Systems, devices, and methods for assembling an applicator and sensor control device

Abstract

Systems, devices, and methods are provided for the assembly and subsequent delivery of an in vivo analyte sensor. An applicator with sensor electronics is inserted into a tray containing an assembly that includes a sharp and an analyte sensor. The insertion causes the assembly to couple with the sensor electronics and form a deliverable sensor control device retained within the applicator, which can then be placed in position on a body of a user to monitor that user's analyte levels.

Description

FIELD

The subject matter described herein relates generally to systems, devices, and methods for assembling an applicator and sensor control device for use in an in vivo analyte monitoring system.

BACKGROUND

Diabetes is a metabolic disease which relates to high blood sugar levels in the body and can be a result of the pancreas failing to produce enough insulin or cells in the body responding improperly to insulin produced. Numerous complications can arise if symptoms of diabetes are not carefully monitored and treated include diabetic ketoacidosis, nonketotick hypersmolar coma, cardiovascular disease, stroke, kidney failure, foot ulcers, eye damage and others. Traditionally, monitoring has involved an individual pricking a finger to draw blood and testing the blood for glucose levels. More recent advancements have allowed for long-term monitoring of blood glucose using sensors which are maintained in the body for periods of days, weeks, or longer.

Long-term monitoring of analytes in bodily fluid can be accomplished when a user assembles a sterile sensor control device with an applicator or insertion mechanism and inserts a sensor of the device into contact with a bodily fluid. While current sensors can be convenient for users, they can suffer from user errors which cause malfunctions. These malfunctions can be caused by improper use due to accidents, lack of education, poor coordination, complicated procedures and other issues. Some prior art systems suffer by relying too much on the precision assembly of a sensor control device and an applicator by the user, prior to actually deploying the sensor control device on the user's body.

Thus, needs exist for more reliable sensor application devices that are easy to use by the patient.

SUMMARY

Provided herein are example embodiments of systems, devices and methods for assembling an applicator and a sensor control device. An applicator can be provided to the user in a sterile package with an electronics housing of the sensor control device contained therein. A structure separate from the applicator, such as a container, can also be provided to the user as a sterile package with a sensor module and a sharp module contained therein. The user can couple the sensor module to the electronics housing and can couple the sharp to the applicator with an assembly process that involves insertion of the applicator into the container in a specified manner. The embodiments provided herein are improved to prevent or reduce the negative impact of the applicator tilting with respect to the container during a sensor assembly process. Other improvements and advantages are provided as well. The embodiments described herein can make the assembly process more reliable and easier to complete by the user. After assembly, the applicator can be used to position the sensor control device on a human body with a sensor in contact with the wearer's bodily fluid (e.g., interstitial fluid, dermal fluid, blood, etc.). The various configurations of these devices and variations to the assembly methods are described in detail by way of the embodiments which are only examples.

Other systems, devices, methods, features and advantages of the subject matter described herein will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, devices, methods, features and advantages be included within this description, be within the scope of the subject matter described herein, and be protected by the accompanying claims. In no way should the features of the example embodiments be construed as limiting the appended claims, absent express recitation of those features in the claims.

BRIEF DESCRIPTION OF THE FIGURES

The details of the subject matter set forth herein, both as to its structure and operation, may be apparent by study of the accompanying figures, in which like reference numerals refer to like parts. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the subject matter. Moreover, all illustrations are intended to convey concepts, where relative sizes, shapes and other detailed attributes may be illustrated schematically rather than literally or precisely.

FIG. 1 is a system overview of a sensor applicator, reader device, monitoring system, network and remote system.

FIG. 2A is a block diagram depicting an example embodiment of a reader device.

FIG. 2B is a block diagram depicting an example embodiment of a sensor control device.

FIG. 3A is a proximal perspective view depicting an example embodiment of a user preparing a tray for an assembly.

FIG. 3B is a side view depicting an example embodiment of a user preparing an applicator device for an assembly.

FIG. 3C is a proximal perspective view depicting an example embodiment of a user inserting an applicator device into a tray during an assembly.

FIG. 3D is a proximal perspective view depicting an example embodiment of a user removing an applicator device from a tray during an assembly.

FIG. 3E is a proximal perspective view depicting an example embodiment of a patient applying a sensor using an applicator device.

FIG. 3F is a proximal perspective view depicting an example embodiment of a patient with an applied sensor and a used applicator device.

FIG. 4A is a side view depicting an example embodiment of an applicator device coupled with a cap.

FIG. 4B is a side perspective view depicting an example embodiment of an applicator device and cap decoupled.

FIG. 4C is a perspective view depicting an example embodiment of a distal end of an applicator device and electronics housing.

FIG. 5A is a proximal perspective view depicting an example embodiment of a tray with sterilization lid coupled.

FIG. 5B is a proximal perspective cutaway view depicting an example embodiment of a tray with sensor delivery components.

FIG. 5C is a proximal perspective view depicting sensor delivery components.

FIG. 6A is a side cross-section depicting an example embodiment of an applicator device and a tray.

FIG. 6B is a side cross-section depicting an example embodiment of an applicator device and a tray showing a first interaction between components.

FIG. 6C is a side cross-section depicting an example embodiment of an applicator device and tray showing a subsequent interaction between components.

FIG. 6D is a side cross-section depicting an example embodiment of an applicator device and tray showing a further interaction between components.

FIG. 6E is a side cross-section depicting an example embodiment of an applicator device and tray showing yet another interaction between components.

FIG. 6F is a side cross-section depicting an example embodiment of an applicator device and tray showing additional component interaction.

FIGS. 6G-H are side cross-section depictions of an example embodiment of an applicator device showing changes in sheath and housing orientation.

FIG. 7A is side view depicting an example embodiment of a housing.

FIG. 7B is a perspective view depicting an example embodiment of a distal end of a housing.

FIG. 7C is a side cross-section depicting an example embodiment of a housing.

FIG. 8A is a side view depicting an example embodiment of a sheath.

FIG. 8B is a perspective view depicting an example embodiment of a proximal end of a sheath.

FIG. 8C is a close-up perspective view depicting an example embodiment of a distal side of a detent snap of a sheath.

FIG. 8D is a side view depicting an example embodiment of features of a sheath.

FIG. 8E is an end view depicting an example embodiment of a proximal end of a sheath.

FIG. 9A is a proximal perspective view depicting an example embodiment of a sensor electronics carrier.

FIG. 9B is a distal perspective view depicting an example embodiment of a sensor electronics carrier.

FIG. 10A is a proximal perspective view depicting an example embodiment of a sharp carrier.

FIG. 10B is a side cross-section depicting an example embodiment of a sharp carrier.

FIG. 11 is a perspective cross-section view depicting an example embodiment of a cap.

FIG. 12A is a proximal perspective view depicting an example embodiment of a platform.

FIG. 12B is a side cross-section depicting an example embodiment of a platform.

FIG. 12C is an end view depicting an example embodiment of a distal end of a platform.

FIG. 12D is a proximal view depicting an example embodiment of a rib feature of a platform.

FIG. 12E is a side cross-section depicting an example embodiment of a sheath push surface of a platform.

FIG. 12F is a side cross-section depicting an example embodiment of a platform unlock rib of a platform.

FIG. 12G is a side view depicting an example embodiment of a sheath clearance unlock feature of a platform.

FIG. 13A is a proximal perspective view depicting an example embodiment of a tray.

FIG. 13B is a side cross-section depicting an example embodiment of a tray.

FIG. 13C is a close-up view depicting an example embodiment of a cutout and rib feature of a tray.

FIG. 14A is a distal perspective view depicting an example embodiment of a mount.

FIG. 14B is a proximal perspective view depicting an example embodiment of a mount.

FIG. 15A is a distal perspective view depicting an example embodiment of a shell.

FIG. 15B is a proximal perspective view depicting an example embodiment of a shell.

FIG. 16A is a top perspective view depicting an example embodiment of a module.

FIG. 16B is a bottom perspective view depicting an example embodiment of a module.

FIG. 17A is a perspective view depicting an example embodiment of a connector.

