U.S. patent application number 16/717910 was filed with the patent office on 2020-05-07 for transcutaneous analyte sensor.
The applicant listed for this patent is DexCom, Inc.. Invention is credited to Mark Brister, Daniel Shawn Codd, John A, Guerre, Apurv Ullas Kamath, Daniel S. Kline, Thomas F. McGee, Paul V. Neale, David Michael Petersen, James R. Petisce, Sean Saint, James Patrick Thrower.
Application Number | 20200138346 16/717910 |
Document ID | / |
Family ID | 35658209 |
Filed Date | 2020-05-07 |
View All Diagrams
United States Patent
Application |
20200138346 |
Kind Code |
A1 |
Brister; Mark ; et
al. |
May 7, 2020 |
TRANSCUTANEOUS ANALYTE SENSOR
Abstract
The present invention relates generally to systems and methods
for measuring an analyte in a host. More particularly, the present
invention relates to systems and methods for transcutaneous
measurement of glucose in a host.
Inventors: |
Brister; Mark; (Encinitas,
CA) ; Neale; Paul V.; (San Diego, CA) ; Saint;
Sean; (San Diego, CA) ; Petisce; James R.;
(Westford, MA) ; Thrower; James Patrick; (Oakland,
NJ) ; Kamath; Apurv Ullas; (San Diego, CA) ;
Kline; Daniel S.; (Encinitas, CA) ; Guerre; John
A,; (Carlsbad, CA) ; Codd; Daniel Shawn;
(Escondido, CA) ; McGee; Thomas F.; (San Diego,
CA) ; Petersen; David Michael; (Escondido,
CA) |
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Applicant: |
Name |
City |
State |
Country |
Type |
DexCom, Inc. |
San Diego |
CA |
US |
|
|
Family ID: |
35658209 |
Appl. No.: |
16/717910 |
Filed: |
December 17, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15470766 |
Mar 27, 2017 |
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16717910 |
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12749981 |
Mar 30, 2010 |
9814414 |
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15470766 |
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11078072 |
Mar 10, 2005 |
9414777 |
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12749981 |
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60587787 |
Jul 13, 2004 |
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60587800 |
Jul 13, 2004 |
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60614683 |
Sep 30, 2004 |
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60614764 |
Sep 30, 2004 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61B 5/0004 20130101;
Y02A 90/26 20180101; A61B 5/14514 20130101; A61B 2562/18 20130101;
A61B 5/14507 20130101; A61B 5/1495 20130101; A61B 5/1411 20130101;
A61B 5/6801 20130101; A61B 5/1486 20130101; A61B 5/150022 20130101;
A61B 2560/045 20130101; A61M 2005/1585 20130101; A61B 5/0002
20130101; A61B 5/6848 20130101; A61B 5/1473 20130101; A61B 5/68335
20170801; A61B 5/145 20130101; A61B 5/6849 20130101; A61B 5/14735
20130101; A61B 5/6833 20130101; A61M 5/14244 20130101; A61B 5/14546
20130101; A61B 5/14 20130101; Y02A 90/10 20180101; A61B 5/14865
20130101; A61B 5/1468 20130101; A61B 2017/3492 20130101; A61B 5/05
20130101; A61B 5/14503 20130101; A61B 5/72 20130101; A61B 5/14532
20130101; A61B 2560/0223 20130101; A61M 5/1723 20130101; A61B
17/3468 20130101 |
International
Class: |
A61B 5/145 20060101
A61B005/145; A61B 5/00 20060101 A61B005/00; A61B 17/34 20060101
A61B017/34; A61B 5/05 20060101 A61B005/05; A61B 5/1486 20060101
A61B005/1486; A61B 5/15 20060101 A61B005/15; A61B 5/1495 20060101
A61B005/1495; A61B 5/1473 20060101 A61B005/1473 |
Claims
1. A method for inserting a transcutaneous analyte sensor into a
host using an applicator, the method comprising the steps of:
pushing on a first component of an applicator for inserting a
transcutaneous analyte sensor into a host, so as to insert an
introducer and the sensor into the skin of the host; and pulling on
a second component of the applicator so as to retract the
introducer from the skin of the host, while leaving the sensor in
the host; wherein the first component and the second component of
the applicator are configured to interact so as to enable insertion
of the sensor and retraction of the introducer using a motion
provided by a user.
2. The method of claim 1, wherein the motion provided the user
includes a continuous motion.
3. The method of claim 1, wherein the motion provided the user
includes a single motion.
4. The method of claim 1, wherein the motion provided the user
includes a single continuous motion.
5. The method of claim 1, wherein the pushing step comprises
pushing on a plunger.
6. The method of claim 1, wherein the pulling step comprises
pulling on a body portion of the second component of the
applicator.
7. The method of claim 1, wherein the applicator is configured to
insert the sensor and retract the introducer by a force provided by
a user's hand.
