US 12,110,583 B2
Analyte sensors and methods for fabricating analyte sensors
Santhisagar Vaddiraju, Plymouth, MN (US); and Dennis Slomski, Porter Ranch, CA (US)
Assigned to Medtronic MiniMed, Inc., Northridge, CA (US)
Filed by MEDTRONIC MINIMED, INC., Northridge, CA (US)
Filed on Nov. 14, 2022, as Appl. No. 17/986,766.
Application 17/986,766 is a division of application No. 15/900,630, filed on Feb. 20, 2018, granted, now 11,512,384.
Claims priority of provisional application 62/504,670, filed on May 11, 2017.
Prior Publication US 2023/0093665 A1, Mar. 23, 2023
Int. Cl. C23C 14/20 (2006.01); A61B 5/145 (2006.01); A61B 5/1486 (2006.01); B23K 26/36 (2014.01); B41M 1/06 (2006.01); B41M 1/10 (2006.01); B41M 1/12 (2006.01); B41M 5/00 (2006.01); C23C 14/14 (2006.01); C23C 14/34 (2006.01); C23C 14/56 (2006.01); C23C 14/58 (2006.01); G01N 27/327 (2006.01); G01N 27/411 (2006.01); C12Q 1/00 (2006.01); G01N 27/40 (2006.01)
CPC C23C 14/205 (2013.01) [A61B 5/14532 (2013.01); A61B 5/14865 (2013.01); B23K 26/36 (2013.01); B41M 1/06 (2013.01); B41M 1/10 (2013.01); B41M 1/12 (2013.01); B41M 5/0047 (2013.01); C23C 14/14 (2013.01); C23C 14/34 (2013.01); C23C 14/562 (2013.01); C23C 14/5813 (2013.01); C23C 14/5873 (2013.01); G01N 27/327 (2013.01); G01N 27/3271 (2013.01); G01N 27/3273 (2013.01); G01N 27/3277 (2013.01); G01N 27/4115 (2013.01); A61B 5/1486 (2013.01); A61B 2562/0209 (2013.01); A61B 2562/125 (2013.01); C12Q 1/006 (2013.01); G01N 27/40 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method for fabricating analyte sensors in a roll-to-roll process, the method comprising:
providing a roll of a polyester substrate having a first side sputtered with a layer of platinum, wherein the platinum is in direct contact with the polyester substrate;
feeding the polyester substrate from the roll to an electrode patterning stage;
patterning the layer of platinum to form working electrodes and reference electrodes;
feeding the polyester substrate to an insulation stage; forming an insulating dielectric layer over the polyester substrate;
feeding the polyester substrate to an insulation curing stage;
curing the insulating dielectric layer; feeding the polyester substrate to an ink printing stage;
depositing silver/silver chloride ink over the reference electrodes;
feeding the polyester substrate to a drying stage;
drying the silver/silver chloride ink;
feeding the polyester substrate to a protection stage;
depositing a protection material over the working electrodes and reference electrodes;
feeding the polyester substrate to a protection layer curing stage;
curing the protection material to form a protection layer over the working electrodes and reference electrodes;
feeding the polyester substrate to a punching stage;
punching the polyester substrate to form ribbons, wherein each ribbon is connected to a remaining polyester substrate web by a tab, and wherein each sensor includes one of the working electrodes and one of the reference electrodes;
feeding the remaining polyester substrate to an enzyme deposition stage;
depositing an enzyme layer over the working electrodes;
feeding the remaining polyester substrate to an enzyme curing stage;
curing the enzyme layer;
feeding the remaining polyester substrate to a membrane formation stage; and
coating the working electrodes with a glucose limiting membrane.