Analyte sensors and methods of manufacturing same

Abstract

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 - 20 . (canceled) 
     
     
         21 . A continuous analyte sensor configured for in vivo use, the continuous analyte sensor comprising:
 an elongated conductive body comprising:
 a substrate comprising a non-conductive polymeric material, wherein the substrate has a non-rectangular cross section; 
 a first electrode disposed on the substrate, wherein the first electrode is a working electrode; 
 a second electrode disposed on the substrate; and 
 a conductive pathway connecting the first electrode and the second electrode to sensor electronics; and 
   a membrane covering at least a portion of the working electrode.   
     
     
         22 . The continuous analyte sensor of  claim 21 , wherein the membrane comprises a polymer having a Shore hardness of from about 70A to about 55C. 
     
     
         23 . The continuous analyte sensor of  claim 21 , having 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. 
     
     
         24 . The continuous analyte sensor of  claim 21 , which is configured for multi-axis bending. 
     
     
         25 . The continuous analyte sensor of  claim 24 , wherein the multi-axis bending is associated with flexing in at least three directions.