Hydrogel adhesion to molded polymers

Abstract

Methods for adhering a hydrogel matrix to a molded polymer substrate and its use as a biosensor, e.g., a continuous or episodic glucose monitor, are disclosed. The presently disclosed subject mater provides a method for adhering a hydrogel matrix to a molded polymer substrate, the method comprising; (a) molding a polymer comprising one or more polymer chains with an oxidizer to form a molded polymer substrate; (b) providing a hydrogel matrix comprising a hydrogel, a component comprising one or more acrylate groups or another functional group that can form one or more radicals upon polymerization in the molded polymer substrate, and a photo initiator; (c) combining the molded polymer substrate and the hydrogel matrix; and (d) curing the combined molded polymer substrate and hydrogel matrix for a period of fime.

That which is claimed: 
     
         1 . A biosensor comprising a hydrogel matrix covalently bound to a molded polymer substrate, wherein the hydrogel matrix comprises a protein-reporter group. 
     
     
         2 . The biosensor of  claim 1 , wherein the hydrogel matrix comprises polyethylene glycol dimethacrylate. 
     
     
         3 . The biosensor of  claim 1 , wherein the molded polymer substrate comprises a material selected from the group consisting of a polycarbonate, a polystyrene, a polyethylene, a copolyester, and a polypropylene. 
     
     
         4 . The biosensor of  claim 1 , wherein the protein comprises a glucose binding protein (GBP). 
     
     
         5 . The biosensor of  claim 1 , wherein said hydrogel matrix is a polyhydroxy acid selected from the group consisting of polylactic acid, polyglycolic acid, polycaproic acid, polybutyric acid, polyvaleric acid, and copolymers thereof. 
     
     
         6 . The biosensor of  claim 1 , wherein said polymer substrate is polyethylene terephthalate. 
     
     
         7 . The biosensor of  claim 1 , wherein said protein-reporter group is labeled with a fluorescent dye. 
     
     
         8 . The biosensor of  claim 1 , wherein said protein-reporter group is a horseradish peroxidase or an antibody. 
     
     
         10 . The biosensor of  claim 1 , wherein said molded polymer substrate comprises a mixture of a polymer having one or more polymer chains and an oxidizer, and said hydrogel matrix comprises a hydrogel, a photoinitiator, and a component comprising one or more functional groups for polymerizing with the molded polymer substrate. 
     
     
         11 . The biosensor of  claim 10 , wherein said one or more functional groups is an acrylate group. 
     
     
         12 . The biosensor of  claim 1 , wherein said biosensor is obtained by a method of molding a mixture of a polymer comprising one or more polymer chains and an oxidizer to form said molded polymer substrate, combining the hydrogel matrix comprising a hydrogel, a component comprising one or more acrylate groups or other functional group that can form one or more radicals upon polymerization in the molded polymer substrate, and a photoinitiator, and curing the combined molded polymer substrate and hydrogel. 
     
     
         13 . A biosensor comprising a molded polymer substrate and a hydrogel matrix having a protein-reporter group covalently bonded to the molded polymer substrate, wherein said molded polymer substrate comprises a polymer having one or more polymer chains and an oxidizer that can break the one or more polymer chains and where the one or more polymer chains can recombine while retaining one or more putative radicals in the molded polymer substrate, and where the hydrogel matrix comprises a hydrogel, a component comprising one or more acrylate groups or other functional group forming a radical upon polymerization in the molded polymer substrate and an initiator. 
     
     
         14 . The biosensor of  claim 13 , wherein said biosensor is obtained by a method of combining said molded polymer substrate and hydrogel and curing to covalently bond the hydrogel matrix to the molded polymer substrate. 
     
     
         15 . The biosensor of  claim 13 , wherein the hydrogel matrix comprises polyethylene glycol dimethacrylate. 
     
     
         16 . The biosensor of  claim 13 , wherein the molded polymer substrate comprises a material selected from the group consisting of a polycarbonate, a polystyrene, a polyethylene, a copolyester, and a polypropylene. 
     
     
         17 . The biosensor of  claim 13 , wherein said hydrogel matrix is a polyhydroxy acid selected from the group consisting of polylactic acid, polyglycolic acid, polycaproic acid, polybutyric acid, polyvaleric acid, and copolymers thereof. 
     
     
         18 . The biosensor of  claim 13 , wherein said polymer substrate is polyethylene terephthalate. 
     
     
         19 . The biosensor of  claim 13 , wherein said protein-reporter group is labeled with a fluorescent dye. 
     
     
         20 . The biosensor of  claim 13 , wherein said protein-reporter group is a horseradish peroxidase or an antibody.