
retraction. Spring retention element 8142 may comprise, e.g., an
arm, a deflection element, a tab, a detent, a snap or any other
feature capable of a retaining function. Spring retention element
8142 may have substantially the same form and function as spring
retention elements 7442a, 7442b of applicator 7100 except as
described below. Second spring 8128 is configured to translate
needle carrier assembly 8108, needle hub 7150, and insertion
element 7174 in the proximal direction from the distal insertion
position to the proximal retracted position. Tang 8129 of second
spring 8128 is released from spring retention element 8142 in the
distal insertion position when spring retention element 8142 is not
backed up by backstop element 8144 and in response to tang 8129 of
second spring 8128 pushing against spring retention element 8142
with a force exceeding a predetermined threshold sufficient to
overcome and deflect spring retention element 8142.
[0399] In some embodiments, transfer of on-skin sensor assembly 360
between insertion and retraction may occur as previously described
in connection with, for example, any of FIGS. 35A-37C.
[0400] Needle carrier assembly 8108 further comprises a backstop
feature 8144, configured to prevent lateral motion of spring
retention element 8142 of holder 8124 in at least the proximal
pre-activation position, thereby supporting retention of second
spring 8128 between spring retention element 8142 and holder 8124
until retraction. In the orientation shown in FIG. 81A, second
spring 8128 is exerting a force against spring retention element
8142 but backstop feature 8144 prevents lateral deflection of
retention element 8142.
[0401] Holder 8124 further comprises needle carrier retention
element 7334, which may comprise a deflectable arm, rigid arm,
deformable feature, snap, catch, or hook. Upon needle carrier
assembly 8108 reaching the proximal retraction position after
activation, needle carrier retention element 7334 is configured to
engage with needle carrier assembly 8108, thereby maintaining
needle carrier assembly 8108, needle hub 7150 and insertion element
7174 in a locked, retracted position, limiting access to insertion
element 7174.
[0402] Although not illustrated in FIGS. 81A-81C, inner housing
7102 of applicator 8100 may further comprise engagement element
7448 and needle carrier assembly 8108 may further comprise
protrusion 7449 and may function substantially as previously
described in connection with at least FIGS. 74A-74C.
[0403] Although not illustrated in FIGS. 81A-81C, inner housing
7102 of applicator 8100 may further comprise a protrusion extending
from inner housing 7102 in the distal direction, substantially as
previously described protrusion 7546. Similar to that previously
described in connection with FIG. 75A, this protrusion may be
configured to contact at least one of spring retention element 8142
and backstop feature 8144 in the pre-activation state such that
spring retention element 8142 is prevented from laterally
deflecting until holder 8124 and needle carrier assembly 8108 have
translated at least a predetermined minimum distance in the distal
direction. Accordingly, the protrusion may provide a measure of
drop protection such that applicator 8100 may not prematurely fire
in response to a concussive shock from being dropped before
activation.
[0404] Applicator 8100 functions substantially similarly to
applicator 7100 with the exception that instead of utilizing spring
retention elements 7442a, 7442b, which are disposed along an
outside of second coil 7128 and are configured to contact and
retain a coil of second spring 7128, applicator 8100 utilizes
spring retention element 8142, which is disposed along an inside of
second spring 8128 and is configured to contact and retain tang
8129 of second spring 8128 along a diameter of second spring 8128.
Disposing spring retention element 8142 within and substantially
along a center of second spring 8128, as opposed to along an
outside of second spring 8128, further ensures that spring
retention element 8142 does not contact the coils of second spring
8128 as second spring 8128 extends during retraction, thereby
smoothing the operation of applicator 8100. In addition, the
arrangement including spring retention element 8142, as opposed to
spring retention elements 7442a, 7442b mitigates the risk of, and
difficulty ensuring that, multiple spring retention elements
trigger or are overcome at substantially the same time.
[0405] Although not shown in FIGS. 81A-81C, in some embodiments,
applicator 8100 may comprise a cap configured to be secured to
distal surface 7130 of inner housing 7102, which may be removed
before use. In some embodiments, such a cap may also function as a
sterile barrier, as previously described in U.S. patent application
Ser. No. 16/011527, hereby incorporated by reference in its
entirety.
[0406] FIG. 81A illustrates a state of applicator 8100 prior to
activation, according to some embodiments. Holder 8124, needle
carrier assembly 8108, needle hub 7150, insertion element 7174,
on-skin sensor assembly 360, first spring 7112 and second spring
7128 are all shown in pre-activation positions.
[0407] Retention element 7332 of holder 8124 is in contact with
inner housing 7102, thereby immobilizing holder 8124, and therefore
also needle carrier assembly 8108, needle hub 7150, insertion
element 7174 and on-skin sensor assembly 360, in the pre-activated
state.
[0408] Backstop feature 8144 of needle carrier assembly 8108 is in
contact with and prevents spring retention element 8142 from
deflecting laterally, thereby ensuring spring retention element
8142 retains tang 8129 of second spring 8128 in the loaded or
pre-activation position shown.
[0409] Activation of applicator 8100 may include a host pressing
applicator 8100 against their skin with sufficient force to
translate outer housing 7101 in a distal direction toward and with
respect to inner housing 7102 until activation element 7104 is
aligned with insertion assembly retention element 7332 of holder
8124, as shown in FIG. 81A. Once such an alignment is achieved, a
host may initiate activation element 7104, thereby deflecting
insertion assembly retention element 7332 sufficiently to release
holder 8124 from inner housing 7102. In some other embodiments,
applicator 8100 may be configured such that activation element 7104
may be activated first, but that actual insertion is not triggered
until outer housing 7101 is translated sufficiently in the distal
direction toward and with respect to inner housing 7102. In yet
other embodiments, activation element 7104 may be biased toward a
center of applicator 8100 such that activation element 7104 need
not be explicitly activated by the host but, instead, activation
element 7104 may be configured to automatically initiate insertion
upon outer housing 7101 being translated sufficiently in the distal
direction toward and with respect to inner housing 7102.
[0410] FIG. 81B illustrates applicator 8100 after activation and
during insertion, according to some embodiments. First spring 7112
drives holder 8124, and so needle carrier assembly 8108, needle hub
7150, insertion element 7174, and on-skin sensor assembly 360, in
the distal direction toward the distal insertion position. FIG. 81B
illustrates on-skin sensor assembly 360 in contact with skin 130 of
the host but where holder 8124 is not yet fully driven, by first
spring 7112, into contact with on-skin sensor assembly 360 or skin
130 of the host.
[0411] In some embodiments, masses of each of holder 8124, needle
carrier assembly 8108, needle hub 7150, insertion element 7174, and
on-skin sensor assembly 360 may be specifically designed to reduce
or substantially eliminate a tendency of needle carrier assembly
8108, needle hub 7150, insertion element 7174, and on-skin sensor
assembly 360 to detach from holder 8124 while being driven in the
distal direction during insertion. In some embodiments, a force
exerted by first spring 7112 may further be selected to be
sufficient for proper operation of applicator 7100, while not so
large as to further exacerbate such above-described inertially
triggered detachment. In some embodiments, a spring (not shown) may
be configured to exert a force against a portion of needle carrier
assembly 8108, for example in the distal direction, sufficient to
prevent needle carrier assembly 7108 from inertially triggered
detaching from holder 8124 during insertion.
[0412] FIG. 81C illustrates applicator 8100 after activation and at
or near the distal insertion position, according to some
embodiments. First spring 7112 has driven holder 8124, needle
carrier assembly 8108 and on-skin sensor assembly 360 in the distal
direction to the distal inserted position. Since first spring 7112
has driven holder 8124 a short distance farther in the distal
direction than needle carrier assembly 8108, backstop feature 8144
is no longer in contact with spring retention element 8142,
allowing second spring 8128 (e.g. tang 8129) to laterally deflect
spring retention element 8142, thereby releasing second spring
8128, which drives needle carrier assembly 8108 in the proximal
direction. Alternatively, similar to that described above in
connection with applicator 7100 in FIG. 75A, where the angle
.theta. of the portion of spring retention element 8142 in contact
with tang 8129 of second spring 7128 is substantially 90.degree.
(e.g., flat), spring retention element 8142 may be biased to
automatically deflect sufficiently to release second spring 7128
once backstop feature 8144 is no longer in contact with spring
retention element 8142, thereby freeing second spring 8128 to drive
needle carrier assembly 8108 in the proximal direction. Although
not shown in FIGS. 81A-81C, inner housing 7102 may further comprise
engagement element 7448 configured to engage with a protrusion 7449
of needle carrier assembly 8108, and to function substantially as
previously described in connection with at least FIGS. 74A-74C. In
some embodiments, a stop feature (not shown) may be disposed at a
bottom of applicator 8100, e.g., on a distal portion of inner
housing 7102. Such a stop feature may be configured to contact one
or more of on-skin sensor assembly 360, needle carrier 8108, or
holder 8124 in the distal insertion position.
[0413] Upon release of second spring 8128, second spring 8128 is
configured to drive needle carrier assembly 8108, needle hub 7150
and insertion element 7174, in the proximal direction. Although not
shown in FIG. 81C, as needle carrier assembly 8108 travels to the
proximal retracted position, needle carrier retention element 7134
may engage with needle carrier assembly 8108, thereby retention
needle carrier assembly 8108, needle hub 7150 and insertion element
7174, in a locked, retracted position limiting access to insertion
element 7174.
[0414] FIG. 81D illustrates a perspective view of holder 8124,
first spring 7112 and second spring 8128 of applicator 8100,
according to some embodiments. FIG. 81D illustrates spring
retention element 8142, retention tang 8129 of second spring 8128
in an orientation within applicator 8100 before retraction.
