CONTINUOUS ANALYTE SENSORS AND METHODS OF MAKING SAME

• US 20140343386A1
• Filed: 08/04/2014
• Published: 11/20/2014
• Est. Priority Date: 07/02/2009
• Status: Abandoned Application

• Current Assignee: DexCom Incorporated
• Original Assignee: DexCom Incorporated
• Inventors: Boock, Robert J., Jackson, Jeff, Zhang, Huashi, Mitchell, Jason
• Application Number:
  US14/451,332
• Publication Number:
  US 20140343386A1
• Time in Patent Office: Days
• US Class Current: 600/345
• CPC Class Codes: A61B 2560/0223 of calibration, e.g. protocols for calibrating sensors
• CPC Class Codes: A61B 2562/0209 Special features of electrodes classified in A61B5/24, A61B5/25, A61B5/283, A61B5/291, A61B5/296, A61B5/053
• CPC Class Codes: A61B 2562/043 in a linear array
• CPC Class Codes: A61B 2562/125 characterised by the manufacture of electrodes
• CPC Class Codes: A61B 5/14503 invasive, e.g. introduced into the body by a catheter or needle or using implanted sensors A61B5/1459, A61B5/1464, A61B5/1473, A61B5/1482, A61B5/14865 take precedence
• CPC Class Codes: A61B 5/1451 for interstitial fluid
• CPC Class Codes: A61B 5/14517 for sweat
• CPC Class Codes: A61B 5/14532 for measuring glucose, e.g. by tissue impedance measurement
• CPC Class Codes: A61B 5/14546 for measuring analytes not otherwise provided for, e.g. ions, cytochromes
• CPC Class Codes: A61B 5/1473 invasive, e.g. introduced into the body by a catheter A61B5/1482 takes precedence
• CPC Class Codes: A61B 5/14865 invasive, e.g. introduced into the body by a catheter or needle or using implanted sensors
• CPC Class Codes: B05C 3/02 the work being immersed in the liquid or other fluent material
• CPC Class Codes: B05C 3/10 the articles being moved through the liquid or other fluent material conveying articles through baths B65G, e.g. B65G49/02
• CPC Class Codes: B05C 3/125 the work being a web, band, strip or the like
• CPC Class Codes: B05C 5/0241 for applying liquid or other fluent material to elongated work, e.g. wires, cables, tubes
• CPC Class Codes: B05D 1/18 performed by dipping
• CPC Class Codes: B05D 3/06 by exposure to radiation B05D3/02 takes precedence ; plasma treatment B05D3/141
• CPC Class Codes: B23K 26/0823 Devices involving rotation of the workpiece
• CPC Class Codes: B23K 26/362 Laser etching
• CPC Class Codes: B29C 2791/009 Using laser curing using laser B29C2035/0838, welding using laser beams B29C65/16
• CPC Class Codes: C23C 2/00 : Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor

Abstract

Described here are embodiments of processes and systems for the continuous manufacturing of implantable continuous analyte sensors. In some embodiments, a method is provided for sequentially advancing an elongated conductive body through a plurality of stations, each configured to treat the elongated conductive body. In some of these embodiments, one or more of the stations is configured to coat the elongated conductive body using a meniscus coating process, whereby a solution formed of a polymer and a solvent is prepared, the solution is continuously circulated to provide a meniscus on a top portion of a vessel holding the solution, and the elongated conductive body is advanced through the meniscus. The method may also comprise the step of removing excess coating material from the elongated conductive body by advancing the elongated conductive body through a die orifice.

Claims

1-8. -8. (canceled)

9. An implantable electrochemical sensor comprising:

a working electrode comprising an electroactive surface, wherein the working electrode is configured to be implanted in a host, wherein the working electrode is configured to measure a signal indicative of an analyte concentration; and

a reference electrode comprising silver particles and silver chloride particles.

10. The sensor of claim 9, wherein the silver particles of the reference electrode have an average particle size with a maximum particle dimension that is less than about 100 microns.

11. The sensor of claim 9, wherein the silver particles of the reference electrode have an average particle size with a maximum particle dimension that is less than about 50 microns.

12. The sensor of claim 9, wherein the silver particles of the reference electrode have an average particle size with a maximum particle dimension that is less than about 30 microns.

13. The sensor of claim 9, wherein the silver particles of the reference electrode have an average particle size with a maximum particle dimension that is less than about 10 microns.

14. The sensor of claim 9, wherein the silver chloride particles of the reference electrode have an average particle size with a maximum particle dimension that is less than about 100 microns.

15. The sensor of claim 9, wherein the silver chloride particles of the reference electrode have an average particle size with a maximum particle dimension that is less than about 80 microns.

16. The sensor of claim 9, wherein the silver chloride particles of the reference electrode have an average particle size with a maximum particle dimension that is less than about 60 microns.

17. The sensor of claim 9, wherein the silver chloride particles of the reference electrode have an average particle size with a maximum particle dimension that is less than about 20 microns.

18. A method for manufacturing an implantable continuous analyte sensor system, the method comprising:

providing a silver/silver chloride paste, wherein the paste comprises a ratio of silver chloride particle;

silver particle from about 0.01;

1 to about 2;

1 by weight;

applying the silver/silver chloride paste onto a portion of a workpiece, whereby the applied silver/silver chloride forms a reference electrode.

19. The method of claim 18, wherein the ratio of silver chloride particle:

silver particle is from about 0.1;

1 to about 1;

1 by weight.

20. The method of claim 19, wherein the paste comprises silver chloride particles and silver particles mixed with a carrier.

21. The method of claim 20, wherein the silver chloride particles and silver particles form about 10% to about 65% by weight of the paste.

22. The method of claim 21, wherein the silver chloride particles and silver particles form about 20% to about 50% by weight of the paste.

23. The method of claim 22, wherein the silver chloride particles and silver particles form about 23% to about 37% by weight of the paste.

24. The method of claim 18, wherein the paste has a viscosity from about 1 to about 500 centipoise.

25. The method of claim 24, wherein the paste has a viscosity from about 10 to about 300 centipoise.

26. The method of claim 25, wherein the paste has a viscosity from about 50 to about 150 centipoise.

27. The method of claim 18, further comprising:

providing a solution comprising polyurethane.

28. The method of claim 27, further comprising:

applying the polyurethane-containing solution to the first electrode.