8. The method of claim 1, wherein the applicator is configured to
insert the sensor and retract the introducer solely by a force
provided by a user's hand.
9. The method of claim 1, wherein the applicator is configured to
insert the sensor and retract the introducer responsive to a
squeezing motion between a user's thumb and fingers.
10. The method of claim 1, wherein the applicator is configured to
sequentially insert the sensor and retract the introducer
responsive to a squeezing motion between a user's thumb and
fingers.
11. The method of claim 1, wherein the applicator is configured to
sequentially insert the sensor and retract the introducer
responsive to a downward force provided by the user.
12. The method of claim 1, wherein the applicator is configured to
sequentially insert the sensor and retract the introducer
responsive to a continuous downward force provided by the user.
13. The method of claim 1, wherein the user is the host.
14. A method for inserting a transcutaneous analyte sensor into a
host using an applicator, the method comprising the steps of:
placing an applicator system against a skin of a host, the
applicator system comprising a housing configured for placement
against the skin of the host, a sensor configured for
transcutaneous placement through the skin of a host, and an
applicator configured for inserting the sensor through the housing
and into the skin of the host; and inserting the sensor into the
host.
15. The method of claim 14, wherein inserting the sensor into the
host includes inserting the sensor into the host by applying a
force to a component of the applicator.
16. A method of using an electrochemical sensor, the method
comprising: adhering a mounting unit to a skin of a patient,
wherein the mounting unit comprises an applicator coupled thereto,
the applicator having an electrochemical sensor disposed therein;
inserting an electrochemical sensor into the skin of the patient
using the applicator; releasing the applicator; and coupling an
electronics unit body to the mounting unit, whereby the mounting
unit is coupled with a plurality of conductive contacts disposed on
the electronics unit body.
17. The method of claim 16, wherein a contact disposed on the
mounting unit is coupled with the plurality of conductive contacts
disposed on the electronics unit body.
18. The method of claim 17, wherein the contact includes a
plurality of conductive contacts.
Description
INCORPORATION BY REFERENCE TO RELATED APPLICATIONS
[0001] Any and all priority claims identified in the Application
Data Sheet, or any correction thereto, are hereby incorporated by
reference under 37 CFR 1.57. This application is a continuation of
U.S. application Ser. No. 15/470,766, filed Mar. 27, 2017, which is
a continuation of U.S. application Ser. No. 12/749,981, filed Mar.
30, 2010, now U.S. Pat. No. 9,814,414, which is a continuation of
U.S. application Ser. No. 11/078,072, filed Mar. 10, 2005, now U.S.
Pat. No. 9,414,777, which claims the benefit of U.S. Provisional
Application No. 60/587,787, filed Jul. 13, 2004; U.S. Provisional
Application No. 60/587,800, filed Jul. 13, 2004; U.S. Provisional
Application No. 60/614,683, filed Sep. 30, 2004; and U.S.
Provisional Application No. 60/614,764, filed Sep. 30, 2004. Each
of the aforementioned applications is incorporated by reference
herein in its entirety, and each is hereby expressly made a part of
this specification.
FIELD OF THE INVENTION
[0002] The present invention relates generally to systems and
methods for measuring an analyte in a host. More particularly, the
present invention relates to systems and methods for transcutaneous
measurement of glucose in a host.
BACKGROUND OF THE INVENTION
[0003] Diabetes mellitus is a disorder in which the pancreas cannot
create sufficient insulin (Type I or insulin dependent) and/or in
which insulin is not effective (Type 2 or non-insulin dependent).
In the diabetic state, the victim suffers from high blood sugar,
which can cause an array of physiological derangements associated
with the deterioration of small blood vessels, for example, kidney
failure, skin ulcers, or bleeding into the vitreous of the eye. A
hypoglycemic reaction (low blood sugar) can be induced by an
inadvertent overdose of insulin, or after a normal dose of insulin
or glucose-lowering agent accompanied by extraordinary exercise or
insufficient food intake.
[0004] Conventionally, a person with diabetes carries a
self-monitoring blood glucose (SMBG) monitor, which typically
requires uncomfortable finger pricking methods. Due to the lack of
comfort and convenience, a person with diabetes normally only
measures his or her glucose levels two to four times per day.
Unfortunately, such time intervals are so far spread apart that the
person with diabetes likely finds out too late of a hyperglycemic
or hypoglycemic condition, sometimes incurring dangerous side
effects. It is not only unlikely that a person with diabetes will
take a timely SMBG value, it is also likely that he or she will not
know if his or her blood glucose value is going up (higher) or down
(lower) based on conventional method. This inhibits the ability to
make educated insulin therapy decisions.
