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.

What is claimed is: 
     
         1 . A system for manufacturing a continuous analyte sensor, the system comprising:
 a coating vessel configured to hold a coating material in liquid form;   a reel-to-reel system configured to advance an elongated conductive body through the coating material, whereby the coating material is applied to the elongated conductive body;   a thickness measurement sensor configured to measure a dimension indicative of a thickness of a coating formed from the coating material applied to the elongated conductive body;   an etching system configured to remove a portion of the coating material applied to the elongated conductive body; and   a cutter configured to cut the elongated conductive body into a plurality of sections, wherein each section is associated with an individual continuous analyte sensor.   
     
     
         2 . The system of  claim 1 , further comprising a die configured to remove a portion of the coating material applied to the elongated conductive body. 
     
     
         3 . The system of  claim 1 , wherein the elongated conductive body is a wire with a circular cross-sectional shape or a substantially circular cross-sectional shape. 
     
     
         4 . The system of  claim 1 , wherein the coating material comprises an insulating material selected from the group consisting of polyurethane, polyethylene, and polyimide. 
     
     
         5 . The system of  claim 1 , wherein the 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. 
     
     
         6 . The system of  claim 1 , further comprising a pump and conduit system configured to circulate the coating material in liquid form in the coating vessel to provide a meniscus at a wall of the coating vessel. 
     
     
         7 . The system of  claim 1 , wherein coating material is a component of a solution, wherein the solution is controlled to have a predetermined viscosity. 
     
     
         8 . The system of  claim 7 , wherein the viscosity is controlled by selecting a concentration of the coating material in the solution or by selecting a solution temperature.