Transcutaneous analyte sensor

Abstract

The present invention relates generally to systems and methods for measuring an analyte in a host. More particularly, the present invention relates to systems and methods for transcutaneous measurement of glucose in a host.

1 . A method for manufacturing a transcutaneous analyte sensor, the method comprising the steps of: 
 coating a first wire with a substantially non-conductive material;    twisting the first wire and a second wire into a helical configuration; and    depositing a membrane system onto the twisted first wire and second wire.    
     
     
         2 . The method of  claim 1 , wherein the step of twisting comprises twisting the first wire and second wire onto a coil.  
     
     
         3 . The method of  claim 1 , wherein the step of twisting the first wire and second wire further comprises forming a plurality of distinct helical portions.  
     
     
         4 . The method of  claim 3 , wherein the step forming a plurality of distinct helical portions further comprises forming indexing therebetween.  
     
     
         5 . The method of  claim 4 , wherein the indexing has a substantially non-twisted configuration.  
     
     
         6 . The method of  claim 1 , wherein the step of depositing comprises serially depositing a plurality of membrane layers.  
     
     
         7 . The method of  claim 6 , wherein the plurality of membrane layers are deposited on a continuous coil of the twisted first wire and second wire.  
     
     
         8 . The method of  claim 7 , further comprising cutting a plurality of sensors from the continuous coil.  
     
     
         9 . The method of  claim 1 , further comprising drying the membrane system.  
     
     
         10 . The method of  claim 1 , wherein the sensor is at least partially manufactured using a continuous reel-to-reel process.  
     
     
         11 . The method of  claim 1 , wherein the sensor is wholly manufactured using a continuous reel-to-reel process.  
     
     
         12 . The method of  claim 1 , wherein at least one step is automated.  
     
     
         13 . The method of  claim 1 , wherein the steps are conducted substantially without manual mounting and fixturing steps.  
     
     
         14 . The method of  claim 1 , wherein the steps are conducted substantially without human interaction.  
     
     
         15 . The method of  claim 1 , wherein the step of depositing a membrane system comprises depositing an electrode domain configured to provide hydrophilicity at at least one exposed electrochemically reactive surface.  
     
     
         16 . The method of  claim 1 , wherein the step of depositing a membrane system comprises depositing an interference domain configured to restrict flow of at least one interferant therethrough.  
     
     
         17 . The method of  claim 1 , wherein the step of depositing a membrane system comprises depositing an enzyme domain comprising an enzyme and configured to catalyze a reaction of the analyte and a co-reactant.  
     
     
         18 . The method of  claim 1 , wherein the step of depositing a membrane system comprises depositing a resistance domain configured to control flux of the analyte therethrough.  
     
     
         19 . The method of  claim 1 , further comprising the step of exposing an electroactive portion of the first electrode.  
     
     
         20 . The method of  claim 1 , further comprising the step of coating the twisted first wire and second wire with a non-conductive material.