SUMMARY OF THE INVENTION
[0005] In a first aspect, a method for inserting a transcutaneous
analyte sensor into a host using an applicator is provided, the
method comprising the steps of: providing an applicator for
inserting a transcutaneous analyte sensor into a host; placing a
mounting unit on a skin of the host, wherein the applicator is
releasably mated to the mounting unit, and wherein the applicator
comprises a needle for inserting a sensor into the host; pushing on
a component of the applicator so as to insert the needle and the
sensor into the skin of the host; pulling on a component of the
applicator so as to retract the needle from the skin of the host,
while leaving the sensor in the host; and releasing the applicator
from the mounting unit.
[0006] In an embodiment of the first aspect, the mounting unit is
adhered to the skin of the host.
[0007] In an embodiment of the first aspect, the step of pushing
comprises pushing on a component of the applicator so as to insert
the needle and the sensor into the skin of the host at an angle of
insertion, wherein the angle of insertion is determined by the
applicator.
[0008] In an embodiment of the first aspect, the mounting unit
comprises at least one electrical contact configured for connection
with the sensor.
[0009] In an embodiment of the first aspect, the step of pushing
comprises inserting the sensor into the skin of the host and to a
position proximal to the electrical contact.
[0010] In an embodiment of the first aspect, the step of pulling
comprises retracting the needle from the sensor such that the
sensor is disposed adjacent to the electrical contact.
[0011] In an embodiment of the first aspect, the electrical contact
is configured to provide a mechanical stability to the sensor when
the sensor is disposed adjacent to the electrical contact.
[0012] In an embodiment of the first aspect, the mounting unit
comprises a subassembly comprising at least one electrical contact,
wherein the subassembly articulates relative to the mounting
unit.
[0013] In an embodiment of the first aspect, the method further
comprises the step of articulating the subassembly between a first
position and a second position.
[0014] In an embodiment of the first aspect, the subassembly is in
the first position during sensor insertion.
[0015] In an embodiment of the first aspect, the step of
articulating is performed after the step of releasing the
applicator from the mounting unit.
[0016] In an embodiment of the first aspect, the step of
articulating comprises pivoting the subassembly between a first
position and a second position, thereby bending the sensor.
[0017] In an embodiment of the first aspect, bending the sensor
provides a flexion configured to absorb movement between two ends
of the sensor.
[0018] In an embodiment of the first aspect, the method further
comprises the step of mating an electronics unit to the mounting
unit.
[0019] In an embodiment of the first aspect, the step of mating
comprises mating the electronics unit to the mounting unit, whereby
an electrical connection between the sensor and the electronics
unit is formed.
[0020] In an embodiment of the first aspect, the step of mating
comprises mating the electronics unit to the mounting unit, whereby
the electrical connection between the sensor and the electronics
unit is substantially sealed.
[0021] In an embodiment of the first aspect, the method further
comprises the step of measuring an analyte concentration in the
host.
[0022] In an embodiment of the first aspect, the method further
comprises the step of calibrating the analyte concentration using
data from a single-point reference analyte monitor.
[0023] In an embodiment of the first aspect, the method further
comprises the step of calibrating the analyte concentration using
stored data from an in vitro test.
[0024] In an embodiment of the first aspect, the method further
comprises the step of calibrating the analyte concentration using
data from another transcutaneous analyte sensor.
[0025] In an embodiment of the first aspect, the applicator is
configured such that the pushing step and the pulling step are
accomplished by a continuous force provided by a user gripping the
applicator.
[0026] In a second aspect, a method for transcutaneously measuring
analyte concentrations in a host over time is provided, the method
comprising: inserting a first transcutaneous analyte sensor in a
host; measuring a first analyte concentration in the host;
inserting a second transcutaneous analyte sensor in the host;
measuring a second analyte concentration in the host; calibrating
the second analyte concentration from the second transcutaneous
analyte sensor using the first analyte concentration from the first
transcutaneous analyte sensor; and removing the first
transcutaneous analyte sensor from the host.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of a transcutaneous analyte
sensor system, including an applicator, a mounting unit, and an
electronics unit.
[0028] FIG. 2 is a perspective view of a mounting unit, including
the electronics unit in its functional position.
[0029] FIG. 3 is an exploded perspective view of a mounting unit,
showing its individual components.
[0030] FIG. 4 is an exploded perspective view of a contact
subassembly, showing its individual components.
[0031] FIG. 5A is an expanded cutaway view of a proximal portion of
a sensor.
[0032] FIG. 5B is an expanded cutaway view of a distal portion of a
sensor.
[0033] FIG. 5C is a cross-sectional view through the sensor of FIG.
5B on line C-C, showing an exposed electroactive surface of a
working electrode surrounded by a membrane system.
[0034] FIG. 6 is an exploded side view of an applicator, showing
the components that facilitate sensor insertion and subsequent
needle retraction.
[0035] FIGS. 7A to 7D are schematic side cross-sectional views that
illustrate applicator components and their cooperating
relationships.
[0036] FIG. 8A is a side view of an applicator matingly engaged to
a mounting unit, prior to sensor insertion.