[0415] During manufacture, applicator 8100 may be assembled in
stages. For example, and not limitation, if present, as previously
described in connection with applicator 7100, first barrier layer
7192 (see FIG. 72) may be affixed to inner housing 7102. Insertion
element 7174 may be coupled to needle hub 7150, which may then be
coupled to on-skin sensor assembly 360. Second spring may be placed
into holder 8124 or needle carrier assembly 8108 and then needle
carrier assembly 8108 may be disposed into holder 8124 and attached
to needle hub 7150 and to on-skin sensor assembly via wearable
retention elements 7372a, 7372b. First spring 7112 may be disposed
in holder 8124, which may then be installed into inner housing
7102. Inner housing 7102 may be inserted into and secured to outer
housing 7102. If present, as previously described in connection
with applicator 7100, second barrier layers 7194 (see FIG. 72) may
be affixed to inner housing 7102. If a separate element, activation
element 7104 may then be disposed into outer housing 7101. Any
labeling, sterilizing and/or packaging may then be applied to
applicator 8100.
[0416] FIGS. 82A-82D illustrate several cutaway views, and various
features and operating positions, of yet another applicator 8200
for an on-skin sensor assembly of an analyte sensor system,
according to some embodiments. In contrast to applicators 7100 and
8100, applicator 8200 utilizes a single spring for both insertion
and retraction of an insertion element 8274 for placing an
associated sensor 338 and on-skin sensor assembly 360.
[0417] Applicator 8200 comprises a housing 8202 and an activation
element 8204 disposed on a top of applicator 8200. However,
activation element 8204 may be disposed on a side or any other
location on applicator 8200.
[0418] Applicator 8200 may further comprise a needle carrier
assembly 8208. Needle carrier assembly 8208 comprises wearable
retention and/or alignment elements 8272a, 8272b configured to pass
through holder 8224 and releasably couple on-skin sensor assembly
360 to holder 8224 and/or to needle carrier assembly 8208. In some
embodiments, wearable retention elements 8272a, 8272b may extend
around rather than through holder 8224. Wearable retention elements
8272a, 8272b may comprise, e.g., arms, deflection element, tabs,
detents, snaps or any other features capable of a retaining
function. Although two wearable retention and/or alignment elements
are illustrated, any number of wearable retention and/or alignment
elements are contemplated. Needle carrier assembly 8208 further
comprises a protrusion 8266 configured to contact or hook a
deployment sleeve 8206 during retraction, thereby causing needle
carrier assembly 8208 to translate in a proximal direction during
retraction, as will be described in more detail below.
[0419] Applicator 8200 further comprises an insertion element 8274
configured to insert sensor 338 of on-skin sensor assembly 360 into
skin 130 of the host (e.g., FIG. 1). In some embodiments, insertion
element 8274 comprises a needle, for example, an open sided-needle,
a needle with a deflected-tip, a curved needle, a polymer-coated
needle, a hypodermic needle, or any other suitable type of needle
or structure, as described in connection with at least FIGS. 47-50
and 80A-B. In yet other embodiments, insertion element 8274 may
comprise sensor 338, sufficiently rigid to be inserted partially
into skin 130 of the host with minimal or no structural
support.
[0420] Although not illustrated in FIGS. 82A-82D, in some
embodiments, applicator 8200 may further comprise needle hub 7150,
configured to couple insertion element 8274 to needle carrier
assembly 8208, as previously described in connection with at least
FIGS. 77-79. In some other embodiments, insertion element 8274 may
be directly coupled to needle carrier assembly 8208 as shown in
FIGS. 82A-82D.
[0421] Applicator 8200 may further include holder 8224 releasably
coupled to deployment sleeve 8206 via holder retention elements
8232a, 8232b and to needle carrier assembly 8208. Holder retention
elements 8232a, 8232b may comprise, e.g., arms, deflection
elements, tabs, detents, snaps or any other features capable of a
retaining function. Holder 8224 is configured to guide on-skin
sensor assembly 360 while coupled to needle carrier assembly 8208
during insertion, e.g., at least during translation from a proximal
position to a distal insertion position. As previously described in
connection with applicators 7100 and 8100, on-skin sensor assembly
360 may be stripped or released from holder 8224 and/or needle
carrier assembly 8208 once on-skin sensor assembly 360 is disposed
on the skin of the host.
[0422] Applicator 8200 may further comprise an insertion assembly
configured to translate holder 8224, insertion element 8274 and
needle carrier assembly 8208, in the distal direction, from a
proximal position to a distal insertion position. Such an insertion
assembly may include a spring 8212. First spring 8212 may be a
compression spring, or any suitable type of spring, and may have a
first end in contact with or coupled to deployment sleeve 8206 and
a second end in contact with or coupled to holder 8224. First
spring 8212 is configured to, upon activation of the insertion
assembly, translate holder 8224, needle carrier assembly 8208,
insertion element 8274 and on-skin sensor assembly 360 in the
distal direction to the distal insertion position. Substantially at
the distal insertion position, needle carrier assembly 8208 may
decouple from holder 8224 and on-skin sensor assembly 360.
[0423] Applicator 8200 may further comprise a retraction assembly
configured to translate needle carrier assembly 8208 and insertion
element 8274, in the proximal direction, from the distal insertion
position to a proximal retracted position. In some embodiments the
initial proximal position may be the same as the proximal retracted
position. In other embodiments, the initial proximal position may
be different from the proximal retracted position. Such a
retraction assembly may also include spring 8212. First spring 8212
is also configured to translate deployment sleeve 8206, needle
carrier assembly 8208 and insertion element 8274 in the proximal
direction from the distal insertion position to the proximal
retracted position in response to on-skin sensor assembly 360
contacting skin 130 of the host and/or reaching a limit of travel
with a force exceeding a predetermined threshold. For example,
although not illustrated, housing 8202 may further comprise
engagement element 7448 configured to engage with a protrusion 7449
of needle carrier assembly 8208, and to function substantially as
previously described in connection with at least FIGS. 74A-74C. In
some embodiments, a stop feature (not shown) may be disposed at a
bottom of applicator 8200, e.g., on a distal portion of housing
8202. Such a stop feature may be configured to contact one or more
of on-skin sensor assembly 360, needle carrier 8208, holder 8224 or
deployment sleeve 8206 in the distal insertion position. Spring
8212 is configured to exert a force sufficient to deflect
deployment sleeve retention elements 8262a, 8262b of deployment
sleeve 8206 when on-skin sensor assembly 360 is in contact with
skin 130 of the host, thereby freeing deployment sleeve retention
elements 8262a, 8262b of deployment sleeve 8206 from protrusions
8264a, 8264b of housing 8202 (see FIGS. 82C-82D), thereby allowing
spring 8212 to translate deployment sleeve 8206, and thus needle
carrier assembly 8208 and insertion element 8274, in the proximal
direction from the distal inserted position. Deployment sleeve
retention elements 8262a, 8262b may comprise, e.g., arms,
deflection elements, tabs, detents, snaps or any other features
capable of a retaining function.
[0424] In some embodiments, transfer of on-skin sensor assembly 360
between insertion and retraction may occur as previously described
in connection with any prior figure, for example, any of FIGS.
35A-37C.
[0425] Such dual insertion/retraction operability of spring 8212 is
possible because, during insertion, deployment sleeve 8206 is
immobilized by deployment sleeve retention elements 8262a, 8262b,
being in contact with respective protrusions 8264a, 8264b of
housing 8202. Thus, when spring 8212 exerts force between
deployment sleeve 8206 and holder 8224, spring 8212 drives holder
8224, and coupled needle carrier assembly 8208, insertion element
8274 and on-skin sensor assembly 360, in the distal direction to
the distal deployed position, where on-skin sensor assembly 360 is
in contact with the skin 130 of the host. Once on-skin sensor
assembly 360 is in contact with the host, holder 8224 is
immobilized against on-skin sensor assembly 360, a travel-limiting
feature of applicator 8200, and/or the skin of the host.
Accordingly, with holder 8224 immobilized, the force exerted by
spring 8212 between immobilized holder 8224 and deployment sleeve
8206 now acts to push deployment sleeve 8206 in the proximal
direction with sufficient force to deflect deployment sleeve
retention elements 8262a, 8262b sufficiently to clear protrusions
8264a, 8264b of housing 8202, thereby freeing deployment sleeve
8206 to be driven further in the proximal direction by spring 8212.
Since protrusion 8266 of needle carrier assembly 8208 is configured
to contact, couple or hook deployment sleeve 8206 as deployment
sleeve 8206 translates in the proximal direction, the action of
spring 8212 translating deployment sleeve 8206 in the proximal
direction also translates needle carrier assembly 8208, and coupled
insertion element 8274, in the proximal direction to the proximal
retracted position. Positions of the above-described features will
now be discussed with respect to FIGS. 82A-82D.
[0426] Although not shown in FIGS. 82A-82D, in some embodiments,
applicator 8200 may comprise a cap configured to be secured to a
distal surface of inner housing 8202 or activation element 8204,
which may be removed before use. In some embodiments, this cap may
create a sealed volume that provides a sterile barrier, as
previously described in U.S. Patent Application No. 16/011527,
hereby incorporated by reference in its entirety.
[0427] FIG. 82A illustrates a state of applicator 8200 prior to
activation, according to some embodiments. Prior to activation,
holder retention elements 8232a, 8232b immobilize holder 8224 to
deployment sleeve 8206. Holder retention elements 8232a, 8232b may
comprise, e.g., arms, deflection elements, tabs, detents, snaps or
any other features capable of a retaining function. Needle carrier
assembly 8208 is coupled to holder 8224. Insertion element 8274 is
coupled to needle carrier assembly 8208. And on-skin sensor
assembly 360 is coupled to needle carrier assembly 8208 via
wearable retention elements 8272a, 8272b. The positions illustrated
may correspond to the proximal position.
[0428] FIG. 82B illustrates a state of applicator 8200 at
activation, according to some embodiments. Activation element 8204
is shown as activated (e.g., pressed down) such that protrusions
8264a, 8264b translate in the distal direction sufficiently to
laterally deflect holder retention elements 8232a, 8232b, thereby
decoupling holder 8224 from deployment sleeve 8206 and freeing
spring 8212 to drive holder 8224, needle carrier assembly 8208,
insertion element 8274 and on-skin sensor assembly 360. As in FIG.