FIG. 17B is a compressed view depicting an example embodiment of a connector.

FIG. 18 is a perspective view depicting an example embodiment of a sensor.

FIG. 19 is a perspective view depicting an example embodiment of a sharp.

FIG. 20A is a side cross-section depicting an example embodiment of an applicator device.

FIG. 20B is a side cross-section depicting an example embodiment of an applicator device during an initial sensor delivery step.

FIG. 20C is a side cross-section depicting an example embodiment of an applicator device during a subsequent sensor delivery step.

FIG. 20D is a side cross-section depicting an example embodiment of an applicator device during a subsequent sensor delivery step, with a sharp disengaging.

FIG. 20E is a side cross-section depicting an example embodiment of an applicator device in a post-sensor delivery process configuration.

FIG. 21A is a perspective view depicting an example embodiment of a distal end of an assembled electronics housing.

FIG. 21B is a perspective view depicting an example embodiment of a proximal end of an assembled electronics housing.

FIG. 21C is a side view depicting an example embodiment of an assembled electronics housing.

FIG. 21D is a proximal view depicting an example embodiment of an assembled electronics housing.

FIG. 22A is a close-up side view of a portion of an example embodiment of an electronics housing carrier.

FIG. 22B is a close-up perspective view of a portion of an example embodiment of an electronics housing carrier.

FIG. 22C is a perspective view another example embodiment of an electronics housing carrier.

DETAILED DESCRIPTION

This disclosure is not limited to the particular embodiments described, as such may, of course, vary. The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

FIG. 1 is a conceptual diagram depicting an example embodiment of an analyte monitoring system 100 that includes a sensor applicator 150, a sensor control device 102, and a reader device 120. Here, sensor applicator 150 can be used to deliver sensor control device 102 to a monitoring location on a user's skin where a sensor 104 is maintained in position for a period of time by an adhesive patch 105. Sensor control device 102 is further described in FIG. 2B and can communicate with reader device 120 via a communication path 140 using a wired or wireless technique. Example wireless protocols include Bluetooth, Bluetooth Low Energy (BLE, BTLE, Bluetooth SMART, etc.), Near Field Communication (NFC) and others. Users can monitor applications installed in memory on reader device 120 using screen 122 and input 121 and the device battery can be recharged using power port 123. More detail about reader device 120 is set forth with respect to FIG. 2A below. Reader device 120 can communicate with local computer system 170 via a communication path 141 using a wired or wireless technique. Local computer system 170 can include one or more of a laptop, desktop, tablet, phablet, smartphone, set-top box, video game console, or other computing device and wireless communication can include any of a number of applicable wireless networking protocols including Bluetooth, Bluetooth Low Energy (BTLE), Wi-Fi or others. Local computer system 170 can communicate via communications path 143 with a network 190 similar to how reader device 120 can communicate via a communications path 142 with network 190, by wired or wireless technique as described previously. Network 190 can be any of a number of networks, such as private networks and public networks, local area or wide area networks, and so forth. A trusted computer system 180 can include a server and can provide authentication services and secured data storage and can communicate via communications path 144 with network 190 by wired or wireless technique.

FIG. 2A is a block diagram depicting an example embodiment of a reader device configured as a smartphone. Here, reader device 120 can include a display 122, input component 121, and a processing core 206 including a communications processor 222 coupled with memory 223 and an applications processor 224 coupled with memory 225. Also included can be separate memory 230, RF transceiver 228 with antenna 229, and power supply 226 with power management module 238. Also included can be a multi-functional transceiver 232 which can communicate over Wi-Fi, NFC, Bluetooth, BTLE, and GPS with an antenna 234. As understood by one of skill in the art, these components are electrically and communicatively coupled in an appropriate manner to make a functional device.

FIG. 2B is a block diagram depicting an example embodiment of a sensor control device 102. Here, sensor device 120 can include an analyte sensor 104 coupled with an application specific integrated circuit (ASIC) 251, which is also coupled with an antenna 261 and power source 260. ASIC 251 can further include an analog front-end (AFE) 252, power management circuitry 254, communication circuitry 258, a processor 256 and memory 253. All elements are electrically and communicatively coupled as would be understood by one of skill in the art.

The components of sensor control device 102 can be acquired by a user in multiple packages requiring final assembly by the user before delivery to an appropriate user location. FIGS. 3A-3D depict an example embodiment of an assembly process for sensor control device 102 by a user, including preparation of separate components before coupling the components in order to ready the sensor for delivery. FIGS. 3E-3F depict an example embodiment of delivery of sensor control device 102 to an appropriate user location by selecting the appropriate delivery location and applying device 102 to the location.

FIG. 3A is a proximal perspective view depicting an example embodiment of a user preparing a container 810, configured here as a tray (although other packages can be used), for an assembly process. The user can accomplish this preparation by removing lid 812 from tray 810 to expose platform 808, for instance by peeling a non-adhered portion of lid 812 away from tray 810 such that adhered portions of lid 812 are removed. Removal of lid 812 can be appropriate in various embodiments so long as platform 808 is adequately exposed within tray 810. Lid 812 can then be placed aside.

FIG. 3B is a side view depicting an example embodiment of a user preparing an applicator device 150 for assembly. Applicator device 150 can be provided in a sterile package sealed by a cap 708. Preparation of applicator device 150 can include uncoupling housing 702 from cap 708 to expose sheath 704 (FIG. 3C). This can be accomplished by unscrewing (or otherwise uncoupling) cap 708 from housing 702. Cap 708 can then be placed aside.

FIG. 3C is a proximal perspective view depicting an example embodiment of a user inserting an applicator device 150 into a tray 810 during an assembly. Initially, the user can insert sheath 704 into platform 808 inside tray 810 after aligning housing orienting feature 922 (or slot or recess) and tray orienting feature 924 (an abutment or detent). Inserting sheath 704 into platform 808 temporarily unlocks sheath 704 relative to housing 702 and also temporarily unlocks platform 808 relative to tray 810. At this stage, removal of applicator device 150 from tray 810 will result in the same state prior to initial insertion of applicator device 150 into tray 810 (i.e., the process can be reversed or aborted at this point and then repeated without consequence).

Sheath 704 can maintain position within platform 808 with respect to housing 702 while housing 702 is distally advanced, coupling with platform 808 to distally advance platform 808 with respect to tray 810. This step unlocks and collapses platform 808 within tray 810. Sheath 704 can contact and disengage locking features (not shown) within tray 810 that unlock sheath 704 with respect to housing 702 and prevent sheath 704 from moving (relatively) while housing 702 continues to distally advance platform 808. At the end of advancement of housing 702 and platform 808, sheath 704 is permanently unlocked relative to housing 702. A sharp and sensor (not shown) within tray 810 can be coupled with an electronics housing (not shown) within housing 702 at the end of the distal advancement of housing 702. Operation and interaction of the applicator device 150 and tray 810 are further described below.

FIG. 3D is a proximal perspective view depicting an example embodiment of a user removing an applicator device 150 from a tray 810 during an assembly. A user can remove applicator 150 from tray 810 by proximally advancing housing 702 with respect to tray 810 or other motions having the same end effect of uncoupling applicator 150 and tray 810. The applicator device 150 is removed with sensor control device 102 (not shown) fully assembled (sharp, sensor, electronics) therein and position for delivery.

FIG. 3E is a proximal perspective view depicting an example embodiment of a patient applying sensor control device 102 using applicator device 150 to a target area of skin, for instance on an abdomen or other appropriate location. Advancing housing 702 distally collapses sheath 704 within housing 702 and applies the sensor to the target location such that an adhesive layer on the bottom side of device 102 adheres to the skin. The sharp is automatically retracted when housing 702 is fully advanced, while the sensor (not shown) is left in position to measure analyte levels.

FIG. 3F is a proximal perspective view depicting an example embodiment of a patient with sensor control device 102 in an applied position. The user can then remove applicator 150 from the application site.

