Analyte sensors and methods of manufacturing same
Analyte sensors and methods of manufacturing same are provided, including analyte sensors comprising multi-axis flexibility. For example, a multi-electrode sensor system 800 comprising two working electrodes and at least one reference/counter electrode is provided. The sensor system 800 comprises first and second elongated bodies E 1 , E 2 , each formed of a conductive core or of a core with a conductive layer deposited thereon, insulating layer 810 that separates the conductive layer 820 from the elongated body, a membrane layer deposited on top of the elongated bodies E 1 , E 2 , and working electrodes 802′, 802 ″ formed by removing portions of the conductive layer 820 and the insulating layer 810 , thereby exposing electroactive surface of the elongated bodies E 1 , E 2.
1. A continuous analyte sensor, the continuous analyte sensor comprising:
an elongated core comprising a working electrode, wherein the elongated core comprises an inner core and an outer core covering the inner core, wherein the inner core comprises a first material, wherein the outer core comprises a second material selected from the group consisting of: platinum, platinum iridium, gold, palladium, iridium, alloys thereof, graphite, carbon, and a conductive polymer, wherein the first material is different from the second material;
an insulating layer covering at least a portion of the elongated core;
a conductive layer comprising a reference electrode or a counter electrode, wherein the conductive layer covers at least a portion of the insulating layer; and
a membrane covering at least a portion of the working electrode;
wherein the sensor has a Young's modulus of from about 180 GPa to about 220 GPa.
2. The continuous analyte sensor of claim 1 , wherein the membrane comprises a polymer having a Shore hardness of from about 70 A to about 55 D.
3. A continuous analyte sensor, the continuous analyte sensor comprising:
an elongated core comprising a working electrode, wherein the elongated core comprises an inner core and an outer core covering the inner core, wherein the inner core comprises a first material, wherein the outer core comprises a second material selected from the group consisting of: platinum, platinum iridium, gold, palladium, iridium, alloys thereof, graphite, carbon, and a conductive polymer, wherein the first material is different from the second material;
an insulating layer covering at least a portion of the elongated core;
a conductive layer comprising a reference electrode or a counter electrode, wherein the conductive layer covers at least a portion of the insulating layer; and
a membrane covering at least a portion of the working electrode;
wherein the sensor has an ultimate tensile strength of from about 120 kPsi to about 500 kPsi.
4. The continuous analyte sensor of claim 3 , having an ultimate tensile strength of from about 150 kPsi to about 280 kPsi.
5. The continuous analyte sensor of claim 1 , having a yield strength of at least 60 kPsi.
6. A continuous analyte sensor, the continuous analyte sensor comprising:
an elongated core comprising a working electrode, wherein the elongated core comprises an inner core and an outer core covering the inner core, wherein the inner core comprises a first material, wherein the outer core comprises a second material selected from the group consisting of: platinum, platinum iridium, gold, palladium, iridium, alloys thereof, graphite, carbon, and a conductive polymer, wherein the first material is different from the second material;
an insulating layer covering at least a portion of the elongated core;
a conductive layer comprising a reference electrode or a counter electrode, wherein the conductive layer covers at least a portion of the insulating layer; and
a membrane covering at least a portion of the working electrode;
wherein the sensor is configured to have a fatigue life of at least 1,000 cycles of flexing of from about 28° to about 110° at a bend radius of about 0.125-inches.
7. The continuous analyte sensor of claim 1 , which is configured for multi-axis bending.
8. The continuous analyte sensor of claim 7 , wherein the multi-axis bending is associated with flexing in at least three directions.
9. The continuous analyte sensor of claim 1 , wherein the conductive layer comprises a silver-containing material.
10. The continuous analyte sensor of claim 9 , wherein the silver-containing material has a particle size associated with a maximum particle dimension that is less than about 100 microns.
11. The continuous analyte sensor of claim 9 , wherein the silver-containing material has a particle shape that is substantially spherical.
12. The continuous analyte sensor of claim 1 , having a cross-sectional radius of from about 5 microns to about 200 microns.
13. A continuous analyte sensor, the continuous analyte sensor comprising:
an elongated core comprising a working electrode, wherein the elongated core comprises an inner core and an outer core covering the inner core, wherein the inner core comprises a first material, wherein the outer core comprises a second material selected from the group consisting of: platinum, platinum iridium, gold, palladium, iridium, alloys thereof, graphite, carbon, and a conductive polymer, wherein the first material is different from the second material;
an insulating layer covering at least a portion of the elongated core;
a conductive layer comprising a reference electrode or a counter electrode, wherein the conductive layer covers at least a portion of the insulating layer; and
a membrane covering at least a portion of the working electrode;
wherein the sensor is configured to have a fatigue life of at least 20 cycles of flexing of from about 45° to about −45° at a bend radius of about 0.031-inches.
14. The continuous analyte sensor of claim 13 , having a fatigue life of at least 40 cycles of flexing of from about 45° to about −45° at a bend radius of about 0.031-inches.
15. The continuous analyte sensor of claim 14 , having a fatigue life of at least 50 cycles of flexing of from about 45° to about −45° at a bend radius of about 0.031-inches.
16. The continuous analyte sensor of claim 15 , having a fatigue life of at least 60 cycles of flexing of from about 45° to about −45° at a bend radius of about 0.031-inches.
17. The continuous analyte sensor of claim 16 , having a fatigue life of at least 65 cycles of flexing of from about 45° to about −45° at a bend radius of about 0.031-inches.
18. The continuous analyte sensor of claim 1 , wherein the working electrode comprises platinum or a platinum alloy.
19. The continuous analyte sensor of claim 1 , wherein the working electrode comprises stainless steel.
20. The continuous analyte sensor of claim 1 , wherein the working electrode comprises palladium.
21. The continuous analyte sensor of claim 1 , wherein the working electrode comprises tantalum.
22. The continuous analyte sensor of claim 3 , wherein the working electrode comprises platinum or a platinum alloy.
23. The continuous analyte sensor of claim 3 , wherein the working electrode comprises stainless steel.
24. The continuous analyte sensor of claim 3 , wherein the working electrode comprises palladium.
25. The continuous analyte sensor of claim 3 , wherein the working electrode comprises tantalum.
26. The continuous analyte sensor of claim 6 , wherein the working electrode comprises platinum or a platinum alloy.
27. The continuous analyte sensor of claim 6 , wherein the working electrode comprises stainless steel.
28. The continuous analyte sensor of claim 6 , wherein the working electrode comprises palladium.
29. The continuous analyte sensor of claim 6 , wherein the working electrode comprises tantalum.
30. The continuous analyte sensor of claim 13 , wherein the working electrode comprises platinum or a platinum alloy.
31. The continuous analyte sensor of claim 13 , wherein the working electrode comprises stainless steel.
32. The continuous analyte sensor of claim 13 , wherein the working electrode comprises palladium.
33. The continuous analyte sensor of claim 13 , wherein the working electrode comprises tantalum.