Rolled electrode array and its method for manufacture

• US 20050051427A1
• Filed: 07/21/2004
• Published: 03/10/2005
• Est. Priority Date: 07/23/2003
• Status: Abandoned Application

• Current Assignee: DexCom Incorporated
• Original Assignee: DexCom Incorporated
• Inventors: Brauker, James H., Simpson, Peter C., Neale, Paul V.
• Time in patent office: 0 Days
• US Class Current: 204/412
• CPC Class Codes: A61B 2562/125 characterised by the manufacture of electrodes
• CPC Class Codes: A61B 5/0031 Implanted circuitry
• CPC Class Codes: A61B 5/076 Permanent implantations telemetry using implanted circuitry A61B5/0031; implanted stimulators for therapy A61N1/3605, A61N1/362, A61N1/372
• CPC Class Codes: A61B 5/1486 using enzyme electrodes, e.g. with immobilised oxidase
• 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: 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

Abstract

An electrode array for use in an electrochemical device is provided. The electrode array includes at least one electrode material and at least one insulating material arranged in a spiral configuration. The electrode array is manufactured by forming a composite stack of the at least one electrode material and the at least one insulating material, such that the insulating material(s) surrounds the electrode material(s) after which the stack is rolled into a spiral roll. The spiral roll can be cut, sliced, and/or dissected in numerous ways to form the electrode array of the preferred embodiments. Optionally, the sections can be further processed by machining, polishing, etching, or the like, to produce a curvature or stepped configuration.

Claims

1. An electrode array for use in an electrochemical device, the electrode array comprising:

a first electrode material; and

an insulating material, wherein the first electrode material and the insulating material are arranged in a spiral configuration.

2. The electrode array of claim 1, wherein a working electrode is formed from the first electrode material, and wherein the first electrode material comprises a material selected from the group consisting of glassy carbon, gold, platinum, palladium, nickel, silver, copper, lead, zinc, silver/carbon, and combinations thereof.

3. The electrode array of claim 1, wherein the first electrode material comprises a sheet.

4. The electrode array of claim 1, wherein the first electrode material comprises a mesh.

5. The electrode array of claim 1, wherein the first electrode material comprises a film.

6. The electrode array of claim 1, wherein the first electrode material comprises a wire.

7. The electrode array of claim 1, further comprising a second electrode material.

8. The electrode array of claim 7, further comprising a counter electrode formed from the second electrode material, wherein the first electrode material, the insulating material, and the second electrode material are arranged in a spiral configuration, and wherein the second electrode material is selected from the group consisting of glassy carbon, gold, platinum, palladium, nickel, silver, copper, lead, zinc, silver/carbon, and combinations thereof.

9. The electrode array of claim 7, wherein the second electrode material comprises a sheet.

10. The electrode array of claim 7, wherein the second electrode material comprises a mesh.

11. The electrode array of claim 7, wherein the second electrode material comprises a film.

12. The electrode array of claim 7, wherein the second electrode material comprises a wire.

13. The electrode array of claim 1, further comprising a reference electrode.

14. The electrode array of claim 13, wherein the first electrode material, the insulating material, and the third electrode material are arranged in a spiral configuration.

15. The electrode array of claim 13, wherein the third electrode material comprises a sheet.

16. The electrode array of claim 13, wherein the third electrode material comprises a mesh.

17. The electrode array of claim 13, wherein the third electrode material comprises a film.

18. The electrode array of claim 13, wherein the third electrode material comprises a wire.

19. The electrode array of claim 13, wherein the reference electrode is located at a center of the spiral configuration.

20. The electrode array of claim 1, further comprising a second electrode material and a third electrode material, wherein the first electrode material comprises a working electrode, wherein the second electrode material comprises a counter electrode, and wherein the third electrode material comprises a reference electrode.

21. The electrode array of claim 1 further comprising a second electrode material and a third electrode material, wherein the first electrode material comprises a first working electrode, wherein the second electrode material comprises a second working electrode, and wherein the third electrode material comprises a reference electrode.

22. The electrode array of claim 21, further comprising a reference electrode.

23. The electrode array of claim 1, further comprising a second electrode material and a third electrode material, wherein the first electrode material comprises a first working electrode, wherein the second electrode material comprises a second working electrode, and wherein the third electrode material comprises a counter electrode.

24. The electrode array of claim 1, wherein the insulating material comprises a silicone or a hydrogel.

25. The electrode array of claim 1, wherein the insulating material comprises a high oxygen soluble polymer.

26. The electrode array of claim 1, wherein the insulating material is selected from the group consisting of polyimide, polyester, polyurethane, perfluorinated polymer, polycarbonate, polyvinyl chloride, high-density polypropylene, low-density polypropylene, Parylene, epoxy, hydrogels, silicone, and mixtures thereof.

27. The electrode array of claim 1, wherein the insulating material comprises a thickness of from about 1 micron to about 1000 microns.

28. The electrode array of claim 1, wherein the insulating material comprises a thickness of from about 1 micron to about 100 microns.

29. The electrode array of claim 1, wherein the electrode array comprises a substantially planar surface.

30. The electrode array of claim 1, wherein the electrode array comprises a substantially curved surface.

31. The electrode array of claim 1, wherein the electrode array comprises a stepped surface.

32. The electrode array of claim 31, further comprising a polymer material formed atop at least one stepped surface.

33. The electrode array of claim 1, wherein the electrode array is flexible.

77. A biosensor comprising the electrode array according to claim 1.

34. A method for manufacturing an electrode array for use in an electrochemical device, the method comprising:

forming a composite stack comprising an electrode material and an insulating material, wherein the insulating material is situated adjacent to the electrode material;

rolling the composite stack into a spiral roll; and

cutting away a portion of the spiral roll to form an electrode array.