System 100, described with respect to FIGS. 3A-3F and elsewhere herein, can provide a reduced or eliminated chance of accidental breakage, permanent deformation, or incorrect assembly of applicator components compared to prior art systems. Since applicator housing 702 directly engages platform 808 while sheath 708 unlocks, rather than indirect engagement via sheath 708, relative angularity between sheath 708 and housing 702 will not result in breakage or permanent deformation of the arms or other components. The potential for relatively high forces (such as in conventional devices) during assembly will be reduced, which in turn reduces the chance of unsuccessful user assembly.

FIG. 4A is a side view depicting an example embodiment of an applicator device 150 coupled with screw cap 708. This is an example of how applicator 150 is shipped to and received by a user, prior to assembly by the user with a sensor. FIG. 4B is a side perspective view depicting applicator 150 and cap 708 after being decoupled. FIG. 4C is a perspective view depicting an example embodiment of a distal end of an applicator device 150 with electronics housing 706 and adhesive patch 105 removed from the position they would have retained within sheath 104 when cap 708 is in place.

FIG. 5A is a proximal perspective view depicting an example embodiment of a tray 810 with sterilization lid 812 removably coupled thereto, which may be representative of how the package is shipped to and received by a user prior to assembly.

FIG. 5B is a proximal perspective cutaway view depicting sensor delivery components within tray 810. Platform 808 is slidably coupled within tray 810. Desiccant 502 is stationary with respect to tray 810. Sensor module 504 is mounted within tray 810.

FIG. 5C is a proximal perspective view depicting sensor module 504 in greater detail. Here, retention arm extensions 1834 of platform 808 releasably secure sensor module 504 in position. Module 2200 is coupled with connector 2300, sharp module 2500 and sensor (not shown) such that during assembly they can be removed together as sensor module 504.

FIGS. 6A-H are now referenced in describing multiple example embodiments of systems, devices, and methods for assembling sensor control device 102 (e.g., for mating electronics housing 706 with sensor module 504) and for attaching sharp module 2500 to applicator device 150. In these embodiments, the process is performed by insertion of applicator device 150 a predetermined distance into tray 810 by a user. These embodiments will make reference to numerous components of system 100 that are shown and described with respect to FIGS. 7A-21D. The full descriptions of those components will therefore follow.

FIG. 6A is a side cross-section depicting an example embodiment of an applicator device 150 and a tray 810. Here, tray 810 provides support and protection for components held inside platform 808. Platform 808 is slidably coupled within tray 810. In the initial position, one or more outer deflectable arms (or structures) 1808 of platform 808 are positioned between platform 808 and tray 810 (see also FIG. 12A) and are locked within a surface contour of tray 810. Here, the surface contour includes an anti-removal feature 1910 (see also FIG. 13A) and a platform initial lock ledge 1904 of a sloped detent 1912 (see FIG. 13B) of tray 810. Here, outer deflectable arms 1808 are configured as detent snaps 1808 and cooperate with feature 1910 to secure platform 808 in its initial position with respect to tray 810.

Sharp module 2500 can be coupled with tray 810 and/or sensor module 504. As described previously, applicator 150 includes exterior housing 702 slidably coupled with sheath 704. Housing 702 is coupled with electronics housing carrier 710 which engages spring 1104 and sharp module carrier 1102.

FIG. 6B is a side cross-section depicting an initial orientation of components when the user aligns sheath 704 and commences insertion of sheath 704 into platform 808 (see FIG. 3C) and tray 810. Sheath 704 includes deflectable locking arms (or structures) 1412 that have a proximally facing surface 1416 (a lock arms interface) which abuts an opposing surface 1502 (an opposing lock interface) on an outwardly extending ledge of electronics housing carrier 710. Lock arms interface 1416 of lock arms 1412 can be engaged with lock interface 1502 of electronics housing carrier 710 in an initial locked configuration prior to insertion of sheath 704 into platform 808. This configuration keeps sheath 704 in a locked position with respect to housing 702 and prevents sheath 704 from being retracted into housing 702. Platform 808 includes sheath unlock abutments, or ribs, 1812 that contact and push against the angled orientation or sloped surface of lock arms 1412 as sheath 704 is advanced distally.

In FIG. 6C, housing 702 has been advanced distally with sheath 704 moving in unison and a distal surface or edge of sheath 704 (for example, sheath push surface 1446 shown in FIG. 8A) can optionally engage a proximal surface of platform 808 (e.g., at the bottom of sheath receiving channel 1840 shown in FIG. 12E). The advancement of sheath 704 distally causes sheath unlock ribs 1812 to slidably engage and push against lock arms 1412 and force them away from their resting position (i.e., against their direction of bias).

Here, ribs 1812 push or move lock arms 1412 in a direction that is laterally outward from an interior of sheath 704, for example, generally in the direction from right-to-left as shown in FIG. 6C. In this embodiment, lock arms 1412 are moved outwardly while no force is applied against a distal surface or edge of sheath 704. For example, sheath push surface 1446 is not in contact with a nonmoving surface within container 810 that can resist the downward (proximal-to-distal) movement of applicator 150. As such, lock arms 1412 are disengaged while no significant or substantial load is applied to sheath 704 in a distal-to-proximal direction.

Once lock arms 1412 are moved such that proximally facing surface 1416 no longer contacts opposing surface 1502, sheath 704 is no longer locked in place with respect to housing 702 (e.g., sheath 704 and housing 702 transition from a state that resists sliding to a state where sheath 704 and housing 702 become relatively more slidable with respect to each other), although sheath 704 is still releasably maintained in position with respect to housing 702 by deflectable positioning arms (or structures) 1402 as described below. At the position of FIG. 6C, if the user ceases to apply force in a distal direction, i.e., stops pushing on housing 702, and removes applicator 150 from platform 808 (and tray 810), then lock arms 1412 will automatically return to their resting position where proximally facing surface 1416 contacts opposing surface 1502, again locking sheath 704 with respect to housing 702. Thus the assembly process can be aborted at this stage and initiated again later (without consequence) if necessary.

Turning to FIG. 6D, platform 808 can include one or more inner deflectable lock arms (or structures) 1815, each of which can include an unlock rib 1816 having a sloped surface 1817. The advancement of sheath 704 also causes sheath push surface 1446 (FIG. 8A) to contact sloped surface 1817 of a platform unlock rib 1816 and displace inner platform lock arm 1815 from engagement with a platform initial ledge lock 1904 of tray 810 (see also FIG. 13C). The advancement of sheath 704 has already caused lock arms interface 1416 to disengage from lock interface 1502, and this can occur before the release of inner platform lock arm 1815, substantially simultaneously with the release of inner platform lock arm 1815, or after the release of inner platform lock arm 1815. Like with lock arms 1412, if the user ceases to apply force in a distal direction, i.e., stops pushing on housing 702, and removes applicator 150 from platform 808 (and tray 810), then lock arms 1815 will automatically return to their resting position where they were contacting platform initial ledge lock 1904, again locking platform 808 with respect to tray 810. Thus the assembly process can be aborted at this stage and initiated again later (without consequence) if necessary.

FIG. 6E shows the system after release of both platform lock arms 1815 and sheath lock arms 1412. Here, platform collapse surface 1342 of housing 702 contacts or engages platform collapse surface 1838 of platform 808. This is also shown in FIG. 6F. In these embodiments, platform 808 is advanced distally by housing 702 and not sheath 704. In other words, in these embodiments, after housing platform collapse surface 1342 contacts platform collapse surface 1838, sheath 704 no longer transfers force from the user's pushing motion to platform 808. That function is performed directly by housing 702.

The force applied by the user to housing 702 against platform 808 should be sufficient to cause detent snap 1808 to move (deflect radially inwardly) from platform initial lock ledge 1904 and over detent 1912 (see FIG. 13B). This releases platform 808 with respect to tray 810 and allows platform 808 to slide distally within tray 810 from the position of FIG. 6E to that of FIG. 6F.

