Analyte sensor and method of making the same
First Claim
Patent Images
1. A sensor produced by the method of:
- i) providing a preformed self-supporting flexible substrate;
ii) sequentially sputter-depositing a plurality of metal layers on the substrate, the plurality of layers including an uppermost layer;
iii) plating a metal layer on the uppermost sputter-deposited metal layer;
iv) etching the plated and sputter-deposited metal layers to form a sensor electrode having a proximal segment and a distal segment;
v) sequentially plating first and second metal layers on the sensor electrode;
vi) coating the sensor electrode with a polymeric material;
vii) forming at least one opening in the coating; and
viii) separating the sensor electrode and at least a portion of the substrate underlying the sensor electrode from the remainder of the substrate.
2 Assignments
0 Petitions
Accused Products
Abstract
A method of making a sensor includes the steps of providing a preformed self-supporting flexible substrate; sputter-depositing a metal layer on the substrate; etching the sputter-deposited metal layers to form a sensor electrode having a proximal segment and a distal segment; plating a metal layer on the sensor electrode; and separating the sensor electrode and at least a portion of the substrate underlying the sensor electrode from the remainder of the substrate. Sensors prepared according to the inventive methods, and sensor sets including the sensors, are also provided.
787 Citations
97 Claims
-
1. A sensor produced by the method of:
-
i) providing a preformed self-supporting flexible substrate;
ii) sequentially sputter-depositing a plurality of metal layers on the substrate, the plurality of layers including an uppermost layer;
iii) plating a metal layer on the uppermost sputter-deposited metal layer;
iv) etching the plated and sputter-deposited metal layers to form a sensor electrode having a proximal segment and a distal segment;
v) sequentially plating first and second metal layers on the sensor electrode;
vi) coating the sensor electrode with a polymeric material;
vii) forming at least one opening in the coating; and
viii) separating the sensor electrode and at least a portion of the substrate underlying the sensor electrode from the remainder of the substrate. - View Dependent Claims (2)
a) a mounting base adapted for mounting onto a patient'"'"'s skin;
b) a sensor as claimed in claim 1;
c) a cannula protruding from the mounting base and having a portion of the sensor; and
d) an insertion needle carried by the mounting base to protrude from the mounting base and having at least a portion of the cannula nested within the insertion needle, the insertion needle defining a longitudinally extending slot along one side to permit sliding withdrawal of the insertion needle from the mounting base and the nested portion of the cannula.
-
-
3. A sensor comprising:
-
a) a self-supporting flexible substrate having an upper surface and a lower surface;
b) at least one deposited metal layer that includes an uppermost surface, wherein the at least one deposited metal layer is deposited on the upper surface of the flexible substrate; and
c) at least one plated metal layer that is plated on the uppermost surface of the at least one deposited metal layer;
wherein the deposited and plated metal layers are etched to yield a sensor electrode having a first and a second edge and a proximal and a distal segment.- View Dependent Claims (4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43)
a) a mounting base adapted for mounting onto a patient'"'"'s skin;
b) the sensor of claim 3;
c) a cannula protruding from the mounting base and having a portion of the sensor; and
d) an insertion needle carried by the mounting base to protrude from the mounting base and having at least a portion of the cannula nested within the insertion needle, the insertion needle defining a longitudinally extending slot along one side to permit sliding withdrawal of the insertion needle from the mounting base and the nested portion of the cannula.
-
-
23. The sensor set of claim 22, further including a polymer coating on the sensor electrode.
-
24. The sensor set of claim 22, wherein the flexible substrate includes a polymeric material.
-
25. The sensor set of claim 22, further including a plurality of deposited metal layers, the plurality of deposited metal layers having an uppermost surface.
-
26. The sensor set of claim 22, further including a plurality of plated metal layers that are plated on the uppermost surface of the deposited metal layer.
-
27. The sensor set of claim 22, wherein the at least one plated metal layer includes a layer of copper.
-
28. The sensor set of claim 22, wherein the at least one deposited metal layer includes a layer of copper.
-
29. The sensor set of claim 22, wherein the sensor further includes a bead on the lower surface of the flexible substrate.
-
30. The sensor set of claim 29, wherein the bead substantially traverses the length of the lower surface of the flexible substrate.
