Method and system for sterilizing an analyte sensor

1. A method of sterilizing a glucose sensor assembly, the method comprising:

assembling a glucose sensor with a sensor mounting unit and a sensor delivery unit, where the glucose sensor comprises at least one electrode, an enzyme area, and a glucose diffusion limiting area, the sensor delivery unit comprises a housing and a metal sharp, and the sensor mounting unit comprises an adhesive;

irradiating the assembly with a predetermined dose level and/or for a predetermined time period to sterilize the assembly;

packaging the assembly in a first container;

packaging the first container in a second container that includes a predetermined number of packaged assemblies; and

irradiating the second container including packaged assemblies at a predetermined dose using one or more electron beam accelerators.

2. The method of claim 1 , comprising positioning the assembly in a container and sealing the assembly in the container with a cover.

3. The method of claim 2 wherein the container includes thermoformed plastic.

4. The method of claim 2 wherein the cover includes aluminum.

5. The method of claim 2 wherein the cover and the container form the seal with an adhesive material disposed therebetween.

6. The method of claim 1 wherein the assembly is irradiated at a surface dosage of between approximately 25 kGy and 60 kGy.

7. The method of claim 1 wherein the irradiation of the packaged assembled analyte sensor and sensor insertion device results in about 10 −6 sterility assurance level.

8. The method of claim 1 wherein the assembly is sterilized to maintain a predetermined sterility level for at least about six months.

9. The method of claim 1 wherein the assembly is sterilized to maintain a predetermined sterility level for at least about 18 months.

10. The method of claim 1 wherein the enzyme area comprises a mediator.

11. The method of claim 10 , wherein the enzyme area comprises a redox polymer.

12. The method of claim 11 wherein the redox polymer comprises an osmium-containing polymer.

13. The method of claim 1 wherein the glucose diffusion limiting area comprises a polymer.

14. The method of claim 1 wherein the sensor comprises a substantially planar substrate on which the at least one electrode is positioned.

15. A method of sensor delivery assembly sterilization, comprising:

assembling an analyte sensor with an analyte sensor insertion device;

packaging the assembled analyte sensor and sensor insertion device in a first container;

packaging the first container in a second container that includes a predetermined number of packaged assembled analyte sensors and sensor insertion devices; and

irradiating the second container including packaged assembled analyte sensor and sensor insertion device at a predetermined dose using one or more electron beam accelerators.

16. The method of claim 15 , wherein the predetermined dose is approximately 30 kGy.

17. The method of claim 15 , wherein the packaged assembled analyte sensor and sensor insertion device are irradiated at a surface dosage of between approximately 25 kGy and 60 kGy.

18. The method of claim 15 , wherein the irradiation of the packaged assembled analyte sensor and sensor insertion device produces about 10 −6 sterility assurance level.

19. The method of claim 15 , wherein the packaged assembled analyte sensor and sensor insertion device are irradiated from two opposing sides using at least two electron beam accelerators.

20. The method of claim 19 , wherein a respective time period associated with the irradiation of the packaged assembled analyte sensor and sensor insertion device from each of the at least two electron beam accelerators are substantially non-overlapping.

21. The method of claim 19 , wherein the irradiation of the packaged assembled analyte sensor and sensor insertion device produces about 10 −6 sterility assurance level.

22. The method of claim 15 , wherein the packaged assembled analyte sensor and sensor insertion device is sterilized with one electron beam accelerator.

23. The method of claim 22 including rotating the packaged assembled analyte sensor and sensor insertion device during irradiation to expose the maximum surface of the packaged assembled analyte sensor and sensor insertion device substantially perpendicular to the electron beam irradiation.

24. The method of claim 22 , wherein the irradiation of the packaged assembled analyte sensor and sensor insertion device produces about 10 −6 sterility assurance level.

25. The method of claim 15 , including providing an indication of sterilization status on the irradiated packaged assembled analyte sensor and sensor insertion device.

26. The method of claim 15 , wherein assembling the analyte sensor with the analyte sensor insertion device includes coupling the analyte sensor to the analyte sensor insertion device.

27. The method of claim 26 wherein coupling includes decoupleably coupling the analyte sensor to a predetermined portion of the analyte sensor insertion device.

28. A method, comprising:

packaging an assembled analyte sensor and sensor insertion device in a first container:

exposing the first container including the analyte sensor and the sensor insertion device to electron beam irradiation to result in approximately 10 −6 sterility assurance level;

packaging the first container in a second container that includes a predetermined number of packaged assembled analyte sensors and sensor insertion devices; and

irradiating the second container including the predetermined number of packaged assembled analyte sensors and sensor insertion devices at a predetermined dose using one or more electron beam accelerators.