[0037] FIG. 8B is a side view of a mounting unit and applicator
after the plunger subassembly has been pushed, extending the needle
and sensor from the mounting unit.
[0038] FIG. 8C is a side view of a mounting unit and applicator
after the guide tube subassembly has been retracted, retracting the
needle back into the applicator.
[0039] FIGS. 9A to 9C are side views of an applicator and mounting
unit, showing stages of sensor insertion.
[0040] FIGS. 10A and 10B are perspective and side cross-sectional
views, respectively, of a sensor system showing the mounting unit
immediately following sensor insertion and release of the
applicator from the mounting unit.
[0041] FIGS. 11A and 11B are perspective and side cross-sectional
views, respectively, of a sensor system showing the mounting unit
after pivoting the contact subassembly to its functional
position.
[0042] FIGS. 12A to 12C are perspective and side views,
respectively, of the sensor system showing the sensor, mounting
unit, and electronics unit in their functional positions.
[0043] FIG. 13 is a block diagram that illustrates electronics
associated with a sensor system.
[0044] FIG. 14 is a perspective view of a sensor system wirelessly
communicating with a receiver.
[0045] FIG. 15A is a block diagram that illustrates a configuration
of a medical device including a continuous analyte sensor, a
receiver, and an external device.
[0046] FIGS. 15B to 15D are illustrations of receiver liquid
crystal displays showing embodiments of screen displays.
[0047] FIG. 16A is a flow chart that illustrates the initial
calibration and data output of sensor data.
[0048] FIG. 16B is a graph that illustrates one example of using
prior information for slope and baseline.
[0049] FIG. 17 is a flow chart that illustrates evaluation of
reference and/or sensor data for statistical, clinical, and/or
physiological acceptability.
[0050] FIG. 18 is a flow chart that illustrates evaluation of
calibrated sensor data for aberrant values.
[0051] FIG. 19 is a flow chart that illustrates self-diagnostics of
sensor data.
[0052] FIGS. 20A and 20B are graphical representations of glucose
sensor data in a human obtained over approximately three days.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0053] The following description and examples illustrate some
exemplary embodiments of the disclosed invention in detail. Those
of skill in the art will recognize that there are numerous
variations and modifications of this invention that are encompassed
by its scope. Accordingly, the description of a certain exemplary
embodiment should not be deemed to limit the scope of the present
invention.
Definitions
[0054] In order to facilitate an understanding of the preferred
embodiments, a number of terms are defined below.
[0055] The term "analyte" as used herein is a broad term and is
used in its ordinary sense, including, without limitation, to refer
to a substance or chemical constituent in a biological fluid (for
example, blood, interstitial fluid, cerebral spinal fluid, lymph
fluid or urine) that can be analyzed. Analytes can include
naturally occurring substances, artificial substances, metabolites,
and/or reaction products. In some embodiments, the analyte for
measurement by the sensing regions, devices, and methods is
glucose. However, other analytes are contemplated as well,
including but not limited to acarboxyprothrombin; acylcarnitine;
adenine phosphoribosyl transferase; adenosine deaminase; albumin;
alpha-fetoprotein; amino acid profiles (arginine (Krebs cycle),
histidine/urocanic acid, homocysteine, phenylalanine/tyrosine,
tryptophan); andrenostenedione; antipyrine; arabinitol enantiomers;
arginase; benzoylecgonine (cocaine); biotinidase; biopterin;
c-reactive protein; carnitine; carnosinase; CD4; ceruloplasmin;
chenodeoxycholic acid; chloroquine; cholesterol; cholinesterase;
conjugated 1-.beta. hydroxy-cholic acid; cortisol; creatine kinase;
creatine kinase MM isoenzyme; cyclosporin A; d-penicillamine;
de-ethylchloroquine; dehydroepiandrosterone sulfate; DNA
(acetylator polymorphism, alcohol dehydrogenase, alpha
1-antitrypsin, cystic fibrosis, Duchenne/Becker muscular dystrophy,
glucose-6-phosphate dehydrogenase, hemoglobin A, hemoglobin S,
hemoglobin C, hemoglobin D, hemoglobin E, hemoglobin F, D-Punjab,
beta-thalassemia, hepatitis B virus, HCMV, HIV-1, HTLV-1, Leber
hereditary optic neuropathy, MCAD, RNA, PKU, Plasmodium vivax,
sexual differentiation, 21-deoxycortisol); desbutylhalofantrine;