During advancement of housing 702 against platform 808, sheath 704 remains engaged with housing 702 and moves in unison with housing 702. As described with respect to FIG. 8C, sheath 704 can include one or more deflectable positioning arms 1402, configured here as detent snaps 1402 (although other configurations can be used), where each snap 1402 includes a bridge section 1408. Initially, a bridge section 1408 of each snap 1402 can rest in a locked groove 1332 of housing 702 (see FIG. 7C). Bridge section 1408 can be moved from groove 1332 to groove 1334 with sufficient force applied by the user. Thus, sheath 704 is releasably maintained in position by the interaction of bridge section 1408 and the various grooves, indentations, or contours on locking rib 1340. In certain embodiments, movement of bridge section 1408 along locking rib 1340 towards the proximal end of housing 702 is only permitted once lock arms 1412 have been deflected and unlocked by moving proximally facing surface 1416 out of contact with opposing surface 1502 as shown in FIG. 6C.

Turning to FIG. 6F, as platform 808 moves distally, sheath 704 comes into contact with a sheath unlock rib 1936 that impedes further distal movement of sheath 704. The surface of sheath 704 the contacts sheath unlock rib 1936 can be any distal or distally-facing surface or edge, including the distal-most edge of sheath 704, which is sheath push surface 1446.

As housing 702 is advanced distally and sheath 704 is prevented from advancing by sheath unlock rib 1936 as shown in FIG. 6F (e.g., further advancement of applicator 150 in the proximal-to-distal direction causes a force to be exerted by the nonmoving sheath unlock rib 1936 against sheath 704), detent snaps 1402 move from locked groove 1332, as shown in FIG. 6G, over a detent or outwardly extending ridge to un-locked groove 1334 as shown in FIG. 6H. The user can sense the movement of sheath 704 from groove 1332 to 1334 and this, as well as the cessation of movement of platform 808, can serve as tactile feedback that the sensor assembly process is complete. FIG. 6F also shows that proximally facing surface 1416 of lock arms 1412 have moved past opposing surface 1502 of carrier 710 and cannot return to the locked position because sheath 704 has moved proximally with respect to carrier 710 and carrier 710 now holds lock arms 1412 in the unlocked position.

Referring back to FIG. 5B, in the initial position, sensor module 504 is beneath one or more retention arm extensions 1834 of platform 808. As platform 808 is moved distally, retention arm extensions 1834 are pushed against sensor module 504 and move radially outward to expose sensor module 504. In the embodiment depicted in FIGS. 12A-D, there are two retention arm extensions 1834 that are positioned opposite to each other. FIG. 5C depicts one of these arm extensions after having been deflected outward by passage over sensor module 504. The distal movement of platform 808 has exposed sharp module 2500 and module snaps 2202 (see also FIG. 16A) of module 2200 as shown in FIG. 5C.

The profile of sensor module 504 can match or be shaped in complementary fashion to the sensor module receptacle 2002 at the base of electronics housing 706 (see FIGS. 14A-B and 21A-D). Receptacle 2002 includes module snap ledges 2010 (see FIG. 14B) that interface and lock with module snaps 2202.

As housing 702 pushes against platform 808 it exposes sharp module 2500 and module snaps 2202. Although not shown here, at the stage of advancement depicted in FIG. 6G, module snaps 2202 have moved into receptacle 2002 and hub 2516 of sharp module 2500 (FIG. 19) is in close proximity with sharp assembly lead-in surface 1624 of sharp retention clip 1620 (FIG. 10B). Further movement of housing 702 towards the position depicted in FIG. 6H causes sensor module 504 to connect with (e.g., snap into) electronics housing 706 as module snaps 2202 slide past module snap ledges 2010 and then deflect outwardly towards their position of normal bias (the position of FIG. 16B). At substantially the same time, the sloped surface of hub 2516 of sharp module 2500 contacts and slides against a complementary sloped lead-in surface 1624 at the base of each retention clip 1620, which pushes clips 1620 radially outwardly away from their position of normal bias until hub 2516 passes the base of each retention clip 1620 and those clips 1620 deflect back towards their position of normal bias. A stop surface 1627 at the distal terminus of each arm 1618 can be a planar face perpendicular to the direction of advancement. This stop surface 1627 can contact a proximal planar face of hub push cylinder 2508 (FIG. 19) and stop the axial advancement of sharp carrier 1102 with respect to sharp module 2500. This stop surface 1627 can also act as the backstop for sharp module 2500 during the sharp insertion process.

Thus, in one embodiment, just before detent snap 1402 passes into unlocked recess 1334 as depicted in FIG. 6H or, in another embodiment, at substantially the same time as detent snap 1402 passes into unlocked recess 1334 as depicted in FIG. 6H, retention clips 1620 capture sharp hub 2516 and lock (or secure) sharp module 2500 to applicator 150, and module snaps 2202 enter into a locked relationship with electronics housing 706 and lock (or secure) sensor module 504 to housing 706, forming a complete sensor control device 102. This position is also depicted in FIG. 3D. At this point applicator 150 can be withdrawn from tray 810 in the direction of the arrows of FIG. 3D and used in the sensor control device delivery process as shown in FIGS. 3E-F and also described with respect to FIGS. 20A-E.

Turning now to a detailed description of various components of system 100, FIG. 7A is side view depicting an example embodiment of housing 702 that can include an internal cavity with support structures for applicator function. A user can push housing 702 in a distal direct to activate the applicator assembly process and then also to cause delivery of sensor control device 102, after which the cavity of housing 702 can act as a receptacle for a sharp. In the example embodiment various features are shown including housing orienting feature 1302 for orienting the device during assembly and use. Tamper ring groove 1304 can be a recess located around an outer circumference of housing 702, distal to a tamper ring protector 1314 and proximal to a tamper ring retainer 1306. Tamper ring groove 1304 can retain a tamper ring so users can identify whether the device has been tampered with or otherwise used. Housing threads 1310 can secure housing 702 to cap 708 by aligning with complimentary cap threads 1708 as shown in FIG. 11A and rotating in a clockwise or counterclockwise direction. A side grip zone 1316 of housing 702 can provide an exterior surface location where a user can grip housing 702 in order to use it. Grip overhang 1318 is a slightly raised ridge with respect to side grip zone 1316 which can aid in ease of removal of housing 702 from cap 708. A shark tooth 1320 can be a raised section with a flat side located on a clockwise edge to shear off a tamper ring 1702 and hold tamper ring 1702 in place after a user has unscrewed cap 708 and housing 702. In the example embodiment four shark teeth 1320 are shown although more or less can be used as desired.

FIG. 7B is a perspective view depicting a distal end of housing 702. Here, three housing guide structures 1321 are located at 120 degree angles with respect to each other and at 60 degree angles with respect to locking structures 1340, of which there are also three at 120 degree angles with respect to each other. Other angular orientations, either symmetric or asymmetric, can be used, as well as any number of one or more structures 1321 and 1340. Here, each structure 1321 and 1340 is configured as a planar rib, although other shapes can be used. Each guide rib 1321 includes a guide edge 1326 that can pass along a surface of sheath 704 (e.g., guide rail 1418 described with respect to FIG. 8A). An insertion hard stop 1322 can be a flat, distally facing surface of housing guide rib 1321 located near a proximal end of housing guide rib 1321. Insertion hard stop 1322 provides a surface for a sensor electronics carrier travel limiter face 1420 of a sheath 704 (FIG. 8B) to abut during use, preventing sensor electronics carrier travel limiter face 1420 from moving any further in a proximal direction. A carrier interface post 1327 passes through an aperture 1510 (FIG. 9A) of housing carrier 710 during an assembly. A sensor electronics carrier interface 1328 can be a rounded, distally facing surface of housing guide ribs 1321 which interfaces with electronics housing carrier 710.

FIG. 7C is a side cross-section depicting an example embodiment of a housing. In the example embodiment side cross sectional profiles of housing guide rib 1321 and locking rib 1340 are shown. Locking rib 1340 includes sheath snap lead-in feature 1330 near a distal end of locking rib 1340 which flares outward from central axis 1346 of housing 702 distally. Each sheath snap lead-in feature 1330 causes detent snap round 1404 of detent snap 1402 of sheath 704 as shown in FIG. 8C to bend inward toward central axis 1346 as sheath 704 moves into housing 702. Once past a distal point of sheath snap lead-in feature 1330, detent snap 1402 of sheath 704 is locked into place in locked groove 1332. As such, detent snap 1402 cannot be easily moved in a distal direction due to a surface with a near perpendicular plane to central axis 1346, shown as detent snap flat 1406 in FIG. 8C.

