Stackable electrochemical analyte sensors, systems and methods including same

• US 9,535,030 B2
• Filed: 10/07/2013
• Issued: 01/03/2017
• Est. Priority Date: 09/30/2009
• Status: Active Grant

• Current Assignee: Ascensia Diabetes Care Holdings AG (PHC Holdings Corporation)
• Original Assignee: Ascensia Diabetes Care Holdings AG (PHC Holdings Corporation)
• Inventors: Gofman, Igor, Sams, Robert S.
• Primary Examiner(s): WRIGHT, PATRICIA KATHRYN
• Application Number:
  US14/047,050
• Publication Number:
  US 20140054169A1
• Time in Patent Office: 1,184 Days
• US Class Current: 1/1
• CPC Class Codes: G01N 27/3271 Amperometric enzyme electrodes for analytes in body fluids, e.g. glucose in blood amperometry per se G01N27/49; aspects concerning the enzyme reagent C12Q1/001
• CPC Class Codes: G01N 27/3272 Test elements therefor, i.e. disposable laminated substrates with electrodes, reagent and channels optical biosensors G01N33/52
• CPC Class Codes: G01N 27/403 Cells and electrode assemblies
• CPC Class Codes: G01N 33/52 Use of compounds or compositions for colorimetric, spectrophotometric or fluorometric investigation, e.g. use of reagent paper and including single- and multilayer analytical elements immunological elements G01N33/54386; involving labelled immunochemicals G01N33/58; for haemoglobin or occult blood G01N33/72
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

In some aspects, an analyte sensor is provided for detecting an analyte concentration level in a bio-fluid sample. The analyte sensor has a base with first and second ends, a concave recess in the first end, a second end receiving surface, and a sidewall extending between the ends. An electrode may be provided on the receiving surface with an electrochemically-active region coupled to the electrode. A conductor in electrical contact with the electrode may extend along the sidewall and may be adapted to be in electrical contact with a first contact of an analyte meter. Manufacturing methods and systems utilizing and dispensing the analyte sensors are provided, as are numerous other aspects.

Claims

1. An analyte sensor, comprising:

a base having a first end and a second end opposite from the first end, a concave recess formed in the first end, a receiving surface on the second end, and a sidewall extending between the first end and the second end;

a first electrode provided proximate to the receiving surface;

an active region electrically coupled with at least the first electrode;

a first conductor in electrical contact with the first electrode and extending along the sidewall, the first conductor adapted to be in electrical contact with a first contact of an analyte meter; and

a member having a stacking end and an entry end opposite the stacking end and a second sidewall extending between the stacking end and the entry end, the stacking end including a second concave recess which is received over the second end of the base, the member further including a second conductor having a second connecting portion which extends along the second sidewall from the entry end towards the stacking end and a second contact portion connected to the second connecting portion which is formed of an annular ring and extends in a radial direction at least partially around the second sidewall.

2. The analyte sensor of claim 1, wherein the member is provided proximate the second end and forms a space between the receiving surface and an inner surface of the member.

3. The analyte sensor of claim 2, wherein the second sidewall of the member further comprises a a frustoconical outer surface.

4. The analyte sensor of claim 1, wherein the first conductor further comprises a contact portion formed of an annular ring extending in a radial direction at least partially around the sidewall.

5. The analyte sensor of claim 1, wherein the sidewall of the base includes a frustoconical outer surface.

6. The analyte sensor of claim 1, wherein the first conductor further comprises:

a connecting portion which extends along the sidewall from the second end towards the first end, and

a contact portion connected to the connecting portion, the contact portion formed of an annular ring which extends in a radial direction at least partially around the sidewall.

7. The analyte sensor of claim 1 further comprising a second electrode provided proximate the first electrode.

8. The analyte sensor of claim 1 wherein the member includes a second electrode having a cavity formed therein.

9. A method of manufacturing an analyte sensor, comprising the steps of:

providing a base having a first end and a second end, and a first sidewall extending between the first end and the second end, the first end including a concave opening and the second end including a receiving surface;

forming a first electrode on the receiving surface;

applying an active region in contact with the first electrode;

providing a conductor in electrical contact with the first electrode and extending along an outer surface of the first sidewall, the conductor including a contact portion adapted to be in electrical contact with a first electrical contact of an analyte meter; and

providing a member having a stacking end and an entry end opposite the stacking end and a second sidewall extending between the stacking end and the entry end, the stacking end including a concave recess which is received over the second end of the base, the member further including a second conductor having a second connecting portion which extends along the second sidewall from the entry end towards the stacking end and a second contact portion connected to the second connecting portion which is formed of an annular ring and extends in a radial direction at least partially around the second sidewall.

10. The method of claim 9 further comprising forming a second electrode proximate to the active region.

11. The method of claim 10 wherein the second electrode is formed in the member and includes a cavity formed therein.