35. The method of claim 34, wherein the composite stack is formed by adhering the electrode material to the insulating material.

36. The method of claim 34, wherein the electrode material is deposited on the insulating material by a method selected from the group consisting of thick film printing, vapor deposition, screen deposition, spray coating, roller coating, vacuum deposition, thin film deposition, sputtering, evaporation, spin coating, and combinations thereof.

37. The method of claim 34, wherein the electrode material comprises a working electrode, and wherein the electrode material is selected from the group consisting of glassy carbon, gold, platinum, palladium, nickel, silver, copper, lead, zinc, silver/carbon, and mixtures thereof.

38. The method of claim 34, wherein the electrode material comprises a sheet.

39. The method of claim 34, wherein the electrode material comprises a mesh.

40. The method of claim 34, wherein the electrode material comprises a film.

41. The method of claim 34, wherein the electrode material comprises a wire.

42. The method of claim 34, wherein the electrode material comprises a first electrode material and a second electrode material, wherein the second electrode material comprises a reference electrode material.

43. The method of claim 42, wherein the reference electrode material comprises a sheet.

44. The method of claim 42, wherein the reference electrode material comprises a mesh.

45. The method of claim 42, wherein the reference electrode material comprises a film.

46. The method of claim 42, wherein the reference electrode material comprises a wire.

47. The method of claim 34, wherein the insulating material comprises a polymer in which oxygen is soluble.

48. The method of claim 47, wherein the insulating material comprises a silicone or a hydrogel.

49. The method of claim 34, wherein the insulating material is selected from the group consisting of polyimide, polyester, polyurethane, perfluorinated polymer, polycarbonate, polyvinyl chloride, high-density polypropylene, low-density polypropylene, Parylene, epoxy, hydrogels, silicone, and mixtures thereof.

50. The method of claim 34, wherein the electrode material comprises one or more wires, and wherein the composite stack is formed by molding or flattening the wires into the insulating material, thereby forming an integrated layer.

51. The method of claim 34, wherein the electrode material comprises a first electrode material and a second electrode material, and wherein a thickness of the first electrode material is at least twice a thickness of the second electrode material.

52. The method of claim 34, wherein the insulating material comprises a thickness of from about 1 micron to about 1000 microns.

53. The method of claim 34, wherein the insulating material comprises a thickness of from about 1 micron to about 100 microns.

54. The of claim 34, wherein the composite stack comprises a first electrode material, a second electrode material, and a third electrode material;

wherein the first electrode material comprises a first working electrode, wherein the second electrode material comprises a second working electrode, and wherein the third electrode material comprises a reference electrode.

55. The method of claim 34, wherein the composite stack comprises a first electrode material, and wherein the first electrode material comprises a working electrode.

56. The method of claim 55, further comprising:

providing a reference electrode.

57. The method for manufacturing the electrode array of claim 55, wherein the composite stack further comprises a second electrode material, wherein the second electrode material comprises a counter electrode.

58. The method of claim 57, further comprising:

providing a reference electrode.

59. The method of claim 57, wherein the composite stack further comprises a third electrode material, wherein the third electrode material comprises a reference electrode.

60. The method of claim 34, wherein the composite stack comprises a first electrode material comprising a first working electrode, a second electrode material comprising a second working electrode, and a third electrode material comprising a counter electrode.

61. The method of claim 60, further comprising:

providing a reference electrode.

62. The method of claim 34, wherein the step of rolling the composite stack comprises selectively rolling the electrode material and the insulating material on a rolling mandrel.

63. The method of claim 34, wherein the step of cutting away is selected from the group consisting of cutting away with a knife, cutting away with a water jet, cutting away with a laser, cutting away with a plasma arc, and cutting away with an oxyfuel.

64. The method of claim 34, wherein the composite stack comprises an elastomeric material, the method further comprising:

freezing the spiral roll, whereby the elastomeric material is hardened, wherein the step of freezing is conducted before the step of cutting away.

65. The method of claim 64, wherein the step of cutting away is selected from the group consisting of cutting away with a knife, cutting away with a water jet, cutting away with a laser, cutting away with a plasma arc, and cutting away with an oxyfuel.

66. The method of claim 34, wherein the step of cutting away a portion of the spiral roll comprises cutting along a plane perpendicular to a longitudinal axis of the spiral roll.

67. The method of claim 34, wherein the step of cutting away a portion of the spiral roll comprises cutting along a plane that is at an angle of less than 90 degrees to a longitudinal axis of the spiral roll.

68. The method of claim 34, wherein the step of cutting away a portion of the spiral roll comprises cutting along a longitudinal axis of the spiral roll.

69. The method of claim 34, wherein the step of cutting away a portion of the spiral roll comprises cutting fully across a diameter of the spiral roll.

70. The method of claim 34, wherein the step of cutting away a portion of the spiral roll comprises cutting partially across a diameter of the spiral roll.

71. The method of claim 34, further comprising the step of

post-processing the electrode array by subjecting at least one surface of the electrode array to machining, polishing, or shaping.

72. The method of claim 71, wherein the post-processing produces a non-planar surface on the electrode array.

73. The method of claim 34, further comprising the step of

post-processing the electrode array by etching away a portion of the electrode material, whereby an etched away portion is obtained.

74. The method of claim 73, further comprising the step of

filling the etched away portion with a polymer.

75. An electrode array manufactured according to the method of claim 34.

76. A biosensor comprising an electrode array manufactured according to the method of claim 34.