-
31. The sensor set of claim 23, wherein the polymer coating is etched to form openings.
-
32. The sensor set of claim 31, wherein the openings include a plated layer of metal.
-
33. The sensor set of claim 32, wherein the plated layer of metal in the openings includes gold.
-
34. A sensor set comprising:
-
a) a mounting base adapted for mounting onto a patient'"'"'s skin;
b) the sensor of claim 3 further including a bead on the lower surface of the flexible substrate; and
c) an insertion needle carried by the mounting base to protrude from the mounting base and having at least a portion of the bead of the sensor nested within the insertion needle, the insertion needle defining a longitudinally extending slot along one side to permit sliding withdrawal of the insertion needle from the mounting base and the nested portion of the sensor.
-
-
35. The sensor of claim 34, further including a polymer coating on the sensor electrode.
-
36. The sensor of claim 34, wherein the flexible substrate includes a polymeric material.
-
37. The sensor of claim 34, further including a plurality of deposited metal layers, the plurality of deposited metal layers having an uppermost surface.
-
38. The sensor of claim 34, further including a plurality of plated metal layers that are plated on the etched metal layer.
-
39. The sensor of claim 34, wherein the at least one plated metal layer includes a layer of copper.
-
40. The sensor of claim 34, wherein the bead substantially traverses the length of the lower surface of the flexible substrate.
-
41. The sensor of claim 35, wherein the polymer coating is etched to form openings.
-
42. The sensor of claim 41, wherein the openings are plated with a layer of metal.
-
43. The sensor of claim 42, wherein the plated layer of metal in the openings includes gold.
-
44. A sensor comprising:
-
a) a self-supporting flexible substrate having an upper surface and a lower surface;
b) at least one deposited metal layer that includes an uppermost surface, wherein the at least one metal layer is deposited on the upper surface of the flexible substrate and the at least one deposited metal layer is then etched to yield a sensor electrode having a first and a second edge and a proximal and a distal segment; and
c) at least one plated metal layer that is plated on substantially the entire uppermost surface of the at least one etched metal layer. - View Dependent Claims (45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85)
a) a mounting base adapted for mounting onto a patient'"'"'s skin;
b) the sensor of claim 44;
c) a cannula protruding from the mounting base and having a portion of the sensor; and
d) an insertion needle carried by the mounting base to protrude from the mounting base and having at least a portion of the cannula nested within the insertion needle, the insertion needle defining a longitudinally extending slot along one side to permit sliding withdrawal of the insertion needle from the mounting base and the nested portion of the cannula.
-
-
67. The sensor set of claim 66, further including a polymer coating on the sensor electrode.
-
68. The sensor set of claim 66, wherein the flexible substrate includes a polymeric material.
-
69. The sensor set of claim 66, further including a plurality of deposited metal layers.
-
70. The sensor set of claim 66, further including a plurality of plated metal layers.
-
71. The sensor set of claim 66, wherein the at least one plated metal layer includes a layer of copper.
-
72. The sensor set of claim 66, wherein the at least one deposited metal layer includes a layer of copper.
-
73. The sensor set of claim 67, wherein the polymer coating is etched to form openings.
-
74. The sensor set of claim 73, wherein the openings include a plated layer of metal.
-
75. The sensor set of claim 74, wherein the plated layer of metal in the openings includes gold.
-
76. A sensor set comprising:
-
a) a mounting base adapted for mounting onto a patient'"'"'s skin;
b) the sensor of claim 44 further including a bead on the lower surface of the flexible substrate; and
c) an insertion needle carried by the mounting base to protrude from the mounting base and having at least a portion of the bead of the sensor nested within the insertion needle, the insertion needle defining a longitudinally extending slot along one side to permit sliding withdrawal of the insertion needle from the mounting base and the nested portion of the sensor.
-
-
77. The sensor set of claim 76, further including a polymer coating on the sensor electrode.
-
78. The sensor set of claim 76, wherein the flexible substrate includes a polymeric material.
-
79. The sensor set of claim 76, further including a plurality of deposited metal layers, the plurality of deposited metal layers having an uppermost surface.
-
80. The sensor set of claim 76, further including a plurality of plated metal layers.
-
81. The sensor set of claim 76, wherein the at least one plated metal layer includes a layer of copper.
-
82. The sensor of claim 76 wherein the bead substantially traverses the length of the lower surface of the flexible substrate.