dihydropteridine reductase; diptheria/tetanus antitoxin;
erythrocyte arginase; erythrocyte protoporphyrin; esterase D; fatty
acids/acylglycines; free .beta.-human chorionic gonadotropin; free
erythrocyte porphyrin; free thyroxine (FT4); free tri-iodothyronine
(FT3); fumarylacetoacetase; galactose/gal-1-phosphate;
galactose-1-phosphate uridyltransferase; gentamicin;
glucose-6-phosphate dehydrogenase; glutathione; glutathione
perioxidase; glycocholic acid; glycosylated hemoglobin;
halofantrine; hemoglobin variants; hexosaminidase A; human
erythrocyte carbonic anhydrase I; 17-alpha-hydroxyprogesterone;
hypoxanthine phosphoribosyl transferase; immunoreactive trypsin;
lactate; lead; lipoproteins ((a), B/A-1, .beta.); lysozyme;
mefloquine; netilmicin; phenobarbitone; phenytoin;
phytanic/pristanic acid; progesterone; prolactin; prolidase; purine
nucleoside phosphorylase; quinine; reverse tri-iodothyronine (rT3);
selenium; serum pancreatic lipase; sissomicin; somatomedin C;
specific antibodies (adenovirus, anti-nuclear antibody, anti-zeta
antibody, arbovirus, Aujeszky's disease virus, dengue virus,
Dracunculus medinensis, Echinococcus granulosus, Entamoeba
histolytica, enterovirus, Giardia duodenalisa, Helicobacter pylori,
hepatitis B virus, herpes virus, HIV-1, IgE (atopic disease),
influenza virus, Leishmania donovani, leptospira,
measles/mumps/rubella, Mycobacterium leprae, Mycoplasma pneumoniae,
Myoglobin, Onchocerca volvulus, parainfluenza virus, Plasmodium
falciparum, poliovirus, Pseudomonas aeruginosa, respiratory
syncytial virus, rickettsia (scrub typhus), Schistosoma mansoni,
Toxoplasma gondii, Trepenoma pallidium, Trypanosoma cruzi/rangeli,
vesicular stomatis virus, Wuchereria bancrofti, yellow fever
virus); specific antigens (hepatitis B virus, HIV-1);
succinylacetone; sulfadoxine; theophylline; thyrotropin (TSH);
thyroxine (T4); thyroxine-binding globulin; trace elements;
transferrin; UDP-galactose-4-epimerase; urea; uroporphyrinogen I
synthase; vitamin A; white blood cells; and zinc protoporphyrin.
Salts, sugar, protein, fat, vitamins and hormones naturally
occurring in blood or interstitial fluids can also constitute
analytes in certain embodiments. The analyte can be naturally
present in the biological fluid, for example, a metabolic product,
a hormone, an antigen, an antibody, and the like. Alternatively,
the analyte can be introduced into the body, for example, a
contrast agent for imaging, a radioisotope, a chemical agent, a
fluorocarbon-based synthetic blood, or a drug or pharmaceutical
composition, including but not limited to insulin; ethanol;
cannabis (marijuana, tetrahydrocannabinol, hashish); inhalants
(nitrous oxide, amyl nitrite, butyl nitrite, chlorohydrocarbons,
hydrocarbons); cocaine (crack cocaine); stimulants (amphetamines,
methamphetamines, Ritalin, Cylert, Preludin, Didrex, PreState,
Voranil, Sandrex, Plegine); depressants (barbituates, methaqualone,
tranquilizers such as Valium, Librium, Miltown, Serax, Equanil,
Tranxene); hallucinogens (phencyclidine, lysergic acid, mescaline,
peyote, psilocybin); narcotics (heroin, codeine, morphine, opium,
meperidine, Percocet, Percodan, Tussionex, Fentanyl, Darvon,
Talwin, Lomotil); designer drugs (analogs of fentanyl, meperidine,
amphetamines, methamphetamines, and phencyclidine, for example,
Ecstasy); anabolic steroids; and nicotine. The metabolic products
of drugs and pharmaceutical compositions are also contemplated
analytes. Analytes such as neurochemicals and other chemicals
generated within the body can also be analyzed, such as, for
example, ascorbic acid, uric acid, dopamine, noradrenaline,
3-methoxytyramine (3MT), 3,4-dihydroxyphenylacetic acid (DOPAC),
homovanillic acid (HVA), 5-hydroxytryptamine (5HT), and
5-hydroxyindoleacetic acid (FHIAA).
[0056] The term "host" as used herein is a broad term and is used
in its ordinary sense, including, without limitation, to refer to
mammals, particularly humans.
[0057] The term "exit-site" as used herein is a broad term and is
used in its ordinary sense, including, without limitation, to refer
to the area where a medical device (for example, a sensor and/or
needle) exits from the host's body.
[0058] The phrase "continuous (or continual) analyte sensing" as
used herein is a broad term and is used in its ordinary sense,
including, without limitation, to refer to the period in which
monitoring of analyte concentration is continuously, continually,
and or intermittently (regularly or irregularly) performed, for
example, about every 5 to 10 minutes.
