Semiconductor based analyte sensors and methods

• US 10,307,092 B2
• Filed: 08/11/2016
• Issued: 06/04/2019
• Est. Priority Date: 02/04/2008
• Status: Active Grant

• Current Assignee: Ascensia Diabetes Care Holdings AG (PHC Holdings Corporation)
• Original Assignee: Ascensia Diabetes Care Holdings AG (PHC Holdings Corporation)
• Inventors: Wu, Mu, Fei, Jiangfeng, Peteu, Serban, Sun, Hoi-Cheong Steve, Gifford, Raeann
• Primary Examiner(s): Weston, Tiffany
• Assistant Examiner(s): Tran, Tho Q
• Application Number:
  US15/235,087
• Publication Number:
  US 20160345882A1
• Time in Patent Office: 1,027 Days
• CPC Class Codes: A61B 2562/125 characterised by the manufacture of electrodes
• 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 5/14865 invasive, e.g. introduced into the body by a catheter or needle or using implanted sensors

Abstract

An analyte sensor is provided that comprises a substrate which includes a semiconductor material. Embodiments may include a core of a conductive material, and a cladding of a semiconductor material, in which the cladding may form at least a portion of a conducting path for a working electrode of the analyte sensor. Method of manufacturing and using the analyte sensor are described, as are numerous other aspects.

Claims

1. An analyte sensor, comprising:

a substrate including;

a care comprised of conductive material;

a cladding comprised of semiconductor material and disposed around the core, wherein the cladding has a tensile strength of at least 1000 MPa;

a working electrode formed from a portion of the cladding, the working electrode being at least partially coated with an electrochemically-active layer formed from at least one of a noble metal, carbon nanotubes, and a conductive polymer; and

an active region positioned on the substrate and adapted to be exposed to a fluid environment, the active region including an agent on the electrochemically-active layer on the working electrode.

2. The analyte sensor of claim 1, wherein the conductive material comprises carbon.

3. The analyte sensor of claim 1, wherein the substrate has a diameter of 150 microns or less.

4. The analyte sensor of claim 1, wherein the substrate has a diameter of about 75 to 150 microns.

5. The analyte sensor of claim 1, wherein the substrate has a length of about 2.5 mm to 100 mm.

6. The analyte sensor of claim 1, wherein the semiconductor material comprises silicon carbide.

7. The analyte sensor of claim 1, wherein the agent includes a catalyst agent, wherein the catalyst agent is adapted to convert an analyte within the fluid environment into a product from which an electrical current is generated at the working electrode.

8. The analyte sensor of claim 1, wherein the portion of the cladding forming the working electrode is 1% to 50% covered by the electrochemically-active layer.

9. The analyte sensor of claim 1, wherein the portion of the cladding forming the working electrode is 51% to 100% covered by the electrochemically-active layer which has a thickness of less than a micron.

10. The analyte sensor of claim 1, wherein the electrochemically-active layer includes at least one of platinum, gold, palladium, and rhodium.

11. The analyte sensor of claim 1, further comprising:

a mediator adapted to provide a transfer of electrons from the agent to produce an electrical current reading correlative with an analyte concentration level.

12. The analyte sensor of claim 1, wherein the substrate is cylindrical.

13. The analyte sensor of claim 1, wherein the substrate is planar.

14. An analyte sensor, comprising:

a substrate including semiconductor material surrounding a conductive core, a first portion of the semiconductor material forming a working electrode;

a second portion of the semiconductor material partially coated with an electrochemically-active layer formed from at least one of a noble metal, carbon nanotubes, and a conductive polymer; and

an active region positioned on the substrate and adapted to be exposed to a fluid environment, the active region including an agent on the electrochemically-active layer adapted to convert an analyte within the fluid environment into a product from which an electrical current may be generated.

15. A method of manufacturing an analyte sensor, comprising:

providing a substrate including semiconductor material surrounding a conductive core, a portion of the semiconductor material forming a working electrode; and

applying an electrochemically-active layer formed from at least one of a noble metal, carbon nanotubes, and a conductive polymer on top of the semiconductor material, the electrochemically-active layer adapted to convert an analyte within a fluid environment into a product from which an electrical current may be generated.

16. The method of claim 15, wherein the semiconductor material has a tensile strength of at least 1000 MPa.

17. A method of using an analyte sensor, comprising:

providing an analyte sensor having a substrate including semiconductor material surrounding a conductive core, a first portion of the semiconductor material forming a working electrode, a second portion of the semiconductor material partially coated with an electrochemically-active layer formed from at least one of a noble metal, carbon nanotubes, and a conductive polymer, and an active region positioned on the substrate and adapted to be exposed to a fluid environment, the active region including an agent on the electrochemically-active layer; and

inserting at least a portion of the analyte sensor into a user'"'"'s body.

18. The method of claim 17 wherein the analyte sensor is at least partially inserted into the user'"'"'s body without the use of a trocar.

19. The method of claim 17 wherein the semiconductor material has a tensile strength of at least 1000 MPa.