82A, the illustrated positions of deployment sleeve 8206, holder
8224, needle carrier assembly 8208, insertion element 8274 and
on-skin sensor assembly 360 may correspond to the initial proximal
position.
[0429] FIG. 82C illustrates a state of applicator 8200 at the end
of insertion, according to some embodiments. First spring 8212 has
translated holder 8224, needle carrier assembly 8208, insertion
element 8274 and on-skin sensor assembly 360 in the distal
direction to the distal insertion position. On-skin sensor assembly
360 is shown in contact with skin 130 of the host, insertion
element 8274 is inserted into skin 130 of the host, and holder 8224
is being pressed against on-skin sensor assembly 360 by spring
8212. In the illustrated positions, spring 8212 is exerting a force
on deployment sleeve 8206 sufficient to laterally deflect
deployment sleeve retention elements 8262a, 8262b, thereby freeing
deployment sleeve 8206 to be translated in the proximal direction
by spring 8212. The illustrated positions of holder 8224, needle
carrier assembly 8208, insertion element 8274 and on-skin sensor
assembly 360 may correspond to the distal inserted position.
[0430] In some embodiments, masses of each of holder 8224, needle
carrier assembly 8208, insertion element 8274, and on-skin sensor
assembly 360 may be specifically designed to reduce or
substantially eliminate a tendency of needle carrier assembly 8208,
insertion element 8274, and on-skin sensor assembly 360 to
prematurely detach from holder 8224 while being driven in the
distal direction during insertion. In some embodiments, a force
exerted by spring 8212 may further be selected to be sufficient for
proper operation of applicator 8200, while not so large as to
further exacerbate such above described inertially triggered
detachment. In some embodiments, a spring (not shown) may be
configured to exert a force, in the distal direction for example,
against a portion of needle carrier assembly 8208 sufficient to
prevent needle carrier assembly 8208 from inertially triggered
detaching from holder 8224 during insertion.
[0431] FIG. 82D illustrates a state of applicator 8200 after
retraction, according to some embodiments. As illustrated, wearable
retention elements 8272a, 8272b detach from on-skin sensor assembly
360 during retraction. First spring 8212 has translated deployment
sleeve 8206 in the proximal direction. Because protrusion 8266 of
needle carrier assembly 8208 is configured to contact deployment
sleeve 8206 during retraction, as deployment sleeve 8206 is driven
in the proximal direction, so is needle carrier assembly 8208 and
insertion element 8274. In some embodiments, it is this proximal
translation that causes wearable retention elements 8272a, 8272b to
detach from on-skin sensor assembly 360. Since spring 8212 pushes
holder 8224 in the distal direction and deployment sleeve 8206,
needle carrier assembly 8208 and insertion element 8274 in the
proximal direction, insertion element 8274 is locked, safely, in
the second proximal retracted position.
[0432] Although not shown in FIGS. 82A-82D, applicator 8200 may
further comprise a displacement-based lockout feature that prevents
deployment sleeve 8206 from translating in the proximal direction,
thereby preventing retraction, until holder 8224 has translated at
least a predetermined distance in the distal direction. Such a
displacement-based lockout feature may operate substantially as
protrusions 7546, 8146 previously described in connection with
FIGS. 75A and 81A-81D. For example, such a protrusion may extend in
the proximal direction from one or more of holder 8224 or needle
carrier assembly 8208 and may be configured to be in physical
contact with deployment sleeve retention elements 8262a, 8262b at
least until holder 8224 or needle carrier assembly 8208 has
translated at least the predetermined distance in the distal
direction, thereby preventing inertial (i.e., reaction force
generated by the acceleration of mass) or accidental activation of
applicator 8200, for example, due to concussive shock from dropping
applicator 8200.
[0433] During manufacture, applicator 8200 may be assembled in
stages. For example, and not limitation, if present, first barrier
layer 7192 or similar may be affixed to housing 8202. Insertion
element 8274 may be coupled to needle hub 7150, if present, which
may then be coupled to on-skin sensor assembly 360. If needle hub
7150 is not present, insertion element 8274 may be coupled directly
to on-skin sensor assembly 360. Needle carrier assembly 8208 may be
at least partly disposed within deployment sleeve 8206 and spring
8212 may be placed into holder 7124. Deployment sleeve 8206 and
needle carrier assembly 7108 may be disposed into holder 7124 and
attached to needle hub 7150, if present, or directly to insertion
element 8274 if needle hub 7150 is not present, and to on-skin
sensor assembly 360 via wearable retention elements 8272a, 8272b.
The assembly including holder 8224, deployment sleeve 8206 and
needle carrier assembly 8208 may then be installed into housing
8202. If present, second barrier layer 7194 or similar may be
affixed to housing 8202. If a separate element, activation element
8204 may then be disposed into housing 8202. Any labeling,
sterilizing and/or packaging may then be applied to applicator
8200.
[0434] FIGS. 83-85 illustrate several alternatives for activation
elements in an applicator. Such alternatives may be directly
applied to any applicator described in this disclosure, especially,
though not in any way limited to, applicators 7100, 8100 and 8200
described above.
[0435] FIG. 83 illustrates a cross-sectional view of an applicator
8300 comprising a deformable layer 8305 disposed over an activation
element 8304, according to some embodiments. Although activation
element 8304 is shown on a side of an outer housing 8301, any other
suitable location for deformable layer 8305 and activation element
8304 is contemplated, e.g., a top, a high side, a low side of outer
housing 8301. In some embodiments, deformable layer 8305 may be
molded over activation element 8304. In some other embodiments,
deformable layer 8305 may be glued or welded over activation
element 8304, for example, utilizing ultrasonic, laser, radio
frequency, heat stake welding processes, or any other suitable
process. In some embodiments, deformable layer 8305 may comprise a
film, an elastomer, a plastic or any other material with sufficient
deformability to allow activation of activation element 8304 as
well as to provide an air and/or fluid-tight sealed surface over
activation element 8304.
[0436] FIG. 84 illustrates a perspective view of an applicator 8400
utilizing a twist-to-activate activation mechanism, according to
some embodiments. Applicator 8400 comprises an outer housing 8401
and an inner housing 8402. In some embodiments, outer housing 8401
and inner housing 8402 may, together, comprise an activation
element in that applicator 8400 is activated by pushing down on
applicator 8400 with sufficient force to immobilize inner housing
8402 against the skin of the host as outer housing 8401 is twisted
with respect to inner housing 8402. Such a design ensures
applicator 8400 is pressed against the skin of the host with at
least a minimum force, which can be designed to a particular
desired threshold based on, for example, a predetermined amount of
force that ensures proper seating and orientation of applicator
8400 for use, the friction coefficient between inner housing 8402
and the skin of the host, as well as based on the twisting force to
trigger applicator 8400.
[0437] FIG. 85 illustrates a cross-sectional view of an applicator
8500 comprising a top-mounted activation element 8504, according to
some embodiments. In some embodiments, activation element 8504 may
comprise any type of activation element described in this
disclosure, including, but not limited to, a dome-shaped button. In
some embodiments, such a dome-shaped button may comprise a
deformable material, as previously described in connection with
FIG. 83 or, alternatively, may be sufficiently rigid to hold its
form when pressed or otherwise utilized by the host.
Insertion Element Embodiments
[0438] Several embodiments of an insertion element, as previously
described herein, will now be described in connection with at least
FIGS. 47-50, in which the insertion element is illustrated as being
a needle.
[0439] FIG. 47 illustrates a cross-sectional view of a kinked
needle 4774 for use in an applicator for an analyte sensor system,
according to some embodiments. Kinked needle 4774 may have at least
two substantially straight portions 4790, 4792 with a bend 4796
between each substantially straight portion such that an angle 4796
between the substantially straight portions is substantially
optimized to reduce lateral motion of a tip of needle 4774 through
the skin of the host as needle 4774 traces an arc during
activation.
[0440] FIGS. 48A-48B illustrate a cross-section and a plan view,
respectively, of a flared open-sided needle 4874 for use in an
applicator for an analyte sensor system, according to some
embodiments. Although FIGS. 48A-48B illustrate open-sided needle
4874 having a C-shaped cross-section, the open-sided needle 4874
may have any shaped cross-section, e.g., a C-shape, a U-shape, a
V-shape. FIG. 48A illustrates a cross-section of an open-sided
needle 4874 having at least one flared edge 4876. For example,
flared edge 4876 may be flared in a lateral direction from a
longitudinal centerline of open-sided needle 4874. Such a flared
edge 4876 may prevent or substantially reduce the incidence of
damage to sensor 138 (e.g., FIG. 1) caused by sharp edges of the
open-sided needle coming in contact with sensor 138 before or
during insertion into the skin of a host.
[0441] FIG. 48B illustrates a plan view of open-sided needle 4874.
Open-sided needle 4874 is illustrated as formed with an end
opposite its tip having a needle skirt 4878. Needle skirt 4878 may
aid directing sensor 138 into the needle lumen to assist with
loading of sensor 138 and/or reduce the opportunity for damage of
sensor 138 during use and/or loading.
[0442] FIG. 49 illustrates a perspective view of a deflected-tip
needle 4974 for use in an applicator for an analyte sensor system,
according to some embodiments. Deflected-tip needle 4974 may
comprise a substantially straight shaft having a substantially
curved tip 4980, such that an angle of entry of deflected-tip
needle 4974 is offset from the substantially straight shaft. Such
an angle offset of the substantially curved tip 4980 may be
particularly useful for reducing tissue damage and insertion
resistance for applicators such as applicator 2500, as previously
described in connection with FIGS. 25-28H, that have an insertion
path for the insertion element that is a substantially curved path.
The substantially curved tip 4980 may steer deflected-tip needle
4974 in the direction of the substantially curved insertion path,
thereby reducing tissue damage caused by lateral movement of the
needle with respect to its direction of extension. FIG. 49
illustrates a magnified view 4950 of the curved tip 4980.