[0059] The term "electrochemically reactive surface" as used herein
is a broad term and is used in its ordinary sense, including,
without limitation, to refer to the surface of an electrode where
an electrochemical reaction takes place. For example, a working
electrode measures hydrogen peroxide produced by the
enzyme-catalyzed reaction of the analyte detected, which reacts to
create an electric current. Glucose analyte can be detected
utilizing glucose oxidase, which produces H.sub.2O.sub.2 as a
byproduct. H.sub.2O.sub.2 reacts with the surface of the working
electrode, producing two protons (2H.sup.+), two electrons
(2e.sup.-) and one molecule of oxygen (O.sub.2), which produces the
electronic current being detected.
[0060] The term "electronic connection" as used herein is a broad
term and is used in its ordinary sense, including, without
limitation, to refer to any electronic connection known to those in
the art that can be utilized to interface the sensing region
electrodes with the electronic circuitry of a device, such as
mechanical (for example, pin and socket) or soldered electronic
connections.
[0061] The term "interferant" and "interferants," as used herein,
are broad terms and are used in their ordinary sense, including,
without limitation, to refer to species that interfere with the
measurement of an analyte of interest in a sensor to produce a
signal that does not accurately represent the analyte measurement.
In one example of an electrochemical sensor, interferants are
compounds with oxidation potentials that overlap with the analyte
to be measured.
[0062] The term "sensing region" as used herein is a broad term and
is used in its ordinary sense, including, without limitation, to
refer to the region of a monitoring device responsible for the
detection of a particular analyte. The sensing region generally
comprises a non-conductive body, a working electrode (anode), a
reference electrode (optional), and/or a counter electrode
(cathode) passing through and secured within the body forming
electrochemically reactive surfaces on the body and an electronic
connective means at another location on the body, and a
multi-domain membrane affixed to the body and covering the
electrochemically reactive surface.
[0063] The term "high oxygen solubility domain" as used herein is a
broad term and is used in its ordinary sense, including, without
limitation, to refer to a domain composed of a material that has
higher oxygen solubility than aqueous media such that it
concentrates oxygen from the biological fluid surrounding the
membrane system. The domain can act as an oxygen reservoir during
times of minimal oxygen need and has the capacity to provide, on
demand, a higher oxygen gradient to facilitate oxygen transport
across the membrane. Thus, the ability of the high oxygen
solubility domain to supply a higher flux of oxygen to critical
domains when needed can improve overall sensor function.
[0064] The term "domain" as used herein is a broad term and is used
in its ordinary sense, including, without limitation, to refer to a
region of the membrane system that can be a layer, a uniform or
non-uniform gradient (for example, an anisotropic region of a
membrane), or a portion of a membrane.
[0065] The phrase "distal to" as used herein is a broad term and is
used in its ordinary sense, including, without limitation, the
spatial relationship between various elements in comparison to a
particular point of reference. In general, the term indicates an
element is located relatively far from the reference point than
another element.
[0066] The term "proximal to" as used herein is a broad term and is
used in its ordinary sense, including, without limitation, the
spatial relationship between various elements in comparison to a
particular point of reference. In general, the term indicates an
element is located relatively near to the reference point than
another element.
[0067] The terms "in vivo portion" and "distal portion" as used
herein are broad terms and are used in their ordinary sense,
including, without limitation, to refer to the portion of the
device (for example, a sensor) adapted for insertion into and/or
existence within a living body of a host.
[0068] The terms "ex vivo portion" and "proximal portion" as used
herein are broad terms and are used in their ordinary sense,
including, without limitation, to refer to the portion of the
device (for example, a sensor) adapted to remain and/or exist
outside of a living body of a host.
[0069] The terms "raw data stream" and "data stream," as used
herein, are broad terms and are used in their ordinary sense,
including, without limitation, to refer to an analog or digital
signal from the analyte sensor directly related to the measured
analyte. For example, the raw data stream is digital data in
"counts" converted by an A/D converter from an analog signal (for
example, voltage or amps) representative of an analyte
concentration. The terms broadly encompass a plurality of time
spaced data points from a substantially continuous analyte sensor,
each of which comprises individual measurements taken at time
intervals ranging from fractions of a second up to, for example, 1,
2, or 5 minutes or longer.
[0070] The term "count," as used herein, is a broad term and is
used in its ordinary sense, including, without limitation, to refer
to a unit of measurement of a digital signal. For example, a raw
data stream measured in counts is directly related to a voltage
(for example, converted by an A/D converter), which is directly
related to current from the working electrode.
[0071] The term "physiologically feasible," as used herein, is a
broad term and is used in its ordinary sense, including, without
limitation, to refer to one or more physiological parameters
obtained from continuous studies of glucose data in humans and/or
animals. For example, a maximal sustained rate of change of glucose
in humans of about 4 to 6 mg/dL/min and a maximum acceleration of
the rate of change of about 0.1 to 0.2 mg/dL/min/min are deemed
physiologically feasible limits. Values outside of these limits are
considered non-physiological and are likely a result of, e.g.,
signal error.
[0072] The term "ischemia," as used herein, is a broad term and is
used in its ordinary sense, including, without limitation, to refer
to local and temporary deficiency of blood supply due to
obstruction of circulation to a part (for example, a sensor).
