Method for polymerizing a monomer solution within a cavity to generate a smooth polymer surface

Abstract

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.   
     
     
         2 . The method of  claim 1 , wherein prior to initiating polymerization, the loaded cavity and membrane pores are coated with wax and the solution is deoxygenated. 
     
     
         3 . The method of  claim 2 , 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. 
     
     
         4 . The method of  claim 3 , wherein removing the wax comprises contacting the wax with an organic solvent. 
     
     
         5 . The method of  claim 4 , wherein the organic solvent is an alkane. 
     
     
         6 . The method of  claim 5 , wherein the alkane is hexane. 
     
     
         7 . The methods of  claim 3 , wherein removing the wax further comprises application of ultrasonic energy. 
     
     
         8 . The method of  claim 1 , wherein the indicator system comprises a fluorophore and an analyte binding moiety. 
     
     
         9 . The method of  claim 1 , wherein the loading step comprises vacuum filling. 
     
     
         10 . The method of  claim 1 , wherein initiating polymerization comprises application of a second initiator selected to undergo a redox reaction with the first initiator. 
     
     
         11 . The method of  claim 1 , wherein initiating polymerization comprises application of thermal or radiation energy.