[0443] FIG. 50 illustrates a curved needle 5074 for use in an
applicator for an analyte sensor system, according to some
embodiments. As shown, curved needle 5074 has a profile that is
substantially curvilinear. Such a curvilinear profile may be
particularly useful for reducing tissue damage and insertion
resistance for applicators such as applicator 2500, as previously
described in connection with FIGS. 25-28H, that have an insertion
path for the insertion element that is a substantially curved path.
The substantially curvilinear profile of needle 5074 may reduce
tissue damage caused by lateral movement of the needle with respect
to its direction of extension. In some embodiments, the curvilinear
profile of needle 5074 may substantially track or trace the
insertion path for the applicator, thereby substantially
eliminating, or at least greatly reducing, lateral movement of the
needle with respect to the skin of the host. In some embodiments,
sensor 138 of on-skin sensor assembly 160 may have a curvilinear
profile also, thereby allowing sensor 138 to rest within a portion
of curved needle 5074.In yet other embodiments, the insertion
element, for example a C-needle may have at least a portion coated
with a polymer that prevents damage to the tissue of the host
and/or to the sensor wire. Such a polymer may include, but is not
limited to, cyanoacrylate, epoxy, elastomeric polymers, urethanes
or any other suitable polymer.
[0444] In some embodiments, at least a sensing portion of sensor
138 may be coated with AgCl to improve the reference capacity of
sensor 138. However, AgCl is a catalyst for corroding the metal in
the insertion element (e.g., open-sided needle). Accordingly, an
AgCl coating on sensor 138 that comes into contact with the
insertion element may be undesirable. One method of decreasing
corrosion of sensor 138 and/or the insertion element is to
selectively remove or substantially decrease the content of AgCl on
at least a proximal end of sensor 138 without substantially
affecting the region of sensor 138 that is inserted into the skin
of the host. This may be accomplished by exposing the desired
portion of sensor 138 to a single frequency or multiple frequencies
of ultraviolet radiation for a predetermined length of time and at
a predetermined intensity. Such a process may be performed at any
time, for example, during the skiving or singulation process.
Another method of removing AgCl is to expose the desired portion of
sensor 138 to an ammonia (NH3) rinse at a desired concentration and
for a desired length of time.
Sharp Protection
[0445] FIGS. 51A-51B illustrate cutaway views of a needle hub of an
applicator for an analyte sensor system, according to some
embodiments. FIG. 51A illustrates a needle hub 5104, an insertion
element 5174, a needle guard 5102, a spring 5174, and a base 5130
of the applicator. First needle hub 5104 may be fixed to a portion
other than a tip of insertion element 5174. Second needle hub 5102
may be configured to encapsulate the tip of insertion element 5174
and may comprise a material that insertion element 5174 may pierce
during deployment and/or may include an aperture or hole through
which insertion element 5174 may pass. Spring 5106 is configured to
keep a predetermined spacing between needle hub 5104 and needle
guard 5102 such that the tip of insertion element 5174 is
encapsulated by needle guard 5102 when the predetermined spacing is
maintained. FIG. 51A illustrates a pre-activation position that may
be returned to after activation, under a returning force provided
by spring 5106, compressed during deployment of insertion element
5174. In some embodiments, the spring can be integrated into needle
hub 5104 or needle guard 5102.
[0446] FIG. 51B illustrates needle hub 5104, insertion element
5174, needle guard 5102, spring 5174, and base 5130 of the
applicator in the distal, deployed position. As shown, insertion
element 5174 has been driven through needle guard 5102 and through
an opening in base 5130. Since needle hub 5104 is fixed to
insertion element 5174, deployment of insertion element 5174 to the
distal, deployed position closes the distance between needle hub
5104 and needle guard 5102, thereby compressing spring 5106 (not
shown in FIG. 51B). The energy stored in compressing spring 5106 is
then utilized to force needle guard 5102 substantially to its
pre-activation position, thereby encapsulating the tip of insertion
element 5174. It is contemplated that the features described in
FIGS. 51A-51B provide protection from needle stick hazards.
[0447] FIGS. 52A-52B illustrate a cross-sectional view and a top
plan view, respectively, of an infusion cannula 5264 integrated
into on-skin sensor assembly 160 of an analyte sensor system,
according to some embodiments. In FIG. 52A, on-skin sensor assembly
160 is illustrated as including sensor 138 and a fill port 5262
configured to receive a fluid, gel, or medication (e.g., insulin)
and cannula 5264 configured to deliver the fluid or gel through
skin 130 of the host. In some embodiments, fill port 5262 comprises
a septum material that maintains a seal for the transcutaneous
cannula and is capable of being pierced (e.g. by a hypodermic
needle attached to a syringe) and allow for dosing the medication.
This septum may be configured to self-seal after removal of the
needle from the skin of the host. The infusion cannula and analyte
sensor may be inserted transcutaneously by the same applicator
device. It is envisioned that a sharp (e.g. needle) placed within
the lumen of an infusion cannula and placed in parallel with the
insertion element (e.g. attached to needle carrier assembly such as
508) for analyte sensors may be added to the analyte applicators
(e.g. applicator 500, 800, 900, 1000, etc.). In FIG. 52B, on-skin
sensor assembly 160 is illustrated as including an adhesive patch
5264 configured to adhere on-skin sensor assembly 160 to skin 130
of the host. Sensor Retention Embodiments
[0448] In some embodiments, an insertion element, such as an
open-sided needle may be utilized to insert at least a portion of a
sensor wire into the skin of a host. However, such embodiments
generally operate best when the sensor wire remains seated in a
channel of the open-sided needle before and during insertion. In
addition, if the open-sided needle does not retain the sensor in
the channel of the needle, the sensor may fail to deploy into the
tissue. Accordingly, FIGS. 53-59 illustrate several embodiments of
applicators that include sensor retention features configured to
retain the sensor wire within a channel of the insertion element at
least before activation of the applicator. Although particular
applicators are shown, these retention features may be incorporated
into any applicator described by this disclosure.
[0449] FIG. 53 illustrates a cross-sectional view of a sensor
retention mechanism for an applicator 5300 for an analyte sensor
system, according to some embodiments. Applicator 5300 includes an
applicator housing 5302 having a retention feature 5384, for
example a hook or protrusion. Applicator 5300 further includes
on-skin sensor assembly 160 having sensor 138, and an insertion
element 5374 configured to guide sensor 138. Applicator 5300
further comprises a retention element 5382, which may comprise an
elastomeric band (e.g., a rubber band), a flexible plastic, or
metallic wire configured to press against an open side of insertion
element 5374 thereby retention sensor 138 in insertion element
5374. Upon activation of applicator 5300, an orientation or
position of one or more of retention feature 5384, retention
element 5382 or insertion element 5374 may be altered such that
sensor 138 is no longer actively retained within insertion element
5374. For example, insertion element 5374 may be configured to
progress in the proximal direction at the beginning of activation.
The insertion element 5374 is withdrawn from the retention element
allowing the retention element to recoil and clear the pathway of
insertion for the on-skin sensor assembly.
[0450] FIG. 54 illustrates a perspective view of another sensor
retention mechanism 5482 for an applicator 5400 for an analyte
sensor system, according to some embodiments. In FIG. 54, sensor
retention mechanism 5482 comprises a flexible or substantially
rigid insert configured to rest against applicator housing 5402 and
against insertion element 5474, thereby retention sensor 138 in
insertion element 5474. For example, retention mechanism 5482 may
comprise a paper, plastic, elastomeric, metallic or polymeric sheet
configured for removal before activation of applicator 5400. In
some embodiments, retention mechanism 5482 may be manufactured or
cut to include a tab 5486 configured to press against insertion
element 5474, thereby retention sensor 138 in insertion element
5474.
[0451] In some embodiments, retention mechanism 5482 may be coupled
to a liner of an adhesive patch of on-skin sensor assembly 160 such
that when the liner is removed, in preparation for application of
on-skin sensor assembly 160, retention mechanism 5482 may be
simultaneously removed.
[0452] In some other embodiments, tab 5486 may be disposed at such
an angle that, rather than holding insertion element 5474 and
sensor 138 between tab 5486 and another portion of retention
mechanism 5482, insertion element 5474 and sensor 138 are
configured to pierce and pass at least partially through tab 5486
such that sensor 138 is retained within a channel of insertion
element 5474.
[0453] FIG. 55 illustrates a cutaway view of another sensor
retention element 5592 for an applicator 5500 for an analyte sensor
system, according to some embodiments. As shown, retention element
5592 may comprise a pad comprising foam, an elastomer, or any other
suitable material, and insertion element 5574 may be inserted at
least partially into retention element 5592 such that sensor 138
(not shown in FIG. 55) is retained within insertion element 5574.
Retention element 5592 may be coupled to a bottom cap 5590 which is
removable prior to activation of applicator 5500.
[0454] FIGS. 56A-56B illustrate perspective views of another sensor
retention element 5682 for an applicator 5600 for an analyte sensor
system, according to some embodiments. Sensor retention element
5682 may comprise a paddle or other surface configured to rest
against insertion element 5674 in a retention position, thereby
retention sensor 138 in the insertion element 5674. FIG. 56A
illustrates sensor retention element 5682 in the retention
position. Sensor retention element 5682 is configured to rotate,
slide, or move away from insertion element 5674 into a
non-retaining position, thereby putting applicator 5600 in a state
for activation. In some embodiments the arm of sensor retention
element 5682 is configured to automatically move during or after
activation into a non-retaining position via a linkage attached to
an element of the applicator. FIG. 56B illustrates sensor retention
element 5682 in the non-retaining position.
