Analyte sensors and methods for fabricating analyte sensors

Abstract

Analyte sensors and methods for fabricating analyte sensors are provided. In an exemplary embodiment, a planar flexible analyte sensor includes a flexible base layer and a first electrode formed from a layer of sputtered platinum on the base layer. Also, the analyte sensor includes an insulating dielectric layer over the base layer, wherein the insulating dielectric layer leaves a portion of the first electrode exposed. Further, the analyte sensor includes an electrochemical sensing stack over the exposed portion of the first electrode, including a glucose oxidase layer over the layer of sputtered platinum and a glucose limiting membrane over the glucose oxidase layer.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)[0001]This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62 / 504,670 filed May 11, 2017, the entire content of which is incorporated by reference herein.TECHNICAL FIELD[0002]Embodiments of the subject matter described herein relate generally to sensors for monitoring analyte levels in patients and to methods for fabricated such sensors. More particularly, embodiments of the subject matter relate to glucose sensors, such as for monitoring blood glucose level continuously, or substantially continuously.BACKGROUND[0003]The pancreas of a normal healthy person produces and releases insulin into the blood stream in response to elevated blood plasma glucose levels. Beta cells (β-cells), which reside in the pancreas, produce and secrete insulin into the blood stream as it is needed. If β-cells become incapacitated or die, a condition known as Type 1 diabetes mellitus (or in some cases, if β-cells produce insufficient q...

AI Technical Summary

Benefits of technology

The patent describes a method for making flexible analyte sensors by depositing a layer of platinum onto a polyester substrate, adding an insulating dielectric layer, and printing with a glucose limiting membrane. The sensors can be made using a roll-to-roll process, which allows for continuous production. The technical effects of this invention include the ability to make flexible analyte sensors with improved accuracy and precision, as well as the ability to produce them in large quantities.

Problems solved by technology

These systems rely on lancing and manipulation of the fingers or alternate blood draw sites, which can be extremely painful and inconvenient, particularly for children.

These sensors are painful during insertion and usually require the assistance of a health care professional.

Subcutaneously implanted sensors may lead to infection and immune response complications.

Another major drawback of currently available continuous monitoring devices is that they require frequent, often daily, calibration using blood glucose results that must be obtained from painful finger-sticks using traditional meters and test strips.

This calibration, and re-calibration, is required to maintain sensor accuracy and sensitivity, but it can be cumbersome as well as painful.

Conventional batch processing is not amenable to high volume production or to significant cost reductions.

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