PRECONNECTED ANALYTE SENSORS
Various analyte sensing apparatuses and associated housings are provided. Some apparatuses comprise one or more caps. Some apparatuses comprise a two-part adhesive patch. Some apparatuses comprise one or more sensor bends configured to locate and/or hold a sensor in place during mounting. Some apparatuses utilize one or more dams and/or wells to retain epoxy for securing a sensor. Some apparatuses utilize a pocket and one or more adjacent areas and various transitions for preventing epoxy from wicking to undesired areas of the apparatus. Some apparatuses include heat-sealable thermoplastic elastomers for welding a cap to the apparatus. Related methods of fabricating such apparatuses and/or housings are also provided.
1 . An analyte sensing apparatus, comprising:
a housing comprising a cavity, the cavity including a first portion and a second portion;
a first conductive contact and a second conductive contact disposed within the first portion of the cavity;
an analyte sensor comprising:
an elongated body;
a first electrode in electrical communication with the first conductive contact, and
a second electrode in electrical communication with the second conductive contact; and
a cap configured to fit on or within the cavity, the cap comprising:
a first portion configured to be disposed over the first portion of the cavity,
a second portion,
a dam disposed on a side of the cap configured to face the cavity, the dam dividing the first portion of the cavity from the second portion of the cavity,
a shelf disposed adjacent to the dam, and
a compliant component configured to seal the first portion of the cavity from the second portion of the cavity.
2 . The apparatus of claim 1 , further comprising an electronics assembly substrate disposed within the housing, wherein the first conductive contact and the second conductive contact extend from the electronics assembly substrate into the first portion of the cavity.
3 . The apparatus of claim 1 , wherein the compliant component is disposed on the shelf and configured to press against a portion of the analyte sensor and against a surface of the housing within the cavity, thereby sealing the first portion of the cavity from the second portion of the cavity.
4 . The apparatus of claim 4 , wherein the first portion of the cap comprises a first hole configured to receive an encapsulating sealant into the first portion of the cavity that seals at least a portion of the analyte sensor from moisture ingress.
5 . The apparatus of claim 4 , wherein the encapsulating sealant is a curable sealant configured to cure based on exposure to ultra-violet radiation and wherein the cap comprises a material substantially transparent to the ultra-violet radiation.
6 . The apparatus of claim 4 , wherein the first portion of the cap comprises a second hole configured to allow excess encapsulating sealant to flow out of the first portion of the cavity.
7 . The apparatus of claim 6 , wherein the compliant component prevents the encapsulating sealant from flowing into the second portion of the cavity.
8 . The apparatus of claim 1 , wherein the second portion of the cap is configured to be disposed over the second portion of the cavity.
9 . The apparatus of claim 1 , wherein the second portion of the cap comprises a slot configured to allow at least a portion of the analyte sensor to pass through the cap.
10 . The apparatus of claim 1 , wherein an outside-facing surface of the cap is configured to fit flush with an outside-facing surface of the housing.
11 . The apparatus of claim 1 , wherein an outside-facing surface of the cap is configured to fit in a recessed position compared to an outside-facing surface of the housing.
12 . The apparatus of claim 1 , wherein the cap is disposed on an outside-facing surface of the housing.
13 . The apparatus of claim 1 , wherein the cap is secured to the cavity utilizing at least one of a toe feature, a snap feature, a friction-fit feature, and a pressure-sensitive adhesive.
14 . The apparatus of claim 1 , wherein the first portion of the cap and the second portion of the cap are and are formed of a single piece.
15 . The apparatus of claim 1 , wherein the dam is configured to contact a portion of the housing within the cavity.
16 . The apparatus of claim 1 , wherein the compliant material comprises a foam or a rubber material.
17 . The apparatus of claim 1 , further comprising an adhesive patch comprising:
a first adhesive portion configured to secure the cap to the housing and to simultaneously adhere to the housing; and
a second adhesive portion configured to adhere the first adhesive portion and the wearable assembly to a skin of a host.
18 . The apparatus of claim 17 , wherein the cap is secured to the first adhesive portion of the adhesive patch before the cap is fit on or within the cavity of the housing.
19 . The apparatus of claim 17 , wherein the first adhesive portion comprises at least one hole configured to substantially coincide with at least one hole within the cap when the cap is secured to the first adhesive portion of the adhesive patch.
20 . The apparatus of claim 1 , wherein the second portion of the cap is configured to be disposed adjacent to the second portion of the cavity.
21 . The apparatus of claim 1 , wherein:
the first portion of the cap extends along a first plane,
the second portion of the cap extends along a second plane different from the first plane,
the dam comprises at least a portion of the cap that extends between the first plane and the second plane and connects the first portion of the cap with the second portion of the cap, and
at least some of the second portion of the cap comprises the shelf.