Method of manufacturing implantable wireless sensor for in vivo pressure measurement

1. A method of manufacturing a sensor for in vivo applications, comprising the steps of:

providing first and second wafers of an electrically insulating material;

forming a recess in said first wafer;

forming a first capacitor plate in said recess of said first wafer;

forming a second capacitor plate in a corresponding region of said second wafer;

mutually imposing said first and second wafers such that said first and second capacitor plates are arranged in parallel, spaced-apart relation; and

affixing said first and second wafers to one another in said mutually imposed position by laser-cutting said mutually imposed wafers to reduce the sensor to its final size and to hermetically fuse the two wafers together.

2. The method of claim 1 , comprising the further step of:

providing an inductor coil having first and second leads;

electrically coupling said first lead of said inductor coil to said first capacitor plate; and

electrically coupling said second lead of said inductor coil to said second capacitor plate.

3. The method of claim 2 , wherein said inductor coil is immobilized with respect to said capacitor plates and changes in coil configuration.

4. method of claim 3 , where the method for coil immobilization comprises using wire of sufficient strength so the coil does not shift position relative to the capacitor plates.

5. The method of claim 3 , where the method for coil immobilization comprises using a coil formed on a bobbin.

6. The method of claim 5 , where the bobbin is comprised of a thermoplastic material and heated to encapsulate and/or adhere to the surface of the coil receiving trench.

7. The method of claim 5 , where the bobbin is press fit to at least one surface of the coil receiving trench.

8. The method of claim 3 , where the method for coil immobilization comprises use of a thermosetting or thermoplastic material applied to a pre-formed coil to impart additional stability to said coil.

9. The method of claim 8 , where a thermosetting polymer is applied to at least one space between the coil and the coil receiving trench in liquid form and cured.

10. The method of claim 8 , where at least one thermoplastic preform is inserted and heated to fill the gap between at least one space between the coil and the coil receiving trench.

11. The method of claim 1 , further comprising the step of reducing the thickness of one of said wafers underlying at least a portion of a corresponding one of said capacitor plates, whereby said reduced thickness portion is more deflectable in response to changes in ambient pressure than the unreduced thickness of said one of said wafers.

12. The method of claim 1 , comprising the further step of forming a recess in said corresponding region of said second wafer, and wherein said step of forming a second capacitor plate in a corresponding region of said second wafer comprises the step of forming a second capacitor plate in said recess of said second wafer.

13. The method of claim 1 , wherein said step of providing first and second wafers of an electrically insulating material comprises the step of providing first and second wafers of a material selected from the group consisting of fused silica, quartz, Pyrex, and sintered zirconia.

14. The method of claim 1 , wherein said step of laser-cutting said mutually imposed wafers comprises the step of controlling a laser to deliver a power sufficiently large to cut and fuse the wafers together, while at the same time being sufficiently small that the internal components of the sensor are not damaged by excessive heat.

15. The method of claim 14 , wherein said step of controlling said laser to deliver a power sufficiently large to cut and fuse the wafers together, while at the same time being sufficiently small that the internal components of the sensor are not damaged by excessive heat, comprises the step of controlling said laser to have a peak wavelength of approximately 10 micrometers when the wafers are comprised of fused silica.

16. The method of claim 1 , wherein said step of forming a first capacitor plate in said recess of said first wafer comprises the step of electroplating.

17. The method of claim 16 , comprising the further step, subsequent to said step of electroplating, of polishing said plate using chemical/mechanical polishing to effect at least one of planarizing and reducing the height of said plate.

18. The method of claim 16 , comprising the further step, subsequent to said step of electroplating, of chemically etching said plate by a selective etchant to reduce the height of said plate.

19. The method of claim 1 , wherein said step of forming a first capacitor plate in said recess of said first wafer comprises the step of using physical vapor deposition to deposit a layer of metal.

20. The method of claim 19 , comprising the further steps, subsequent to said step of using physical vapor deposition, of:

applying photoresist over at least a portion of said layer of metal;

using a mask to pattern said photoresist; and

selectively etching exposed portions of said photoresist to define a desired pattern.

21. The method of claim 1 , wherein said capacitor plates are spaced apart by a distance of from 0.1 to 10 micrometers.

22. The method of claim 1 , wherein said capacitor plates are spaced apart by a distance of from 0.1 to 2 micrometers.