Stackable Electrochemical Analyte Sensors, Systems and Methods Including Same

• US 20110073476A1
• Filed: 09/29/2010
• Published: 03/31/2011
• Est. Priority Date: 09/30/2009
• Status: Active Grant

• Current Assignee: Ascensia Diabetes Care Holdings AG (PHC Holdings Corporation)
• Original Assignee: Bayer Healthcare LLC (Bayer AG)
• Inventors: Gofman, Igor, Sams, Robert S.
• Granted Patent: US 8,574,510 B2
• Time in Patent Office: Days
• US Class Current: 204/403.01
• 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; and

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.

2. The analyte sensor of claim 1, further comprising a second member provided proximate the second end and forming a space between the receiving surface and an inner surface of the second member.

3. The analyte sensor of claim 2, wherein the second member further comprises a stacking end and an entry end opposite the stacking end, the stacking end including a concave recess which is received over the second end of the base.

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 further comprising a second 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.

9. The analyte sensor of claim 1, further comprising a second 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 second 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. An analyte sensor dispenser system, comprising:

a dispenser body having a channel extending in the dispenser body;

a plurality of analyte sensors provided in a stacked configuration within the channel, each analyte sensor including at least one conductor;

an advancer coupled to at least one of the plurality of analyte sensors;

a port from which individual analyte sensors of the plurality of analyte sensors are adapted to be incrementally dispensable; and

an electrical contact in the port adapted to provide electrical contact with the at least one conductor.

11. The analyte sensor dispenser system of claim 10, further comprising a first electrical contact and a second electrical contact adapted to contact a first conductor and a second conductor provided on the individual analyte sensor.

12. The analyte sensor dispenser system of claim 10, wherein the advancer further comprises a pusher adapted to contact an end analyte sensor of the plurality of analyte sensors.

13. The analyte sensor dispenser system of claim 12, wherein the advancer further comprises a ratchet arm coupled to a reel and adapted to advance the pusher within the channel.

14. The analyte sensor dispenser system of claim 13, wherein the ratchet arm is coupled to the pusher by a cable.

15. The analyte sensor dispenser system of claim 10, wherein the plurality of analyte sensors provided in a stacked configuration within the channel are included within a cartridge assembly.

16. 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; and

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.

17. The method of claim 16 further comprising providing a second member over the second end of the base.

18. The method of claim 16 further comprising forming a second electrode proximate to the active region.

19. The method of claim 18 further comprising providing a second conductor in electrical contact with the second electrode and extending along an outer surface of a second member, the second conductor including a contact portion adapted to be in electrical contact with a second electrical contact of the analyte meter.