[0455] In some embodiments, sensor 138 may be retained in a channel
of an insertion element by an elastomeric band disposed around at
least a portion of insertion element (e.g., an O-ring or any other
flexible band material). The elastomeric band may be removed
manually before deployment, or alternatively, may be removed from
insertion element automatically by some operation of the applicator
upon activation. In some embodiments (e.g. applicator 500) the
insertion element is configured to move in the proximal direction
during the first portion (e.g. by changing the starting position of
the scotch-yoke mechanism) of the insertion cycle. In this
embodiment the elastomeric element is able to clear the distal tip
of the insertion element and recoil to clear the pathway of
insertion of the on skin assembly.
[0456] In some other embodiments, sensor 138 may be retained in a
channel of an insertion element by a foam, paper, cardboard,
plastic, polymeric tab configured to be pierced by insertion
element such that the tab is disposed substantially around a tip of
insertion element, thereby retaining sensor 138 in the channel of
the insertion element. The tab may be removed manually before
deployment, or alternatively, may be removed from insertion element
automatically by some operation of the applicator upon
activation.
[0457] FIG. 57 illustrates a perspective view of yet another sensor
retention element 5782 for an applicator for an analyte sensor
system, according to some embodiments. Sensor retention element
5782 includes a needle hub (not shown in FIG. 57) configured to
guide insertion element 5774 (e.g., a C-needle), which is it turn
configured to guide sensor 138. A flexible sleeve comprising a
first portion 5706a and a second portion 5706b is disposed over
sensor 138 and insertion element 5774, thereby retaining sensor 138
in insertion element 5774. Upon activation, the needle hub is
configured to drive insertion element 5774 in the distal direction,
thereby splitting the flexible sleeve and separating first portion
5706a and second portion 5706b. Once split, the flexible sleeve may
no longer retain sensor 138 in insertion element 5774.
[0458] FIG. 58 illustrates a perspective view of yet another sensor
retention element 5882 for an applicator for an analyte sensor
system, according to some embodiments. Sensor retention element
5882 includes a needle hub (not shown in FIG. 58) configured to
guide insertion element 5874 (e.g., a C-needle), which is it turn
configured to guide sensor 138. A flexible sleeve comprising a
first portion 5806a and a second portion 5806b is disposed over
sensor 138 within a channel of insertion element 5874, thereby
retaining sensor 138 in insertion element 5874. Upon activation,
the needle hub is configured to drive insertion element 5874 in the
distal direction, thereby splitting the flexible sleeve and
separating first portion 5806a and second portion 5806b. Once
split, the flexible sleeve may no longer retain sensor 138 in
insertion element 5874.
[0459] FIGS. 59A-59B illustrate cutaway views of yet another sensor
retention element for an applicator for an analyte sensor system,
according to some embodiments. FIG. 59A illustrates a position of
on-skin sensor assembly 160, an insertion element 5974 guiding
sensor 138, and a cannula (e.g. a tube such as PTFE, PE, polymer,
metallic, etc.) 5962, configured to retain sensor 138 in an open
sided insertion element 5974, during and before applicator
activation. In FIG. 59A, cannula 5962 may be coupled to on-skin
sensor assembly 160 or at least configured to be driven to the
distal inserted position along with on-skin sensor assembly
160.
[0460] FIG. 59B illustrates on-skin sensor assembly 160, sensor
assembly 138, and cannula 5962 in the inserted distal position with
respect to skin 130 of the host, insertion element 5974 having been
retracted to the proximal retracted position (not shown in FIG.
59B). As shown, sensor 138 may be inserted and disposed through
cannula 5962, into skin 130 of the host. Cannula 5962 may provide
strain relief and a minimum bend radius for sensor 138, thereby
reducing the probability of damage to sensor 138 during deployment
and operation. A significant portion of the elongated body of the
analyte sensor may extend subcutaneously beyond the cannula so as
not to interfere with sensor function.
On-Skin Sensor Assembly Features
[0461] FIG. 68 illustrates a perspective view of an on-skin sensor
assembly 6860, which may include a base 6828. An adhesive patch
6826 can couple the base 6828 to the skin 6830 of the host. In some
embodiments, the adhesive patch 6826 may comprise an adhesive
suitable for skin adhesion, for example a pressure sensitive
adhesive (e.g., acrylic, rubber-based, or other suitable type)
bonded to a carrier substrate (e.g., spun lace polyester,
polyurethane film, or other suitable type) for skin attachment,
though any suitable type of adhesive is also contemplated. An
on-skin sensor assembly 6860 may comprise an electronics unit 6840
(e.g., a transmitter) which may further comprise a glucose sensor
module 6834 coupled to a glucose sensor 6838 and to base 6828.
[0462] The applicator system can couple adhesive patch 6826 to skin
6830. The glucose sensor module 6834 may be secured to base 6828
(e.g., via retention elements such as snap fits and/or interference
features, adhesive, welding, etc.) to ensure glucose sensor 6838 is
coupled to base 6828. In alternative embodiments, the sensor module
6834 and base 6828 are preassembled or manufactured as a single
component.
[0463] After on-skin sensor assembly 6860 is applied to a user's
skin, a user (or an applicator) can couple electronics unit 6840
(e.g., a transmitter) to on-skin sensor assembly 6860 via retention
elements such as snap fits and/or interference features.
Electronics unit 6840 can measure and/or analyze glucose indicators
sensed by glucose sensor 6838. Electronics unit 6840 can transmit
information (e.g., measurements, analyte data, glucose data) to a
remotely located device (e.g., 110-114 shown in FIG. 1).
[0464] On-skin sensor assembly 6860 may be attached to the host
with use of an applicator adapted to provide convenient and secure
application. Such an applicator may also be used for attaching
electronics unit 6840 to base 6840, inserting sensor 6838 through
the host's skin, and/or connecting sensor 6838 to electronics unit
6840. Once electronics unit 6840 is engaged with the base and
sensor 6838 has been inserted into the skin (and is connected to
the electronics unit 6840), the sensor assembly can detach from the
applicator.
[0465] FIG. 69 illustrates a perspective view of electronics unit
6840 coupled to base 6828 via retention elements such as snap fits
and/or interference features. In some embodiments, electronics unit
6840 and base 6828 are coupled by adhesive, welding, or other
bonding techniques. Adhesive patch 6826, on a distal face of base
6828, is configured to couple sensor assembly 6860 to the skin.
[0466] Reverting to on-skin sensor assembly 160 as previously
described in connection with FIG. 1, FIG. 70 illustrates a
perspective view of on-skin sensor assembly 6860. On-skin sensor
assembly 6860 may be disposable or reusable. FIG. 70 further
illustrates electronics unit 6840 coupled to a base 6828, and
adhesive patch 6826 configured to be attached to on-skin sensor
assembly 6860, which, when combined, may be held within the
applicator. Adhesive patch 6826 may or may not have a non-adhesive
liner when held in the applicator.
[0467] Further, with respect to any of on-skin sensor assembly 160,
260, 360 of FIGS. 1 and 2A-4, or on-skin sensor assembly 6860 of
FIGS. 68-70, on-skin sensor assembly 160, 260, 360, 6860 is
subjected to stress on portions of sensor 138, 238, 338, 6838 that
are bent as the direction of extension of sensor 138, 238, 338,
6838 transitions from substantially horizontal, within on-skin
sensor assembly 160, 260, 360, 6860 to substantially vertical, at
the interface between on-skin sensor assembly 160, 260, 360, 6860
and skin 130. FIGS. 58-63 describe several embodiments that
minimize the incidence of sensor damage as well as host discomfort
at this interface. While the following description may identify
portions of on-skin sensor assembly 160 of FIG. 1, such description
may be equally applicable to on-skin sensor assembly 260, 360, 6860
of FIGS. 2A-4, and 68-70.
[0468] FIG. 60 illustrates a cutaway view of on-skin sensor
assembly 160 having at least a portion of sensor 138 potted in a
flexible material, according to some embodiments. On-skin sensor
assembly 160 is shown as including at least sensor electronics 140,
an insertion element 6074, such as a C-needle for example, passing
through an opening in on-skin sensor assembly 160, and sensor 138
coupled or couplable to sensor electronics 140 at a first end, and
having a portion that is bent along a bend radius such that a
portion of sensor 138 beyond the bend is nested within or against
insertion element 6074. Sensor 138 is further illustrated as having
a flexible material 6002, e.g., an elastomeric material such as
silicone, disposed around at least a portion of the bend in sensor
138. Flexible material 6002 may operate as a strain-relief element
by limiting the bend radius of the bend to some predetermined
minimum radius that substantially reduces or eliminates damage to
sensor 138. In some embodiments, flexible material 6002 may extend
to the hole through which sensor 138 passes at the on-skin sensor
assembly-to-skin interface, which further provides a seal from
moisture ingress to on-skin sensor assembly 160. In some
embodiments, a dedicated seal comprising a flexible material may be
provided at the hole through which sensor 128 passes in addition to
or as an alternative to flexible material 6002.
[0469] FIG. 61 illustrates a cutaway view of on-skin sensor
assembly 160 comprising an open cavity configured to allow a larger
bend radius in sensor 138, compared to that shown in FIG. 60,
according to some embodiments. On-skin sensor assembly 160 is shown
as including at least sensor electronics 140, an insertion element
6174, such as a C-needle for example, passing through an opening in
on-skin sensor assembly 160, and sensor 138 coupled or couplable to
sensor electronics 140 at a first end, and having a portion that is
bent along a bend radius such that a portion of sensor 138 beyond
the bend is nested within or against insertion element 6174. A
bottom of on-skin sensor assembly 160 further includes an open
cavity 6102. Open cavity 6102 allows sensor 138 to bend along a
larger minimum bending radius than would be possible for an on-skin
sensor assembly that does not include open cavity 6102. Sensor 138
is shown in FIG. 61 as initiating this bend in advance of reaching
open cavity 6102 and arcing in an upward direction at the beginning
of the bend, further increasing the potential minimum bend radius
of sensor 138. Such a larger bend radius reduces stress and strain
on sensor 138, thereby reducing the probability of damage to sensor
138.