When housing 702 has been moved further distally with respect to sheath 704 to shift detent snaps 1402 into the un-locked grooves 1334, applicator 150 is in an “armed” position, ready for use. Thus, when a user applies distal pressure to housing 702 while sheath 704 is pressed against the skin, detent snap 1402 passes over firing detent 1344. This begins a firing sequence (as described with respect to FIGS. 20A-C) due to release of stored energy in the deflected detent snaps 1402 and detent snap 1402 travels proximally toward sheath stopping ramp 1338 which is slightly flared outward with respect to central axis 1346 and slows sheath 704 movement during the firing sequence. The next groove encountered by detent snap 1402 after un-locked groove 1334 is final lockout groove 1336 which detent snap 1402 enters at the end of the stroke or pushing sequence performed by the user. Final lockout recess 1336 can be proximal to a surface oriented perpendicular to central axis 1346 which, after detent snap 1402 passes, engages a detent snap flat 1406 and prevents reuse of the device by securely holding sheath 704 in place with respect to housing 702.

Housing platform collapse surface 1342 is a distal surface of housing 702 which a user uses to engage a platform collapse surface 1838 of platform 808 as shown in FIG. 12A. Insertion hard stop 1322 prevents sheath 704 from advancing proximally with respect to housing 702 by engaging sensor electronics carrier travel limiter face 1420.

FIGS. 8A and 8B are a side view and perspective view, respectively, depicting an example embodiment of sheath 704. In this example embodiment, sheath 704 can stage sensor control device 102 above a user's skin surface prior to application. Sheath 704 can also contain features that help retain a sharp in a position for proper application of a sensor, determine the force required for sensor application, and guide sheath 704 relative to housing 702 during application. Detent snaps 1402 are near a proximal end of sheath 704, described further with respect to FIG. 8C below. Sheath 704 can have a generally cylindrical cross section with a first radius in a proximal section (closer to top of figure) that is shorter than a second radius in a distal section (closer to bottom of figure). Also shown are a plurality of detent clearances 1410, three in the example embodiment. Sheath 704 can include one or more detent clearances 1410, each of which can be a cutout with room for sheath snap lead-in feature 1330 to pass distally into until a distal surface of locking rib 1340 contacts a proximal surface of detent clearance 1410.

Guide rails 1418 are disposed between a sensor electronics carrier traveler limiter face 1420 at a proximal end of sheath 704 and a cutout around lock arms 1412. Each guide rail 1418 can be a channel between two ridges where the guide edge 1326 of housing guide rib 1321 can slide distally with respect to sheath 704.

Lock arms 1412 are disposed near a distal end of sheath 704 and can include an attached distal end and a free proximal end, which can be lock arm interface 1416. Lock arms 1412 can lock sensor electronics carrier 710 to sheath 704 when lock arm interface 1416 of lock arms 1412 engage lock interface 1502 of sensor electronics carrier 710. Lock arm strengthening ribs 1414 can be disposed near a central location of each lock arm 1412 and can act as a strengthening point for an otherwise weak point of each lock arm 1412 to prevent lock arm 1412 from bending excessively or breaking.

Detent snap stiffening features 1422 can be located along the distal section of detent snaps 1402 and can provide reinforcement to detent snaps 1402. Alignment notch 1424 can be a cutout near the distal end of sheath 704, which provides an opening for user alignment with sheath orientation feature of platform 808. Stiffening ribs 1426 can include buttresses, that are triangularly shaped here, which provide support for detent base 1436. Housing guide rail clearance 1428 can be a cutout for a distal surface of housing guide rib 1321 to slide during use.

FIG. 8C is a close-up perspective view depicting an example embodiment of a distal side of a detent snap 1402 of sheath 704. Detent snap 1402 can include a detent snap bridge 1408 located near or at its proximal end. Detent snap 1402 can have a proximal feature which includes a detent snap flat 1406 on a distal side of detent snap bridge 1408. A proximal surface and outer surface of detent snap bridge 1408 can be detent snap rounds which are rounded surfaces, allowing for easier movement of detent snap bridge 1408 across some interior surfaces of housing 702.

FIG. 8D is a side view depicting an example embodiment of sheath 704. Here, alignment notch 1424 can be relatively close to detent clearance 1410. Detent clearance 1410 is in a relatively proximal location on distal portion of sheath 704. Additionally, a distal portion of sheath 704 can be relatively short enough so that sheath 704 does not contact a platform or at least is not the primary advancement surface of an applicator but rather housing 702 in order to prevent alignment issues.

FIG. 8E is an end view depicting an example embodiment of a proximal end of sheath 704. Here, a back wall for guide rails 1446 can provide a channel for housing guide rib 1321 of housing 702 to slidable couple with. Sheath rotation limiter 1448 can be notches which reduce or prevent rotation of the sheath 704.

FIG. 9A is a proximal perspective view depicting an example embodiment of sensor electronics carrier 710 that can retain sensor electronics within applicator 150. It can also retain introducer carrier 1102 with sharp module 2500. In this example embodiment sensor electronics carrier 710 generally has a hollow round flat cylindrical shape, and can include one or more deflectable introducer carrier lock arms (or structures) 1524 (e.g., three) extending proximally from a proximal surface surrounding a centrally located spring alignment ridge 1516 (for maintaining alignment of spring 1104 as seen in FIG. 6A). Each lock arm 1524 has a detent or retention feature 1526 located at or near its proximal end. Shock lock 1534 can be a tab located on an outer circumference of sensor electronics carrier 710 extending outward and can lock sensor electronics carrier 710 for added safety prior to firing. Rotation limiter 1506 can be a proximally extending relatively short protrusion on a proximal surface of sensor electronics carrier 710 which limits rotation of carrier 710. Introducer carrier lock arms 1524 can interface with carrier 1102 as described with reference to FIGS. 10A-10B below.

FIG. 9B is a distal perspective view of sensor electronics carrier 710. Here, one or more sensor electronics retention spring arms (or structures) 1518 (e.g., three) are normally biased towards the position shown and include a detent 1519 that can pass over the distal surface of electronics housing 706 of device 102 when housed within recess or cavity 1521. In certain embodiments, after sensor control device 102 has been adhered to the skin with applicator 150, the user pulls applicator 150 proximally away from the skin. The adhesive force retains sensor control device 102 on the skin and overcomes the lateral force applied by spring arms 1518. As a result, spring arms 1518 deflect radially outwardly and disengage detents 1519 from sensor control device 102 thereby releasing sensor control device 102 from applicator 150.

FIGS. 10A and 10B are a proximal perspective view and side cross-section view, respectively, depicting an example embodiment of sharp carrier 1102. Sharp carrier 1102 can grasp and retain sharp module 2500 within applicator 150. It can also automatically retract as a result of a spring changing from a compressed to an extended state during an insertion process, as described with respect to FIG. 20D. Near a distal end of sharp carrier 1102 can be anti-rotation slots 1608 which prevent sharp carrier 1102 from rotating when located within a central area of introducer carrier lock arms 1524. Anti-rotation slots 1608 can be located between sections of sharp carrier base chamfer 1610 which can ensure full retraction of sharp carrier 1102 through sheath 704 upon retraction of sharp carrier 1102 at the end of the deployment procedure.

Sharp retention arms (or structures) 1618 can be located in an interior of sharp carrier 1102 about a central axis and can include a sharp retention clip 1620 at a distal end of each arm 1618. Sharp retention clips 1620 can have a proximal surface which can be nearly perpendicular to the central axis and can abut a distally facing surface of sharp hub 2516 (FIG. 19).

