Abstract: An insertion set is provided for transcutaneous placement of a sensor such as a glucose sensor at a selected site within the body of a patient. The insertion set comprises a slotted insertion needle extending through a mounting base adapted for mounting onto the patient's skin. A flexible thin film sensor includes a proximal segment carried by the mounting base and defining conductive contacts adapted for electrical connection to a suitable monitor, and a distal segment protruding from the mounting base with sensor electrodes for transcutaneous placement. The proximal and distal segments of the sensor are linearly offset or misaligned, with the distal segment fitted within the insertion needle for transcutaneous sensor placement with the needle as the mounting base is pressed onto the patient's skin. The insertion needle can then be withdrawn to leave the sensor distal segment at the selected insertion position with the sensor electrodes in contact with patient blood or other extracellular fluid.

Abstract: An improved method is provided for making thin film electrochemical sensors, such as subcutaneous glucose sensors used to monitor blood glucose levels in a diabetic patient. The fabrication method comprises placing a thin film base layer of insulative material onto a rigid flat substrate, with a curable adhesive interposed between the perimeter of the base layer and substrate to define a shallow cavity underlying a central portion of the base layer. The subassembly is subjected to heat and pressure to cure the adhesive, resulting in air expulsion from the cavity such that the central portion of the base layer is drawn into intimate contact with the substrate. Appropriate conductor elements for one or more sensors are formed on the base layer as by conventional contact mask photolithography, and a thin film cover layer of insulative material is applied thereover with apertures in the cover layer exposing distal end sensor electrodes and proximal end contact pads.

Abstract: An improved power supply adapter is provided for plug-in connection to a standard AC power supply receptacle, and to provide a DC voltage to an associated electronic instrument. The power supply adapter comprises a relatively compact case having an end face with a plurality of conductive prongs protruding therefrom for plug-in connection to an AC receptacle, such as one socket of a standard duplex or quad wall outlet or the like. An AC adapter assembly is mounted within the adapter case with the components of the AC adapter assembly arranged generally in-line between the conductive prongs and a power cord adapted for connection to the associated electronic instrument. This in-line geometry permits the adapter case to have a relatively narrow width and low profile height conforming with a single electrical socket, whereby plug-in connection of the adapter to an electrical socket does not obstruct access to adjacent sockets.

Abstract: An adapter plug clip is provided for convenient and secure temporary support of an electrical plug associated with an electronic instrument, particularly wherein the plug is formed as part of a relatively heavy AC/DC plug-in power supply adapter. The adapter plug clip is designed for clip-on mounting to a support structure, such as a bracket arm of a clamp fixture having an electronic instrument such as a medical fluid infusion pump mounted thereon. The adaptor plug clip includes a face plate having a visually identifiable pattern of holes formed therein for seated reception of the conductive prongs of the electrical plug, thereby providing a stable temporary plug mounting site.

Abstract: An improved battery pack is provided for short term battery power operation of a medical instrument such as an infusion pump. The battery pack comprises a substantially closed and compact housing one or more rechargeable batteries inaccessibly encased therein, with the battery pack housing being adapted for mounting directly onto the casing of an electronic medical instrument. The batteries are mounted on a base plate beneath a foil shield and a housing cap, both of which are attached to the base plate in a manner precluding nondestructive removal thereof and thereby substantially preventing access to the batteries. The assembled battery pack housing includes seal members for preventing passage of any gases discharged from the batteries into the medical instrument casing, and further defines at least one vent for exhaust passage of such gases to the exterior of the battery pack and medical instrument.