[0470] Open cavity 6102 may further promote healing of the open
wound caused by insertion of sensor 138 by insertion element 6174
by providing access air access that improves drying of the wound
site. Although not shown in FIG. 61, on-skin sensor assembly 160
may further include a porous, woven, or spun lace material
configured to wick away moisture from sweating or any other source,
such as blood from the wound. Open cavity 6102 would further
provide a location for small amounts of this liquid, e.g., blood,
to collect, thereby preventing it from seeping out and being
visible to the host. Although not shown in FIG. 61, sensor 138 may
further include flexible material 6002, e.g., silicone, disposed
around at least a portion of the bend in sensor 138 and/or a seal
at the hole through which sensor 138 passes, as previously
described in connection with FIG. 60.
[0471] FIG. 62 illustrates a cutaway view of on-skin sensor
assembly 160 comprising an open cavity configured to allow a larger
bend radius in sensor 138, compared to that shown in FIG. 60,
according to some embodiments. On-skin sensor assembly 160 is shown
substantially as previously described in connection with FIG. 61,
however, sensor 138 is shown as initiating the upward bend upon
reaching, rather than in advance of reaching, open cavity 6102.
Although not shown in FIG. 62, sensor 138 may further include
flexible material 6002, e.g., silicone, disposed around at least a
portion of the bend in sensor 138 and/or a seal at the hole through
which sensor 138 passes, as previously described in connection with
FIG. 60. Such a larger bend radius reduces stress and strain on
sensor 138, thereby reducing the probability of damage to sensor
138.
[0472] FIG. 63 illustrates a cutaway view of on-skin sensor
assembly 160 comprising an open cavity configured to allow a larger
bend radius in sensor 138, compared to that shown in FIG. 60,
according to some embodiments. Such a larger bend radius reduces
stress and strain on sensor 138, thereby reducing the probability
of damage to sensor 138. On-skin sensor assembly 160 is shown
substantially as previously described in connection with FIG. 61,
however, sensor 138 is shown as initiating a bend upon reaching,
rather than in advance of reaching, open cavity 6102 and this bend
is substantially in the downward direction, rather than first in an
upward direction. Although not shown in FIG. 63, sensor 138 may
further include flexible material 6002, e.g., silicone, disposed
around at least a portion of the bend in sensor 138 and/or a seal
at the hole through which sensor 138 passes, as previously
described in connection with FIG. 60.
[0473] In yet other embodiments, at least a portion of sensor 138
may have a braided polyurethane material disposed thereon to
provide further strain relief. In addition, or in the alternative,
additional materials such as an elastomer, flexible adhesive, or
other braided or molded polymer material may be disposed thereon,
in some embodiments, at least on the bend in sensor 138 and/or at a
transition into on-skin sensor assembly 160, to provide further
strain relief. It is contemplated that the components and features
described above and/or with respect to FIGS. 60-63 can be
implemented in other on-skin sensor assemblies described herein,
such as on-skin sensor assembly 260 and 360.
[0474] In addition, during pressure fluctuations, such as at high
altitude or vacuum during sterilization processes for example, air
present within the applicator may exert a deforming force on
on-skin sensor assembly 160. Although not shown in any of FIGS.
60-63, in some embodiments, on-skin sensor assembly 160 may have at
least a portion formed with a reduced thickness and, therefore,
reduced strength and rigidity, such that when applicator 460 is
exposed to such pressure fluctuations, the portions having the
reduced thickness expand in a controlled manner, thereby reducing
or eliminating damage that would otherwise occur to on-skin sensor
assembly 160 due to undesirable uncontrolled expansion of on-skin
sensor assembly 160. Such a feature may be present in the
applicator housing of any applicator described herein.
[0475] FIGS. 64A-64B illustrate an optional battery connection
feature for on-skin sensor assembly 160, 260, 360 in accordance
with some embodiments. FIG. 64A illustrates a storage mode,
pre-activation. On-skin sensor assembly 160 is illustrated as
including a battery 6410 configured to power at least sensor
electronics (e.g., transmitter/sensor electronics 140, see FIG. 1).
On-skin sensor assembly 160 further includes an electrical contact
6402, configured to physically and electrically contact battery
6410, an electrically insulating material 6404 (e.g., polyethylene
terephthalate (PET), or any other electrically insulative material)
disposed between electrical contact 6402, and a flexible material
6406 (e.g., ductile PET, TPSiV.RTM. or any other suitable material)
coupled to on-skin sensor assembly 160 and to electrically
insulating material 6404. In operation, pre-activation,
electrically insulating material 6404 prevents electrical contact
between electrical contact 6402 and battery 6410, maintaining
on-skin sensor assembly 160 in an unpowered storage mode that
prevents battery drain before deployment. During activation, some
portion 6408 of applicator may be configured to push down on
flexible material 6406, which is physically coupled to electrically
insulating material 6404, thereby shifting electrically insulating
material 6404 such that electrical contact 6402 comes into
electrical contact with battery 6410 and shifting on-skin sensor
assembly 160 into a battery connected operational mode, as will be
shown in more detail in connection with FIG. 64B.
[0476] FIG. 64B illustrates the battery connected, operational mode
of on-skin sensor assembly 160, 260, 360 discussed in FIG. 64A.
Portion 6408 of applicator is illustrated as having pushed down or
deformed flexible material 6406 and moved electrically insulating
material 6404 laterally such that electrical contact 6402 is in
electrical contact with battery 6410.
[0477] FIGS. 88A-88B illustrate another optional battery connection
feature for on-skin sensor assembly 160, 260, 360 in accordance
with some embodiments. FIGS. 88A illustrates a first perspective
view of a battery socket 8804 configured to hold a coin battery
8810 (see FIG. 88B), according to some embodiments. FIG. 88B
illustrates a second perspective view of the battery socket 8804,
according to some embodiments. Battery socket 8804 comprises a
first terminal comprising a tab 8806, configured to make physical
and electrical contact with one of a positive terminal or a
negative terminal of battery 8810. Battery socket 8804 further
comprises a second terminal comprising one or more clips 8808
configured to make physical and electrical contact with the other
of the positive terminal or the negative terminal of battery 8810.
In some embodiments, a portion of a PCB 8802 may insulate tab 8806
from the one or more clips 8808. In some embodiments, battery
socket 8804 may be soldered to PCB 8802 to provide electrical
and/or structural connections between battery socket 8804 and one
or more electrical components on PCB 8802. In some embodiments, PCB
8802 may comprise a single unitary piece. In some embodiments,
battery 8810 may be secured to battery socket 8804 during assembly
of on-skin sensor assembly 160, 260, 360. In some embodiments,
battery 8810 may be secured to tab 8806 via one or more tack welds.
In some embodiments, battery 8810 may be additionally or
alternatively secured to tab 8806 utilizing a spring, a piece of
foam, or any other element disposed between battery 8810 and a
housing or other portion of on-skin sensor assembly 160, 260, 360
and configured to push or retain battery 8810 against tab 8806. In
some embodiments, battery 8810 may additionally or alternatively be
secured to the one or more clips 8808 via one or more respective
tack welds.
Sterilization, Packaging, and Sealing Embodiments
[0478] For any of the embodiments of applicators expressly
described herein, sterilization, packaging, and/or sealing features
may also be included. In some embodiments, a user removing the
applicator from its packaging and/or its sterilization features may
partially or fully energize the applicator (e.g., load unloaded
springs). For example, motions such as pulling, twisting, pushing,
or tilting required to remove an applicator from its packaging or
to remove one or more sterilization and/or sealing features from
the applicator may be harnessed to load partially unloaded or fully
unloaded springs within the applicator. Such features would provide
a benefit in that less energy would have to be stored in the
springs of the applicator during its shelf life, prior to its use.
Examples of sterilizing, sealing and packaging features
contemplated for inclusion with any applicator described herein are
described more fully in U.S. patent application Ser. No. 16/011527,
which is incorporated herein by reference it its entirety.
[0479] FIG. 67 illustrates exemplary sterilization, packaging and
sealing features of an applicator configured to apply an on-skin
sensor assembly to skin of a host, according to some embodiments.
In some embodiments, the applicator (e.g. applicator 500, 800, 900,
1000, etc.). may incorporate features such as sterile barrier,
tamper evidence, device sealing and/or device protection. Methods
of sterile barrier, tamper evidence, device sealing, and/or device
protection are also described in U.S. patent application Ser. No.
16/011527. Non-limiting examples may include a tamper evident
feature 6810 (e.g. FIGS. 1A-5B), a capsule sealing feature 6820
(e.g. FIGS. 1A-3C), a gas permeable 6830 and/or non-gas permeable
sterile barrier 6840 (e.g. FIGS. 1A, 2B, 4B, 5B, 7B, 8B, 9, 11A,
13A, 15A-27B, 29-30B), or device protection feature 6850 (e.g. FIG.
1A-24B).
[0480] Tamper evident sealing or other tamper evidence features
6810 allow a consumer to identify when an applicator has been
previously used or containment has been breached and, thus, avoid
using an applicator that may be faulty or pose an increased health
risk if used. Non-limiting examples of tamper evident features 6810
also described in U.S. patent application Ser. No. 16/011527,
include ring, peelable layer, perforated tab, adhesive mounted tab,
and/or twist-off collar. These features may be incorporated in
current embodiments within an applicator housing (e.g. 502) or
additional bodies added to the applicator assembly (e.g. cap,
shell, lid, tab, peelable layer, frangible, ring, etc.).
[0481] Capsule sealing features 6820 create an enclosed volume from
multiple components. Non limiting examples of capsule sealing
features also described in U.S. patent application Ser. No.
16/011527, include one or more removable caps on the top (e.g.,
proximal) or bottom (e.g., distal) ends of the applicator, through
one or more trigger mechanisms comprising integrated caps, through
one or more sealing layers that cover one or more orifices,
apertures or vents of the applicator, through sterilizable
gas-permeable polymers, through sterilizable gas-permeable trigger
mechanisms, through protective cups, or any combinations of the
same, described in more detail with at least some of FIGS. 1A-33.
