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 E1, E2, 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 E1, E2, 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 E1, E2.

What is claimed is: 
     
         1 . 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.   
     
     
         2 . The continuous analyte sensor of  claim 1 , wherein the membrane comprises a polymer having a Shore hardness of from about 70A to about 55 C. 
     
     
         3 . The continuous analyte sensor of  claim 1 , 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. 
     
     
         4 . The continuous analyte sensor of  claim 1 , which is configured for multi-axis bending. 
     
     
         5 . The continuous analyte sensor of  claim 4 , wherein the multi-axis bending is associated with flexing in at least three directions. 
     
     
         6 . The continuous analyte sensor of  claim 2 , 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.