Methods for needle alignment for wearable biosensors
Various examples are described for methods for needle alignment for wearable biosensors. One example device includes a housing comprising an upper portion and a lower portion, the housing defining a cavity between the upper portion and the lower portion and configured to be worn on a wearer's skin, wherein: the upper portion defines a first opening extending through the upper portion to the cavity, and the lower portion defines a second opening extending through the lower portion to the cavity, the cavity establishing a substantially unobstructed pathway including the first opening and the second opening to enable an insertion needle to be inserted through the housing; and a needle guide extending into and along a portion of the pathway and aligned with a sensor wire to enable alignment between the insertion needle and the sensor wire.
1 . A method of manufacturing a wearable sensor device comprising:
forming an upper portion of a housing, the upper portion defining a first opening extending therethrough;
forming a lower portion of the housing, the lower portion defining a second opening extending therethrough;
positioning a needle guide to extend through the first opening and the second opening, wherein the needle guide is aligned with a portion of a sensor wire, the portion of the sensor wire extending through the second opening and distally beyond the lower portion of the housing, wherein the needle guide includes a projection extending from a perimeter of the first opening to a centerline of an insertion axis;
physically coupling the upper portion to the lower portion to define a pathway between the upper portion and the lower portion, the pathway extending from the first opening to the second opening, the pathway configured to enable a needle to be inserted through the housing; and
positioning the sensor wire to extend through the second opening.
2 . The method of claim 1 , wherein forming the upper portion of the housing comprises injection molding the upper portion of the housing, and forming the lower portion of the housing comprises injection molding the lower portion of the housing.
3 . The method of claim 1 , wherein forming the upper portion of the housing comprises casting the upper portion of the housing, and forming the lower portion of the housing comprises casting the lower portion of the housing.
4 . The method of claim 1 , wherein the first opening and the second opening define an axis, wherein the axis is perpendicular to a lower surface of the lower portion of the housing.
5 . The method of claim 1 , wherein the first opening and the second opening define an axis, wherein the axis is at an oblique angle to a lower surface of the lower portion of the housing.
6 . The method of claim 1 , wherein positioning the needle guide comprises forming the needle guide as a part of at least one of the upper portion or lower portion.
7 . The method of claim 1 , wherein the housing is configured to be worn on a wearer's skin.
8 . The method of claim 1 , wherein the projection extends into and along a portion of the pathway and the needle includes a channel spanning at least a portion of a length of the needle to enable the projection to be received by the channel upon insertion of the needle through the housing.
9 . The method of claim 1 , further comprising:
physically coupling a support structure to at least one of the upper portion or the lower portion; and
physically coupling the sensor wire to the support structure and extending from the support structure.
10 . The method of claim 9 , further comprising physically coupling the needle guide to the support structure.
11 . The method of claim 1 , where the needle has a cross-section corresponding to a perimeter of the first opening.
12 . A method of aligning a needle with a pathway in a housing of a wearable sensor device, comprising:
aligning the needle with a first opening defined in the housing of the wearable sensor device, the housing comprising an upper portion and a lower portion, wherein:
the upper portion comprises the first opening extending therethrough,
the lower portion comprises a second opening extending therethrough, and
the pathway extends from the first opening to the second opening enabling the needle to be inserted through the housing;
aligning the needle with a needle guide extending into and along a portion of the pathway through the first and second openings, wherein the needle guide is aligned with a portion of a sensor wire, the portion of the sensor wire extending through the second opening and distally beyond the lower portion of the housing, wherein the needle guide includes a projection; and
inserting the needle through the housing along the pathway, the needle guide preventing damage to the sensor wire as the needle is inserted through the housing.
13 . The method of claim 12 , wherein the needle guide includes a projection extending into and along the portion of the pathway and the needle includes a channel spanning at least a portion of a length of the needle to enable the projection to be received by the channel upon insertion of the needle through the housing.
14 . The method of claim 12 , further comprising:
coupling a support structure to at least one of the upper portion or the lower portion; and
coupling the sensor wire to the support structure and extending from the support structure.