Method for polymerizing a monomer solution within a cavity to generate a smooth polymer surface
View Patent ↗In preferred embodiments, the present invention relates to methods for polymerizing a monomer solution within a cavity covered by a porous membrane to generate a smooth polymer surface. More specifically, the method can be used to provide a medical device or sensor with a smooth polymer surface.
1. A method for making an analyte sensor having a smooth outer surface, comprising:
providing an optical fiber comprising a cavity covered by a membrane having pores;
loading the cavity and the membrane pores with a solution comprising polymerizable monomers, an analyte indicator system and a polymerization initiator; and
initiating polymerization of said monomers;
wherein prior to initiating polymerization, the loaded cavity and membrane pores are coated with wax and the solution is deoxygenated.
2. The method of claim 1 , wherein the wax coating is removed after polymerization is completed to leave a smooth outer surface, wherein the analyte indicator system is immobilized within the cavity.
3. The method of claim 2 , wherein removing the wax comprises contacting the wax with an organic solvent.
4. The method of claim 3 , wherein the organic solvent is an alkane.
5. The method of claim 4 , wherein the alkane is hexane.
6. The method of claim 2 , wherein removing the wax further comprises application of ultrasonic energy.
7. The method of claim 1 , wherein the indicator system comprises a fluorophore and an analyte binding moiety.
8. The method of claim 1 , wherein the loading step comprises vacuum filling.
9. The method of claim 1 , wherein initiating polymerization comprises application of a second initiator selected to undergo a redox reaction with the polymerization initiator.
10. The method of claim 1 , wherein initiating polymerization comprises application of thermal or radiation energy.