Ischemia can be caused, for example, by mechanical obstruction (for
example, arterial narrowing or disruption) of the blood supply.
[0073] The term "matched data pairs", as used herein, is a broad
term and is used in its ordinary sense, including, without
limitation, to refer to reference data (for example, one or more
reference analyte data points) matched with substantially time
corresponding sensor data (for example, one or more sensor data
points).
[0074] The term "Clarke Error Grid", as used herein, is a broad
term and is used in its ordinary sense, including, without
limitation, to refer to an error grid analysis, for example, an
error grid analysis used to evaluate the clinical significance of
the difference between a reference glucose value and a sensor
generated glucose value, taking into account 1) the value of the
reference glucose measurement, 2) the value of the sensor glucose
measurement, 3) the relative difference between the two values, and
4) the clinical significance of this difference. See Clarke et al.,
"Evaluating Clinical Accuracy of Systems for Self-Monitoring of
Blood Glucose", Diabetes Care, Volume 10, Number 5,
September-October 1987, the contents of which are hereby
incorporated by reference herein in their entirety and are hereby
made a part of this specification.
[0075] The term "Consensus Error Grid," as used herein, is a broad
term and is used in its ordinary sense, including, without
limitation, to refer to an error grid analysis that assigns a
specific level of clinical risk to any possible error between two
time corresponding measurements, e.g., glucose measurements. The
Consensus Error Grid is divided into zones signifying the degree of
risk posed by the deviation. See Parkes et al., "A New Consensus
Error Grid to Evaluate the Clinical Significance of Inaccuracies in
the Measurement of Blood Glucose", Diabetes Care, Volume 23, Number
8, August 2000, the contents of which are hereby incorporated by
reference herein in their entirety and are hereby made a part of
this specification.
[0076] The term "clinical acceptability", as used herein, is a
broad term and is used in its ordinary sense, including, without
limitation, to refer to determination of the risk of an inaccuracy
to a patient. Clinical acceptability considers a deviation between
time corresponding analyte measurements (for example, data from a
glucose sensor and data from a reference glucose monitor) and the
risk (for example, to the decision making of a person with
diabetes) associated with that deviation based on the analyte value
indicated by the sensor and/or reference data. An example of
clinical acceptability can be 85% of a given set of measured
analyte values within the "A" and "B" region of a standard Clarke
Error Grid when the sensor measurements are compared to a standard
reference measurement.
[0077] The term "sensor" as used herein is a broad term and is used
in its ordinary sense, including, without limitation, to refer to
the component or region of a device by which an analyte can be
quantified.
[0078] The term "needle," as used herein is a broad term and is
used in its ordinary sense, including, without limitation, to refer
to a slender hollow instrument for introducing material into or
removing material from the body.
[0079] The terms "operably connected" and "operably linked" as used
herein are broad terms and are used in their ordinary sense,
including, without limitation, to refer to one or more components
linked to one or more other components. The terms can refer to a
mechanical connection, an electrical connection, or a connection
that allows transmission of signals between the components. For
example, one or more electrodes can be used to detect the amount of
analyte in a sample and to convert that information into a signal;
the signal can then be transmitted to a circuit. In such an
example, the electrode is "operably linked" to the electronic
circuitry.
[0080] The term "baseline" as used herein is a broad term and is
used in its ordinary sense, including, without limitation, is the
component of an analyte sensor signal that is not related to the
analyte concentration. In one example of a glucose sensor, the
baseline is composed substantially of signal contribution due to
factors other than glucose (for example, interfering species,
non-reaction-related hydrogen peroxide, or other electroactive
species with an oxidation potential that overlaps with hydrogen
peroxide). In some embodiments wherein a calibration is defined by
solving for the equation y=mx+b, the value of b represents the
baseline of the signal.
[0081] The terms "sensitivity" and "slope," as used herein are
broad terms and are used in their ordinary sense, including,
without limitation, to refer to an amount of electrical current
produced by a predetermined amount (unit) of the measured analyte.
For example, in one preferred embodiment, a sensor has a
sensitivity (or slope) of about 3.5 to about 7.5 picoAmps of
current for every 1 mg/dL of glucose analyte.
[0082] The term "membrane system," as used herein, is a broad term
and is used in its ordinary sense, including, without limitation,
to refer to a permeable or semi-permeable membrane that can be
comprised of two or more domains and is typically constructed of
materials of a few microns thickness or more, which is permeable to
oxygen and is optionally permeable to, e.g., glucose or another
analyte. In one example, the membrane system comprises an
immobilized glucose oxidase enzyme, which enables a reaction to
occur between glucose and oxygen whereby a concentration of glucose
can be measured.
[0083] The terms "processor module" and "microprocessor," as used
herein, are broad terms and are used in their ordinary sense,
without limitation, to refer to a computer system, state machine,
processor, or the like designed to perform arithmetic or logic
operations using logic circuitry that responds to and processes the
basic instructions that drive a computer.