These features may be incorporated in current embodiments within an
applicator housing (e.g. 502) or additional bodies added to the
applicator assembly (e.g. cap, shell, lid, tab, peelable layer,
elastomer, 0-ring, adhesive, button, etc.).
[0482] Gas permeable sterile barriers 6830 allow a device to create
an enclosed volume that is permeable to a gas (e.g. a sterilization
gas) and maintain a microbial barrier to an exterior volume. A
non-gas permeable sterile barrier 6840 performs the same functions
of a gas permeable sterile barrier with the additional function of
blocking gasses than may have deleterious effects (e.g. water
vapor). Gas permeable 6830 and/or non-gas permeable sterile barrier
6840 may be used in conjunction or independently as also described
in U.S. patent application Ser. No. 16/011527. These features may
be incorporated in current embodiments within an applicator housing
(e.g. 502) or additional bodies added to the applicator assembly
(e.g. cap, shell, lid, tab, peelable layer, packaging, seal,
button, etc.).
[0483] Device protection features 6850 may be adapted to protect
functional components of applicators (e.g. applicator 500, 800,
900, 1000, etc.). Functions may include inadvertent activation
prevention, drop protection, needle damage protection, or other
functions also disclosed in U.S. patent application Ser. No.
16/011527. These features may be incorporated in current
embodiments within an applicator housing (e.g. 502) or additional
bodies added to the applicator assembly (e.g. cap, shell, lid, tab,
peelable layer, frangible, packaging, seal, button, etc.). Methods
of Applying an On-Skin Sensor Assembly to Skin of a Host
[0484] FIG. 65 illustrates a flowchart 6500 of a method for
applying an on-skin sensor assembly to skin of a host, according to
some embodiments. Steps in flowchart 6500 may be performed
utilizing any applicator as previously described in connection with
any of the previous FIGS. Although certain steps are set forth
below, a method of using such an applicator may comprise more,
fewer, or different steps, in the same or different order from that
set forth below.
[0485] Flowchart 6500 illustrates block 6502, including providing
an applicator comprising an applicator housing, a needle carrier
assembly comprising an insertion element configured to insert a
sensor of the on-skin sensor assembly into the skin of the host, a
holder releasably coupled to the needle carrier assembly and
configured to guide the on-skin sensor assembly while coupled to
the needle carrier assembly, a drive assembly, and an activation
element. In some embodiments, the distal direction and the proximal
direction extend along an insertion axis of the insertion
element.
[0486] Flowchart 6500 further illustrates block 6504, including
activating an activation element, wherein activating the activation
element causes the drive assembly to drive the insertion element in
a distal direction to a distal insertion position and in a proximal
direction from the distal insertion position to a proximal
retraction position, thereby inserting the sensor of the on-skin
sensor assembly at least partially into the skin of the host.
[0487] FIG. 89 illustrates a flowchart 8900 of another method for
applying an on-skin sensor assembly to skin of a host, according to
some embodiments. Steps in flowchart 8900 may be performed
utilizing any applicator as described in connection with any FIGs.,
for example but not limitation, FIGS. 71-88. Although certain steps
are set forth below, a method of using such an applicator may
comprise more, fewer, or different steps, in the same or different
order from that set forth below.
[0488] Flowchart 8900 illustrates block 8902, including providing
an applicator comprising a housing having an activation element, an
insertion assembly, and a retraction assembly.
[0489] Flowchart 8900 further illustrates block 8904, including
activating the activation element, wherein activating the
activation element causes the insertion assembly to translate a
needle carrier assembly and the on-skin sensor assembly in a distal
direction from a proximal position to a distal insertion position,
thereby inserting a sensor of the on-skin sensor assembly at least
partially into the skin of the host, and the retraction assembly to
translate the needle carrier assembly in a proximal direction from
the distal inserted position to a proximal retracted position, the
retraction assembly configured to activate in response to on-skin
sensor assembly contacting the skin of the host. In some
embodiments, the distal direction and the proximal direction extend
along an insertion axis of an insertion element of the applicator.
Exemplary Mechanisms for Applicator Features
[0490] FIG. 66 illustrates exemplary mechanisms for several
features of an applicator configured to apply an on-skin sensor
assembly to skin of a host, according to some embodiments. The
mechanisms described in connection with FIG. 66 are exemplary and
not limiting.
[0491] For example, the feature activation element 6610 as used
herein may be considered to include any type of mechanism that,
when operated as intended, serves to activate a drive mechanism of
an applicator and, thereby, apply an on-skin sensor assembly to
skin of a host. For example, an activation element may include an
element configured to trigger when pushed, pulled, switched,
toggled, slid, triggered, deflected, rotated, deformed or flexed
from a first position or state to at least a second position or
state. General examples include but are not limited to buttons,
slides, hooks, switches, a flexible portion of the applicator
housing itself, tabs, or strings. Moreover, although certain
embodiments of applicators are described herein as having an
activation element in a particular location, any applicator
described herein is also contemplated having one or more activation
members in any other position, e.g., a top, upper side, medial
side, lower side, or bottom of the applicator. Moreover, in some
embodiments, two or more activation elements may be operated in
tandem in order to activate the applicator. The above-described
activation elements may be applied or utilized in connection with
any applicator described herein.
[0492] The feature insertion element 6620 as used herein may be
considered to include any type of mechanism that, when operated as
intended, serves to insert a sensor or sensor wire at least
partially into a skin of a host. For example, an insertion element
may include, but is not limited to, a regular, circumferential
needle, an open sided-needle (e.g., FIGS. 48A-48B), a needle with a
deflected tip (e.g., FIG. 49), a curved, bent or kinked needle
(e.g., FIGS. 47 and 50), a polymer-coated needle, a hypodermic
needle, or the sensor or sensor wire tip itself.
[0493] The feature retention element or on-skin sensor assembly
retention element 6630 as used herein may be considered to include
any type of mechanism that, when operated as intended, serves to
retain an on-skin sensor assembly in a particular position,
orientation or constrain the feature to a particular path of
motion. For example, a retention element may include, but is not
limited to, a hook, a claw, a tab, an arm, an undercut and snap
feature, a press fit feature, a deformable and/or elastomeric
element (as described in connection with any of FIGS. 5-7D, 12-14E,
25-27E, 32A-37C and 41A-46), or any on-skin sensor assembly
retention element illustrated in U.S. patent application Ser. No.
15/387088 as described above.
[0494] The feature spring and/or energy source 6650 as used herein
may be considered to include any suitable type of spring configured
to store potential energy when loaded and configured to release at
least a portion of that stored potential energy to drive one or
more portions of an applicator as required or desired. For example,
a spring may include, but is not limited to, a compression spring,
which is configured to store energy when compressed to less than
its resting length (e.g., FIG. 32), an extension spring, which is
configured to store energy when stretched to greater than its
resting length (e.g., FIG. 21), a single or double torsion spring
(e.g., FIG. 12), clock spring or power spring, which are configured
to store energy in torsional deformation of a portion of the spring
from its resting profile, or a leaf spring (e.g., FIGS. 22 and 25),
which is configured to store energy in the physical deformation of
the spring from its resting profile.
[0495] Insertion and/or retraction mechanisms 6660 may be
considered to include any suitable mechanism for causing a movement
of an insertion element in a distal direction to a distal inserted
position, and/or in a proximal direction to a proximal retracted
position. For example, such mechanisms may include, but are not
limited to, a scotch yoke mechanism (e.g., FIG. 5) a barrel cam
(e.g., FIG. 29), opposing springs mechanism, a reverse toggling
mechanism comprising a lever having a first end, a second end, and
a fulcrum at a point between the first and second ends (e.g., FIG.
31), a flexible linkage (e.g., FIGs.18-23), a spring linkage (e.g.
FIG. 12-14E), or any hinging or pivoting (e.g. FIG. 25-28H)
apparatus that operates as described in this disclosure.
[0496] Energy storage 6640, for example, as potential energy stored
in a spring, for any applicator described in this disclosure may be
pre-loaded (e.g., in the factory or before provision to a user),
mechanism loaded (e.g., some operation of the applicator loads the
spring), or user loaded (e.g., the user provides energy in some
form of motion that is utilized to store potential energy in a
spring).
[0497] Sensor retention 6670 for any applicator described in this
disclosure may be user-removable (e.g., FIGS. 54, 57, 58),
mechanism-removable (e.g., FIGS. 53, 56A-56B, 57 and 58), ex-vivo
support feature (e.g., FIGS. 55-58), or in-vivo support feature
(e.g., FIGS. 59A-59B). For example, an elastomeric element such as
a rubber band (see FIG. 53), a foam, rubber or other pad (see FIG.
55), a frangible element (see FIGS. 57-58), an adhesive layer, or a
wire.
[0498] Elements within each feature category (e.g., 6610, 6620,
6630, 6640, 6650, 6660, 6670) are interchangeable for any
applicator described herein. For instance, applicator 500 shown in
FIGS. 5-611 includes a push button and deflecting arm activation
element 504, an open-sided needle insertion element 674, an
undercut/snap feature 678a, 678b for on-skin sensor assembly 160
retention, a pre-loaded energy storage in which the energy source
is a single torsion spring 512, and a scotch yoke
insertion/retraction mechanism 510. However, in an alternative
embodiment, applicator 500 may instead include a switch/toggle
activation element, a curved/bent needle insertion element (e.g.,
5074), a press fit on-skin sensor assembly retention, and an
ex-vivo support feature sensor retention (e.g., FIGS. 55-58).
[0499] In another example, applicator 2500 shown in FIGS. 25-28H
includes a push button and deflecting arm activation element 2504,
an open-sided needle insertion element 2674, an undercut/snap
feature (e.g., similar to 678a, 678b) on needle carrier assembly
2508 for on-skin sensor assembly 160 retention, a pre-loaded energy
storage in which the energy source is a compression spring 2512 and
leaf springs 2528, and a hinging or pivoting apparatus 2508, 2524.