FIG. 11 is a perspective cross-section view depicting an example embodiment of cap 708, which, when coupled with housing 702 via threads 1708 can create a sterile or at least dust-free environment during shipping and storage and can protect electronics housing 706 and prevent adhesive layer 105 from becoming dirty. Tamper ring 1702 can be at a distal end of cap 708. A sensor electronics support 1712 can support electronics housing 706 while retained within carrier 710.

FIGS. 12A and 12B are a proximal perspective view and side cross-sectional view, respectively, depicting an example embodiment of platform 808 that can retain and protect sharp module 2500 and sensor module 504 within a loader assembly such as tray 810. Platform 808 can have various features to engage sheath 704. These can include a platform collapse surface 1838, which can engage housing platform collapse surface 1342. A sheath push surface 1810 can provide a proximal surface for distal sheath push surface 1446. One or more sheath unlock members or ribs 1812 of platform 808 can extend radially outward from a central region or surface of platform 808 into sheath receiving channel 1840 to engage lock arms 1412 of sheath 704. In other embodiments, the orientation of the parts can be reversed such that ribs 1812 can extend radially inward from the platform sidewall and lock arms 1412 deflect inwardly into a free space to unlock sheath 704. In all embodiments, ribs 1812 can have any desired structure and/or shape that functions to oppose the sloped surface of lock arms 1412 and cause them to deflect away from their resting position (i.e., the position to which they are biased).

One or more tilt reducing members or ribs 1828 and one or more outside diameter members or ribs 1818 can reduce the likelihood of sheath 704 tilting within sheath receiving channel 1840 due to a thickness which is greater than a standard wall thickness of platform 808. Sheath orientation feature (e.g., a ridge) 1802 can interface with alignment notch 1424 of sheath 704. A cutout or space 1830 can provide a clearance for sheath unlock rib 1936 (FIG. 13A) in a distal surface of platform 808.

Platform 808 can also have various features to engage tray 810. One or more detent arms or snaps 1808 can maintain a platform orientation and engagement within tray by interfacing with platform assembly lead in 1908, platform initial lock ledge 1904, and detent rib 1912 of tray 810. A motion guide member 1822 can maintain alignment with a tray 810 during use. One or more introducer retention arms 1820 each with a retention arm extension 1834 can maintain a position of sharp module 2500 within tray 810.

FIG. 12C is a bottom up view depicting a distal end of platform 808. An orientation feature core out 1804 can ensure that sheath orientation feature 1802 does not interfere with alignment and distal pushing of sheath 704 when performing a sharp capture operation. A deflectable tab 1832 can maintain a module assembly in place for drop and shock robustness. Clearance 1822 for introducer retention features 1820 allows retention features to swing clear during distal movement of platform 808. As such, clearance 1822 provides room for a sensor module to be captured by an applicator during assembly. FIG. 12D is a top down view depicting a proximal end of platform 808, showing sheath unlock ribs 1812, platform unlock ribs 1816, and lock snaps 1814, the functions of which were described with respect to FIGS. 6A-H.

FIG. 12E is a side cross-section of platform 808. Alignment and orientation surfaces 1806 can be located at regular or irregular intervals around an exterior circumference of sheath 808. These are typically channels with walls extending from a proximal to a distal end of sheath 808 and open at the distal end and proximal end. The alignment and orientation features 1806 can engage guide ribs 1906 of tray 810.

FIG. 12F is a side cross-sectional view depicting platform 808. In certain embodiments, a stepped down surface can serve as a patch clearance feature 1836 that can provide clearance for an adhesive patch to ensure it does not become adhered to this proximal surface or face of platform 808 during the assembly process. Similarly, platform unlock ribs 1816 can be set further distally in order to delay a contact between sheath 704 and platform unlock ribs.

FIG. 12G is a side view depicting platform 808. Here, one or more clearances or cutouts 1830 for sheath unlock ribs 1836 can be extended further distally than prior designs. This can provide additional clearance for sheath 704 since upon reaching this area sheath 704 is no longer a pushing surface for platform 808 yet unlocking of sheath 704 is desirable for proper applicator use.

FIG. 13A is a proximal perspective view depicting an example embodiment of tray or container 810. Tray 810 and lid 812 can create a sterile environment for a sensor and sharp. Here, a foil seal surface 1920 can be a proximal surface that seals with lid 812 using a standard adhesive or a heat-activated adhesive for sterilization purposes. Lock ribs 1902 can contain geometry allowing a platform 808 to lock into a pre-use position. A platform initial lock ledge 1904 can be flat and interact with platform 808 to lock platform 808 from accidental collapse prior to assembly of applicator to loader. Guide ribs 1906 can be ribs that act to orient and guide platform 808 prior and during assembly of applicator and loader. Anti-removal feature 1910 can prevent removal of platform 808 from tray 810 after it has been initially installed. Sheath unlock rib (platform) clearance ledge 1918 can clear sheath unlock ribs on platform 808 when platform 808 is in a collapsed state within tray 810. Desiccant engaging rib 1926 can flex out to allow for desiccant assembly and ensure that desiccant stays in place during drop, shock or vibration. Sharp clearance hole 1930 can be a hole which provides clearance for sharp tip 2502 (FIG. 19) so that the tip is not damaged during shipping or other movement. Module locating post 1932 can be a post that locates sensor module 504 within tray 810. Module support 1934 can set the height of sensor module 504 and sharp module 2500 within tray 810. Alignment mark 1940 can aid a user in aligning an applicator to a container during assembly.

One or more transition features 1938 can be included that extend proximally from module support 1934. These features 1938 can also be seen in FIGS. 5C and 13B. Transition features 1938 can have various shapes. Here there are two that are configured as projections with inner sidewalls that can lie flush against sensor module 504 and provide added support and resistance to tilting or lateral motion. Projections 1938 can have a sloped or rounded outed surface and can be positioned directly beneath retention arm extensions 1834 when in the resting position of FIG. 12B. As platform 808 moves distally, retention arm extensions 1834 come into contact with and slide over the rounded or sloped outer surface of transition features 1938. The rounded or sloped surfaces help retention arm extensions 1834 deflect and transition over sensor module 504 and onto tray 810 without disrupting or adjusting the position of module 504.

FIG. 13B is a side cross-sectional view depicting tray 810. Platform assembly lead-in 1908 can be a lead-in chamfer to aid in assembly of platform 808 to tray 810. Detent rib 1912 can be a rib or member that includes curved surface 1914. Surface 1914 can allow platform 808 to build a predetermined force prior to distal movement during assembly of the applicator and sensor control device 102. Friction reducing undercut surface 1916 can be an undercut that lowers the total friction seen by platform 808 as it collapses during assembly of the applicator to the loader. Platform motion guide surface 1928 can be a running surface that guides motion of platform 808 with respect to tray 810 during assembly of loader to applicator.

FIG. 13C is a close-up view depicting an example embodiment of sheath unlock rib 1936 of tray 810. Unlock rib 1936 can have any desired shape and/or structure that functions as a rigid stop for the advancement of sheath 704, e.g., an abutment formed in or extending from the base or bottom of tray 810.

A platform initial lock ledge 1904 can support platform 808 and ensure it is not accidentally pushed or collapsed distally. Sheath unlock rib (platform) clearance feature 1918 can be short as not to impact unlock ribs 1812 of platform 808 early during a distal advancement by a user. Likewise, a lock rib 1902 can be relatively short. If a user were to proximally retreat housing 702 and its coupled components, lock arms 1412 would re-engage lock interface 1502 as in the primary configuration shown in FIG. 6A. This feature can prevent misfiring of the applicator by dropping or incorrectly aligning when re-assembling applicator with cap. A cutout 1942 can allow clearance for lock arms 1815 of platform 808.

FIGS. 14A and 14B are a distal perspective view and a proximal perspective view, respectively, depicting an example embodiment of a distal portion of electronics housing 706. Shown here is a receptacle 2002 for receiving sensor module 504. One or more carrier grips or recesses 2008 can interface with retention detents 1519 of carrier 710 for coupling housing 706 to carrier 710. One or more module snap ledges 2010 can engage deflectable module arms or snaps 2202 (FIG. 16A).