-
83. The sensor set of claim 77, wherein the polymer coating is etched to form openings.
-
84. The sensor set of claim 83, wherein the openings include a plated layer of metal.
-
85. The sensor set of claim 84, wherein the plated layer of metal in the openings includes gold.
-
86. A sensor comprising:
-
a) a self-supporting flexible substrate including an upper and lower surface;
b) a plurality of sputter-deposited metal layers on the upper surface of the flexible substrate, the plurality of layers including an uppermost layer;
c) a metal layer plated on the uppermost sputter-deposited metal layer, wherein the plated and sputter-deposited metal layers are etched to form a sensor electrode having a proximal segment and a distal segment;
d) a plurality of plated metal layers on the etched sensor electrode;
e) a polymeric coating on the sensor electrode, wherein the coating is etched to form at least one opening in the coating; and
f) a bead on the lower surface of the flexible substrate. - View Dependent Claims (87)
a) a mounting base adapted for mounting onto a patient'"'"'s skin;
b) the sensor of claim 86; and
c) an insertion needle carried by the mounting base to protrude from the mounting base and having at least a portion of the bead of the sensor nested within the insertion needle, the insertion needle defining a longitudinally extending slot along one side to permit sliding withdrawal of the insertion needle from the mounting base and the nested portion of the sensor.
-
-
88. A sensor comprising:
-
a) a self-supporting flexible substrate including an upper and lower surface;
b) a plurality of sputter-deposited metal layers on the upper surface of the flexible substrate, the plurality of layers including an uppermost layer;
c) a metal layer plated on the uppermost sputter-deposited metal layer, wherein the plated and sputter-deposited metal layers are etched to form a sensor electrode having a proximal segment and a distal segment;
d) a plurality of plated metal layers on the etched sensor electrode; and
e) a polymeric coating on the sensor electrode, wherein the coating is etched to form at least one opening in the coating. - View Dependent Claims (89)
a) a mounting base adapted for mounting onto a patient'"'"'s skin;
b) the sensor of claim 88;
c) a cannula protruding from the mounting base and having a portion of the sensor; and
d) an insertion needle carried by the mounting base to protrude from the mounting base and having at least a portion of the cannula nested within the insertion needle, the insertion needle defining a longitudinally extending slot along one side to permit sliding withdrawal of the insertion needle from the mounting base and the nested portion of the cannula.
-
-
90. A sensor produced by the method comprising:
-
a) providing a self-supporting flexible substrate having an upper surface and a lower surface;
b) depositing at least one deposited metal layer that includes an uppermost surface, wherein the at least one deposited metal layer is deposited on the upper surface of the flexible substrate; and
c) plating at least one plated metal layer on the uppermost surface of the deposited metal layer;
wherein the deposited and plated metal layers are etched to yield a sensor electrode having a first and a second edge and a proximal and a distal segment.
-
-
91. A sensor produced by the method comprising:
-
a) providing a self-supporting flexible substrate having an upper surface and a lower surface;
b) depositing at least one deposited metal layer that includes an uppermost surface, wherein the at least one metal layer is deposited on the upper surface of the flexible substrate and the at least one deposited metal layer is then etched to yield a sensor electrode having a first and a second edge and a proximal and a distal segment; and
c) plating at least one plated metal layer on substantially the entire uppermost surface of the etched metal layer.
-
-
92. A sensor comprising:
-
a) a self-supporting flexible substrate having an upper surface and a lower surface;
b) at least one deposited metal layer deposited on the upper surface of the flexible substrate; and
c) at least one plated metal layer plated on the deposited metal layer, wherein the at least one plated metal layer is plated with a metal other than platinum-black or a mixture of silver and silver chloride.
-
- 93. A sensor comprising a self-supporting flexible substrate having an upper surface and a lower surface and at least one interlayered metal layer, wherein the interlayered metal layer includes at least one deposited metal layer and at least one plated metal layer and covers an area greater than an area of the sensor to be plated with sensor electrochemistry materials.
-
95. A sensor comprising:
-
a) a self-supporting flexible substrate having an upper surface and a lower surface;
b) at least one deposited metal layer deposited on the upper surface of the flexible substrate; and
c) at least one plated metal layer plated on the deposited metal layer, wherein the at least one plated metal layer is plated on an area of the deposited metal layer that is greater than an area of the sensor to be plated with sensor electrochemistry materials. - View Dependent Claims (96, 97)
-
Specification