However, in an alternative embodiment, applicator 2500 may instead
include a switch/toggle activation element, a curved/bent needle
insertion element (e.g., 5074), a press fit on-skin sensor assembly
retention, and an ex-vivo support feature sensor retention (e.g.,
FIGS. 55-58).
[0500] It should be appreciated that all methods and processes
disclosed herein may be used in any glucose monitoring system,
continuous or intermittent. It should further be appreciated that
the implementation and/or execution of all methods and processes
may be performed by any suitable devices or systems, whether local
or remote. Further, any combination of devices or systems may be
used to implement the present methods and processes.
[0501] Methods and devices that are suitable for use in conjunction
with aspects of the preferred embodiments are disclosed in U.S.
Pat. Nos. 4,757,022; 4,994,167; 6,001,067; 6,558,321; 6,702,857;
6,741,877; 6,862,465; 6,931,327; 7,074,307; 7,081,195; 7,108,778;
7,110,803; 7,134,999; 7,136,689; 7,192,450; 7,226,978; 7,276,029;
7,310,544; 7,364,592; 7,366,556; 7,379,765; 7,424,318; 7,460,898;
7,467,003; 7,471,972; 7,494,465; 7,497,827; 7,519,408; 7,583,990;
7,591,801; 7,599,726; 7,613,491; 7,615,007; 7,632,228; 7,637,868;
7,640,048; 7,651,596; 7,654,956; 7,657,297; 7,711,402; 7,713,574;
7,715,893; 7,761,130; 7,771,352; 7,774,145; 7,775,975; 7,778,680;
7,783,333; 7,792,562; 7,797,028; 7,826,981; 7,828,728; 7,831,287;
7,835,777; 7,857,760; 7,860,545; 7,875,293; 7,881,763; 7,885,697;
7,896,809; 7,899,511; 7,901,354; 7,905,833; 7,914,450; 7,917,186;
7,920,906; 7,925,321; 7,927,274; 7,933,639; 7,935,057; 7,946,984;
7,949,381; 7,955,261; 7,959,569; 7,970,448; 7,974,672; 7,976,492;
7,979,104; 7,986,986; 7,998,071; 8,000,901; 8,005,524; 8,005,525;
8,010,174; 8,027,708; 8,050,731; 8,052,601; 8,053,018; 8,060,173;
8,060,174; 8,064,977; 8,073,519; 8,073,520; 8,118,877; 8,128,562;
8,133,178; 8,150,488; 8,155,723; 8,160,669; 8,160,671; 8,167,801;
8,170,803; 8,195,265; 8,206,297; 8,216,139; 8,229,534; 8,229,535;
8,229,536; 8,231,531; 8,233,958; 8,233,959; 8,249,684; 8,251,906;
8,255,030; 8,255,032; 8,255,033; 8,257,259; 8,260,393; 8,265,725;
8,275,437; 8,275,438; 8,277,713; 8,280,475; 8,282,549; 8,282,550;
8,285,354; 8,287,453; 8,290,559; 8,290,560; 8,290,561; 8,290,562;
8,292,810; 8,298,142; 8,311,749; 8,313,434; 8,321,149; 8,332,008;
8,346,338; 8,364,229; 8,369,919; 8,374,667; 8,386,004; 8,394,021;
8,527,025; 7,896,809; 9,119,528; and 9,119,529.
[0502] Methods and devices that are suitable for use in conjunction
with aspects of the preferred embodiments are disclosed in U.S.
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[0503] The above description presents the best mode contemplated
for carrying out the present invention, and of the manner and
process of making and using it, in such full, clear, concise, and
exact terms as to enable any person skilled in the art to which it
pertains to make and use this invention. This invention is,
however, susceptible to modifications and alternate constructions
from that discussed above that are fully equivalent. Consequently,
this invention is not limited to the particular embodiments
disclosed. On the contrary, this invention covers all modifications
and alternate constructions coming within the spirit and scope of
the invention as generally expressed by the following claims, which
particularly point out and distinctly claim the subject matter of
the invention. While the disclosure has been illustrated and
described in detail in the drawings and foregoing description, such
illustration and description are to be considered illustrative or
exemplary and not restrictive.
[0504] All references cited herein are incorporated herein by
reference in their entirety. To the extent publications and patents
or patent applications incorporated by reference contradict the
disclosure contained in the specification, the specification is
intended to supersede and/or take precedence over any such
contradictory material.
[0505] Unless otherwise defined, all terms (including technical and
scientific terms) are to be given their ordinary and customary
meaning to a person of ordinary skill in the art, and are not to be
limited to a special or customized meaning unless expressly so
defined herein. It should be noted that the use of particular
terminology when describing certain features or aspects of the
disclosure should not be taken to imply that the terminology is
being re-defined herein to be restricted to include any specific
characteristics of the features or aspects of the disclosure with
which that terminology is associated. Terms and phrases used in
this application, and variations thereof, especially in the
appended claims, unless otherwise expressly stated, should be
construed as open ended as opposed to limiting. As examples of the
foregoing, the term `including` should be read to mean `including,
without limitation,` including but not limited to,' or the like;
the term `comprising` as used herein is synonymous with
`including,` containing,' or `characterized by,` and is inclusive
or open-ended and does not exclude additional, unrecited elements
or method steps; the term `having` should be interpreted as `having
at least;` the term `includes` should be interpreted as `includes
but is not limited to;` the term `example` is used to provide
exemplary instances of the item in discussion, not an exhaustive or
limiting list thereof; adjectives such as `known`, `normal`,
`standard`, and terms of similar meaning should not be construed as
limiting the item described to a given time period or to an item
available as of a given time, but instead should be read to
encompass known, normal, or standard technologies that may be
available or known now or at any time in the future; and use of
terms like `preferably,` preferred,"desired," or `desirable,` and
words of similar meaning should not be understood as implying that
certain features are critical, essential, or even important to the
structure or function of the invention, but instead as merely
intended to highlight alternative or additional features that may
or may not be utilized in a particular embodiment of the invention.
Likewise, a group of items linked with the conjunction `and` should
not be read as requiring that each and every one of those items be
present in the grouping, but rather should be read as `and/or`
unless expressly stated otherwise. Similarly, a group of items
linked with the conjunction `or` should not be read as requiring
mutual exclusivity among that group, but rather should be read as
`and/or` unless expressly stated otherwise.
[0506] Where a range of values is provided, it is understood that
the upper and lower limit, and each intervening value between the
upper and lower limit of the range is encompassed within the
embodiments.
[0507] With respect to the use of substantially any plural and/or
singular terms herein, those having skill in the art can translate
from the plural to the singular and/or from the singular to the
plural as is appropriate to the context and/or application. The
various singular/plural permutations may be expressly set forth
herein for sake of clarity. The indefinite article `a` or `an` does
not exclude a plurality. A single processor or other unit may
fulfill the functions of several items recited in the claims. The
mere fact that certain measures are recited in mutually different
dependent claims does not indicate that a combination of these
measures cannot be used to advantage. Any reference signs in the
claims should not be construed as limiting the scope.
[0508] It will be further understood by those within the art that
if a specific number of an introduced claim recitation is intended,
such an intent will be explicitly recited in the claim, and in the
absence of such recitation no such intent is present. For example,
as an aid to understanding, the following appended claims may
contain usage of the introductory phrases `at least one` and `one
or more` to introduce claim recitations. However, the use of such
phrases should not be construed to imply that the introduction of a
claim recitation by the indefinite articles `a` or `an` limits any
particular claim containing such introduced claim recitation to
embodiments containing only one such recitation, even when the same
claim includes the introductory phrases `one or more` or `at least
one` and indefinite articles such as `a` or `an` (e.g., `a` and/or
`an` should typically be interpreted to mean `at least one` or `one
or more`); the same holds true for the use of definite articles
used to introduce claim recitations. In addition, even if a
specific number of an introduced claim recitation is explicitly
recited, those skilled in the art will recognize that such
recitation should typically be interpreted to mean at least the
recited number (e.g., the bare recitation of `two recitations,`
without other modifiers, typically means at least two recitations,
or two or more recitations). Furthermore, in those instances where
a convention analogous to `at least one of A, B, and C, etc.` is
used, in general such a construction is intended in the sense one
having skill in the art would understand the convention (e.g., `a
system having at least one of A, B, and C` would include but not be
limited to systems that have A alone, B alone, C alone, A and B
together, A and C together, B and C together, and/or A, B, and C
together, etc.). In those instances where a convention analogous to
`at least one of A, B, or C, etc.` is used, in general such a
construction is intended in the sense one having skill in the art
would understand the convention (e.g., `a system having at least
one of A, B, or C` would include but not be limited to systems that
have A alone, B alone, C alone, A and B together, A and C together,
B and C together, and/or A, B, and C together, etc.). It will be
further understood by those within the art that virtually any
disjunctive word and/or phrase presenting two or more alternative
terms, whether in the description, claims, or drawings, should be
understood to contemplate the possibilities of including one of the
terms, either of the terms, or both terms. For example, the phrase
`A or B` will be understood to include the possibilities of `A` or
`B` or `A and B.`
[0509] All numbers expressing quantities of ingredients, reaction
conditions, and so forth used in the specification are to be
understood as being modified in all instances by the term `about.`
Accordingly, unless indicated to the contrary, the numerical
parameters set forth herein are approximations that may vary
depending upon the desired properties sought to be obtained. At the
very least, and not as an attempt to limit the application of the
doctrine of equivalents to the scope of any claims in any
application claiming priority to the present application, each
numerical parameter should be construed in light of the number of
significant digits and ordinary rounding approaches.
[0510] Furthermore, although the foregoing has been described in
some detail by way of illustrations and examples for purposes of
clarity and understanding, it is apparent to those skilled in the
art that certain changes and modifications may be practiced.
Therefore, the description and examples should not be construed as
limiting the scope of the invention to the specific embodiments and
examples described herein, but rather to also cover all
modification and alternatives coming with the true scope and spirit
of the invention.
* * * * *