FIGS. 15A and 15B are a distal perspective view and a proximal perspective view, respectively, depicting an example embodiment of a proximal portion of housing 706 that can be securely coupled with the distal portion of housing 706 depicted in FIGS. 14A-B. An aperture 2102 is present through which distal tip 2502 of the sharp can pass through during assembly of applicator 150 and retraction of sharp after insertion of the sensor.

FIGS. 16A and 16B are a top perspective view and a bottom perspective view, respectively, depicting an example embodiment of sensor module 504. Module 504 can hold a connector 2300 (FIGS. 17A-B) and a sensor 104 (FIG. 18). Module 504 is capable of being securely coupled with electronics housing 706. One or more deflectable arms or module snaps 2202 can snap into the corresponding features 2010 of housing 706. A sharp slot 2208 can provide a location for sharp tip 2502 to pass through and sharp shaft 2504 to temporarily reside. A sensor ledge 2212 can define a sensor position in a horizontal plane, prevent a sensor from lifting connector 2300 off of posts and maintain sensor 104 parallel to a plane of connector seals. It can also define sensor bend geometry and minimum bend radius. It can limit sensor travel in a vertical direction and prevent a tower from protruding above an electronics housing surface and define a sensor tail length below a patch surface. A sensor wall 2216 can constrain a sensor and define a sensor bend geometry and minimum bend radius.

FIGS. 17A and 17B are perspective views depicting an example embodiment of connector 2300 in an open state and a closed state, respectively. Connector 2300 can be made of silicone rubber that encapsulates compliant carbon impregnated polymer modules that serve as electrical conductive contacts 2302 between sensor 104 and electrical circuitry contacts for the electronics within housing 706. The connector can also serve as a moisture barrier for sensor 104 when assembled in a compressed state after transfer from a container to an applicator and after application to a user's skin. A plurality of seal surfaces 2304 can provide a watertight seal for electrical contacts and sensor contacts. One or more hinges 2208 can connect two distal and proximal portions of connector 2300.

FIG. 18 is a perspective view depicting an example embodiment of sensor 104. A neck 2406 can be a zone which allows folding of the sensor, for example ninety degrees. A membrane on tail 2408 can cover an active analyte sensing element of the sensor 104. Tail 2408 can be the portion of sensor 104 that resides under a user's skin after insertion. A flag 2404 can contain contacts and a sealing surface. A biasing tower 2412 can be a tab that biases the tail 2408 into sharp slot 2208. A bias fulcrum 2414 can be an offshoot of biasing tower 2412 that contacts an inner surface of a needle to bias a tail into a slot. A bias adjuster 2416 can reduce a localized bending of a tail connection and prevent sensor trace damage. Contacts 2418 can electrically couple the active portion of the sensor to connector 2300. A service loop 2420 can translate an electrical path from a vertical direction ninety degrees and engage with sensor ledge 2212 (FIG. 16B).

FIG. 19 is a perspective view depicting an example embodiment of sharp module 2500. A sharp tip 2502 can penetrate the skin while carrying sensor tail 2408 in a hollow or recess of shaft 2504 to put the active surface into contact with bodily fluid. A hub push cylinder 2508 can provide a surface for a sharp carrier to push during insertion. A hub small cylinder 2512 can provide a space for the extension of sharp hub contact faces 1622 (FIG. 10B). A hub snap pawl locating cylinder 2514 can provide a cylindrical surface of a snap pawl for faces 1622 to abut. A hub snap pawl 2514 can be a conical surface that opens clip 1620 during installation of sharp module 2500.

FIGS. 20A-20E are side cross-sectional views depicting an example embodiment of an applicator 150 during deployment of sensor control device 102. FIG. 20A shows applicator 150 in a state ready to be positioned against a user's skin. In FIG. 20B, housing 702 has been advanced with respect to sheath 704 but the sharp has not yet exited applicator 150. Here, the housing has been advanced in a proximal-to-distal direction along a longitudinal axis of applicator 150. In FIG. 20C, housing 702 has been fully advanced by the user's manual push force, and the sharp and sensor are extending their maximum distance from the distal end of sheath 704. Also, the introducer carrier retention features 1526 of arms 1524 have cleared an inner diameter of sheath 704 and are free to move as shown in FIG. 20D.

In FIG. 20D, sharp carrier 1102 is no longer constrained by electronics housing carrier arms 1524. Thus, spring 1104 is free to expand from its compressed orientation in a proximal direction and push the proximal end of electronics housing carrier arms 1524 radially outward as it expands. This causes sharp module 2500 to retract from the user's skin and into a central area of spring 1104 within housing 702.

In FIG. 20E, spring 1104 has expanded until a proximal end of sharp carrier 1102 reaches a distal surface of sheath 704 and thus the whole device is locked in position. An adhesive on distal surface of an electronics housing causes it to remain on the user's skin with the sensor in the skin when the user proximally removes the device from the skin.

FIGS. 21A-D are distal perspective, proximal perspective, side, and distal end views, respectively, depicting an additional example embodiment of electronics housing 706. Here, receptacle 2002 can be seen where sensor module 504 can be received during assembly. Adhesive 2102 is present on adhesive layer 105. Outer seal 2028 can protect the electronics in the interior of electronics housing 706.

FIG. 22A is a close-up side view of an example embodiment of a retention detent 1519 on the interior surface of a retention spring arm 1518 of electronics housing carrier 710. FIG. 22B is a close-up perspective view of this example embodiment and FIG. 22C is a perspective view of an example embodiment of carrier 710 with three arms 1518 and retention detents 1519 visible on the interior of two of the three arms 1518 (the third is obscured).

In these embodiments, retention detents 1519 each have a partially conical (projecting) proximal (or upper) surface 2201 and a distal (or lower or underside) surface 2202. Partially conical upper surface 2201 slopes away from the interior surface of each arm 1518 such that the proximal terminus of surface 2201 is closer to the interior surface of arm 1518 than a point along the distal edge of surface 2201. After sensor control device 102 is adhered to the surface of the body, this sloped or tapered surface 2201 slides along a similarly shaped but complementary (recessed) surface of carrier grip 2008 (FIG. 21C) and causes the respective arm 1518 to deflect radially outwards (against its bias), thereby releasing sensor control device 102.

The distal edge 2203 of proximal surface 2201 (at the transition to distal surface 2202) is not perpendicular to the direction of axial movement of sensor control device 102 with respect to carrier 1102 (i.e., the proximal-distal direction P-D shown in FIG. 22A) but is rather transverse or at an angle to the proximal-distal direction. Here, the angle is approximately 45 degrees, although greater and lesser angles can be used (e.g., 30 degrees, 60 degrees, etc.).

This angling reduces the chance that edge 2203 will catch on a portion of sensor control device 102 after adhesive attachment to the skin, such as gap or groove 2009 shown in FIG. 21C, which may be a seam or interface between a distal portion of electronics housing 706 (as depicted in FIGS. 14A-B) and a proximal portion of electronics housing 706 (as depicted in FIGS. 15A-B) and can be perpendicular or otherwise transverse to direction P-D. Edge 2203 is preferably transverse to a longitudinal axis of an elongate gap, groove, seam, or interface on sensor control device that is proximal to carrier grip 2008. Catching of edge 2203 on sensor control device 102 could adversely remove sensor control device 102 from the skin when applicator 150 is removed. There is no similarly angled groove or edge on sensor control device 102 that can catch edge 2203 when angled as shown. Distal surface 2202 is planar or substantially planar, here, although other shapes or contours can be used so long as edge 2203 remains angled.

In another example embodiment, the configurations just described can be reversed such that retention detents 1519 with the partially conical surface and the complementary carrier grips 2008 can be reversed such that the retention detents 1519 are present on sensor control device 102 and the complementary grips 2008 are present on applicator 150, such as on arms 1518. In such an embodiment, the orientation of detents 1519 and grips 2008 are inverted (turned upside down) to allow proper deflection of arms 1518 upon withdrawal of applicator 150.

