Continuous analyte sensors and methods of making same

Abstract

Described here are embodiments of processes and systems for the continuous manufacturing of implantable continuous analyte sensors. In some embodiments, a method is provided for sequentially advancing an elongated conductive body through a plurality of stations, each configured to treat the elongated conductive body. In some of these embodiments, one or more of the stations is configured to coat the elongated conductive body using a meniscus coating process, whereby a solution formed of a polymer and a solvent is prepared, the solution is continuously circulated to provide a meniscus on a top portion of a vessel holding the solution, and the elongated conductive body is advanced through the meniscus. The method may also comprise the step of removing excess coating material from the elongated conductive body by advancing the elongated conductive body through a die orifice. For example, a provided elongated conductive body 510 is advanced through a pre-coating treatment station 520 , through a coating station 530 , through a thickness control station 540 , through a drying or curing station 550 , through a thickness measurement station 560 , and through a post-coating treatment station 570.

1 - 8 . (canceled) 
     
     
         9 . A system for manufacturing an implantable continuous glucose sensor, the system comprising:
 a first coating station configured to apply a first material to an elongated conductive body, wherein the elongated conductive body is formed of a biocompatible material and is a precursor to an implantable continuous glucose sensor;   a second coating station configured to apply a second material to the elongated conductive body;   an automated transport system configured to:
 transfer the elongated conducted body to a first position where the first material is applied onto the elongated conductive body; 
 transfer the elongated conductive body from the first station to the second station; and 
 transfer the elongated conductive body to a second position where the second material is applied onto the elongated conductive body; 
   wherein the automated transport system is configured to move the elongated conductive body through use of three dimensional movements;   wherein at least one of the first material or the second material comprises an enzyme-containing membrane material.   
     
     
         10 . The system of  claim 9 , wherein the automated transport system comprises an elongated conductive body holder configured to move the elongated conductive body through programmed motions to perform a variety of tasks. 
     
     
         11 . The system of  claim 10 , wherein the elongated conductive body holder is programmed to dip the elongated conductive body into a coating vessel for a plurality of dips, with each dip interspersed by drying or curing of the coating. 
     
     
         12 . The system of  claim 9 , wherein the elongated conductive body is a precursor to one implantable continuous glucose sensor. 
     
     
         13 . The system of  claim 9 , wherein the elongated conductive body is a precursor to a plurality of implantable continuous glucose sensors. 
     
     
         14 . The system of  claim 9 , further comprising a die configured to remove a portion of the first coating material applied to the elongated conductive body. 
     
     
         15 . The system of  claim 9 , wherein the elongated conductive body is a wire with a circular or a substantially circular cross-sectional shape. 
     
     
         16 . The system of  claim 9 , wherein the first coating material comprises an insulating material selected from the group consisting of polyurethane, polyethylene, and polyimide. 
     
     
         17 . The system of  claim 9 , wherein the first coating material comprises a conductive material selected from the group consisting of platinum, silver/silver chloride, platinum-iridium, gold, palladium, iridium, graphite, carbon, conductive polymers, and alloys and combinations thereof. 
     
     
         18 . The system of  claim 9 , wherein at least one of the first coating station or the second coating station comprises a pump and conduit system configured to circulate the first coating material or the second coating material in liquid form in the coating vessel to provide a meniscus at a wall of the coating vessel. 
     
     
         19 . The system of  claim 9 , wherein the first coating material is a component of a solution, wherein the solution is controlled to have a predetermined viscosity. 
     
     
         20 . The system of  claim 15 , wherein the viscosity is controlled by selecting a concentration of the first coating material in the solution or by selecting a solution temperature.