Flexible Electrochemical Sensor Design for Continuous Analyte Meters

The patent transitions from planar 2D electrode arrangement to a 3D立体 structure by folding the sensor into multiple layers. This allows the electrode area to extend in the vertical dimension while maintaining a small footprint on the skin, effectively increasing the electrode area without increasing the sensor's planar dimensions. The folded configuration enables multiple electrodes to be stacked vertically, providing sufficient reaction area for accurate analyte measurement while keeping the sensor thin and flexible for comfortable wear.

The patent implements a nested structure where multiple electrode layers are stacked inside each other like dolls. The first electrode layer contains working, reference, and counter electrodes, while subsequent layers contain additional electrodes that are electrically connected through conductive vias. This nested arrangement maximizes the electrode area within a compact volume, ensuring sufficient electrochemical reaction area while maintaining a small sensor size that reduces insertion pain and wear discomfort.

The patent utilizes the vertical dimension by folding the sensor into multiple layers, allowing electrodes to be arranged in three dimensions rather than confined to a single plane. This enables the electrode area to be increased without expanding the sensor's planar width or length, thus avoiding increased insertion pain and wear discomfort. The multi-layer configuration packs more electrode material into the same footprint by exploiting the Z-axis dimension.

The patent employs flexible thin film substrates that can be folded and bent into compact multi-layer configurations. These flexible films allow the sensor to maintain a small planar size while providing sufficient electrode area through vertical stacking. The flexibility enables the thin film structure to conform to the skin surface and be inserted with minimal discomfort, while the stacked layers ensure adequate electrochemical reaction area for accurate measurement.

The patent divides the sensor into multiple thin layers, each performing a specific function. The electrode structure is segmented into separate working, reference, and counter electrode layers, with insulating layers and conductive vias distributed throughout. This segmentation allows each layer to be manufactured with standard precision techniques, and the overall thin profile is achieved by stacking these precisely manufactured thin layers. The modular layered structure makes the manufacturing process more manageable despite the reduced overall thickness.

The patent changes the physical and chemical parameters of the materials used in each layer to optimize both thinness and manufacturability. Conductive materials with high conductivity are used in thin film form, insulating materials with appropriate dielectric properties are selected, and the thickness of each layer is precisely controlled within specific ranges. These parameter optimizations enable the formation of functional electrodes and insulation structures even at reduced thickness, maintaining manufacturing precision while achieving a thin sensor profile.