A number of deflectable structures are described herein, including but not limited to deflectable positioning arms 1402, deflectable locking arms 1412, introducer carrier lock arms 1524, sharp retention arms 1618, outer deflectable arms 1808, inner deflectable lock arms 1815, retention arm extensions 1834, and module snaps 2202. These deflectable structures are composed of a resilient material such as plastic or metal (or others) and operate in a manner well known to those of ordinary skill in the art. The deflectable structures each has a resting state or position that the resilient material is biased towards. If a force is applied that causes the structure to deflect or move from this resting state or position, then the bias of the resilient material will cause the structure to return to the resting state or position once the force is removed (or lessened). In many instances these structures are configured as arms with detents, or snaps, but other structures or configurations can be used that retain the same characteristics of deflectability and ability to return to a resting position, including but not limited to a leg, a clip, a catch, an abutment on a deflectable member, and the like.

As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

It should be noted that all features, elements, components, functions, and steps described with respect to any embodiment provided herein are intended to be freely combinable and substitutable with those from any other embodiment. If a certain feature, element, component, function, or step is described with respect to only one embodiment, then it should be understood that that feature, element, component, function, or step can be used with every other embodiment described herein unless explicitly stated otherwise. This paragraph therefore serves as antecedent basis and written support for the introduction of claims, at any time, that combine features, elements, components, functions, and steps from different embodiments, or that substitute features, elements, components, functions, and steps from one embodiment with those of another, even if the following description does not explicitly state, in a particular instance, that such combinations or substitutions are possible. It is explicitly acknowledged that express recitation of every possible combination and substitution is overly burdensome, especially given that the permissibility of each and every such combination and substitution will be readily recognized by those of ordinary skill in the art.

While the embodiments are susceptible to various modifications and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that these embodiments are not to be limited to the particular form disclosed, but to the contrary, these embodiments are to cover all modifications, equivalents, and alternatives falling within the spirit of the disclosure. Furthermore, any features, functions, steps, or elements of the embodiments may be recited in or added to the claims, as well as negative limitations that define the inventive scope of the claims by features, functions, steps, or elements that are not within that scope.

Claims

1. A method of assembling an in vivo analyte sensor control device, comprising: orienting an applicator with respect to a container, wherein the applicator comprises a housing, a sheath, and an electronics housing of the sensor control device, the sheath being slidably coupled with the housing and comprising (a) a deflectable lock arm in contact with the housing such that the housing is prevented from moving distally with respect to the sheath and (b) a deflectable positioning arm having a detent releasably positioned within a first groove of the housing, andwherein the container holds a sensor module and a sharp module and comprises a platform having a sheath unlock abutment located thereon;distally advancing the applicator into the container such that the sheath unlock abutment contacts a sloped surface of the deflectable lock arm and causes the lock arm to deflect from contact with the housing, whereby the sheath is unlocked from the housing and releasably maintained in position with respect to the housing by the deflectable positioning arm;distally advancing the housing against the platform to move the platform into the container until contact of the container against the sheath causes the sheath to move with respect to the housing such that the detent of the deflectable positioning arm moves from the first groove to a releasable position within a second groove and the deflectable lock arm is held in an unlocked position.

2. The method of claim 1, wherein the sensor module couples with the electronics housing to assemble the sensor control device when the detent moves from the first groove to the second groove.

3. The method of claim 2, wherein the sharp module couples with the applicator when the detent moves from the first groove to the second groove.

4. The method of claim 3, further comprising: removing the applicator from the container after the detent moves from the first groove to the second groove; anddelivering the sensor control device to a user's body with the applicator.

5. The method of claim 4, wherein the sensor module couples with the electronics housing to assemble the sensor control device and the sharp module couples with the applicator at substantially the same time as the detent enters the second groove.

6. The method of claim 4, wherein the first and second grooves are in the housing, and wherein delivering the sensor control device to the user's body with the applicator comprises: placing a surface of the sheath against the user's body; andadvancing the housing with respect to the sheath to cause the detent to move from the second groove along a surface of the housing to a third groove, wherein upon entering the third groove the sheath is locked in position with respect to the housing.

7. The method of claim 1, wherein the platform comprises an inner deflectable lock arm having a sloped surface, and wherein distal advancement of the applicator into the container causes the sheath to contact the sloped surface of the platform's inner deflectable lock arm and causes the platform's inner deflectable lock arm to deflect from contact with the container.

8. The method of claim 7, wherein an outer deflectable lock arm of the platform releasably holds the platform in position with respect to the container until distal advancement of the housing against the platform causes the outer deflectable lock arm of the platform to disengage from a surface contour of the container, whereby the platform is free to move into the container.

9. The method of claim 8, wherein distal advancement of the housing against the platform moves the platform into the container until a sheath unlock rib of the container contacts the sheath through an opening in the platform and causes the sheath to move with respect to the housing such that the detent of the deflectable positioning arm moves from the first groove to a releasable position within the second groove and the deflectable lock arm is held in the unlocked position.

10. The method of claim 1, wherein the sensor module comprises a sensor adapted to measure a glucose level when placed in contact with a bodily fluid of a user.

11. An in vivo analyte monitoring system, comprising: an applicator comprising a housing, a sheath, and an electronics housing of a sensor control device, the sheath being slidably coupled with the housing and comprising (a) a deflectable lock arm configured to contact the housing and releasably lock the housing in position with respect to the sheath and (b) a deflectable positioning arm comprising a detent releasably positioned within a first groove of the housing, the deflectable positioning arm being configured to releasably maintain the sheath in position with respect to the housing after the deflectable lock arm is unlocked; anda container holding a sensor module and a sharp module therein and comprising a platform having a sheath unlock abutment located thereon,wherein the sheath unlock abutment is positioned on the platform such that, when the applicator is inserted into the container, the sheath unlock abutment is capable of contacting a sloped surface of the deflectable lock arm and causing the deflectable lock arm to deflect from contact with the housing to unlock the sheath from the housing, andwherein the applicator and container are configured such that distal advancement of the housing against the platform moves the platform into the container until contact of the container against the sheath causes the sheath to move with respect to the housing such that the detent of the deflectable positioning arm moves from the first groove to a releasable position within a second groove and the deflectable lock arm is held in an unlocked position.

12. The system of claim 11, wherein the applicator and container are configured such that the sensor module can couple with the electronics housing to assemble the sensor control device when the detent moves from the first groove to the second groove.

13. The system of claim 12, wherein the applicator and container are configured such that the sharp module can couple with the applicator when the detent moves from the first groove to the second groove.

14. The system of claim 13, wherein the applicator is configured to deliver the sensor control device to a user's body once the detent moves from the first groove to the second groove.

15. The system of claim 14, wherein the applicator and container are configured such that the sensor module couples with the electronics housing to assemble the sensor control device and the sharp module couples with the applicator at substantially the same time as the detent enters the second groove.

16. The system of claim 14, wherein the first and second grooves are in the housing, and wherein the applicator is configured such that the housing can be moved with respect to the sheath to cause the detent to move from the second groove along a surface of the housing to a third groove, wherein upon entering the third groove the sheath is locked in position with respect to the housing.

17. The system of claim 11, wherein the platform comprises an inner deflectable lock arm having a sloped surface, and the applicator and container are configured such that distal advancement of the applicator into the container causes the sheath to contact the sloped surface of the platform's inner deflectable lock arm and causes the platform's inner deflectable lock arm to deflect from contact with the container.

18. The system of claim 17, wherein an outer deflectable lock arm of the platform is configured to releasably hold the platform in position with respect to the container, and wherein the applicator and container are configured such that distal advancement of the housing against the platform causes the outer deflectable lock arm of the platform to disengage from a surface contour of the container, whereby the platform is free to move into the container.

19. The system of claim 18, wherein the applicator and container are configured such that distal advancement of the housing against the platform moves the platform into the container until a sheath unlock rib of the container contacts the sheath through an opening in the platform and causes the sheath to move with respect to the housing such that the detent of the deflectable positioning arm moves from the first groove to a releasable position within the second groove and the deflectable lock arm is held in the unlocked position.

20. The system of claim 11, wherein the sensor module comprises a sensor adapted to measure a glucose level when placed in contact with a bodily fluid of a user.