[0084] The terms "smoothing" and "filtering," as used herein, are
broad terms and are used in their ordinary sense, without
limitation, to refer to modification of a set of data to make it
smoother and more continuous or to remove or diminish outlying
points, for example, by performing a moving average of the raw data
stream.
[0085] The term "algorithm," as used herein, is a broad term and is
used in its ordinary sense, without limitation, to refer to a
computational process (for example, programs) involved in
transforming information from one state to another, for example, by
using computer processing.
[0086] The term "regression," as used herein, is a broad term and
is used in its ordinary sense, including, without limitation, to
refer to finding a line for which a set of data has a minimal
measurement (for example, deviation) from that line. Regression can
be linear, non-linear, first order, second order, or the like. One
example of regression is least squares regression.
[0087] The term "calibration," as used herein, is a broad term and
is used in its ordinary sense, including, without limitation, to
refer to the process of determining the relationship between the
sensor data and the corresponding reference data, which can be used
to convert sensor data into meaningful values substantially
equivalent to the reference data. In some embodiments, namely, in
continuous analyte sensors, calibration can be updated or
recalibrated over time as changes in the relationship between the
sensor data and reference data occur, for example, due to changes
in sensitivity, baseline, transport, metabolism, or the like.
[0088] The terms "interferants" and "interfering species," as used
herein, are broad terms and are used in their ordinary sense,
including, without limitation, to refer to effects and/or species
that interfere with the measurement of an analyte of interest in a
sensor to produce a signal that does not accurately represent the
analyte concentration. In one example of an electrochemical sensor,
interfering species are compounds with an oxidation potential that
overlap that of the analyte to be measured, thereby producing a
false positive signal.
Sensor System
[0089] A transcutaneous analyte sensor system is provided that
includes an applicator for inserting the transdermal analyte sensor
under a host's skin. The sensor system includes a sensor for
sensing the analyte, wherein the sensor is associated with a
mounting unit adapted for mounting on the skin of the host. The
mounting unit houses the electronics unit associated with the
sensor and is adapted for fastening to the host's skin. In certain
embodiments, the system further includes a receiver for receiving
and/or processing sensor data.
[0090] FIG. 1 is a perspective view of a transcutaneous analyte
sensor system 10. In the preferred embodiment of a system as
depicted in FIG. 1, the sensor includes an applicator 12, a
mounting unit 14, and an electronics unit 16. The system can
further include a receiver 158, such as is described in more detail
with reference to FIG. 14.
[0091] The mounting unit 14 includes a base 24 adapted for mounting
on the skin of a host, a sensor adapted for transdermal insertion
through the skin of a host (see FIG. 4), and one or more contacts
28 configured to provide secure electrical contact between the
sensor and the electronics unit 16. The mounting unit 14 is
designed to maintain the integrity of the sensor in the host so as
to reduce or eliminate translation of motion between the mounting
unit, the host, and/or the sensor.
[0092] In one embodiment, an applicator 12 is provided for
inserting the sensor 32 through the host's skin at the appropriate
insertion angle with the aid of a needle (see FIGS. 6 through 8),
and for subsequent removal of the needle using a continuous
push-pull action. Preferably, the applicator comprises an
applicator body 18 that guides the applicator components (see FIGS.
6 through 8) and includes an applicator body base 60 configured to
mate with the mounting unit 14 during insertion of the sensor into
the host. The mate between the applicator body base 60 and the
mounting unit 14 can use any known mating configuration, for
example, a snap-fit, a press-fit, an interference-fit, or the like,
to discourage separation during use. One or more release latches 30
enable release of the applicator body base 60, for example, when
the applicator body base 60 is snap fit into the mounting unit
14.
[0093] The electronics unit 16 includes hardware, firmware, and/or
software that enable measurement of levels of the analyte via the
sensor. For example, the electronics unit 16 can comprise a
potentiostat, a power source for providing power to the sensor,
other components useful for signal processing, and preferably an RF
module for transmitting data from the electronics unit 16 to a
receiver (see FIGS. 13 to 15). Electronics can be affixed to a
printed circuit board (PCB), or the like, and can take a variety of
forms. For example, the electronics can take the form of an
integrated circuit (IC), such as an Application-Specific Integrated
Circuit (ASIC), a microcontroller, or a processor. Preferably,
electronics unit 16 houses the sensor electronics, which comprise
systems and methods for processing sensor analyte data. Examples of
systems and methods for processing sensor analyte data are
described in more detail below and in co-pending U.S. application
Ser. No. 10/633,367 filed Aug. 1, 2003, and entitled, "SYSTEM AND
METHODS FOR PROCESSING ANALYTE SENSOR DATA."
[0094] After insertion of the sensor using the applicator 12, and
subsequent release of the applicator 12 from the mounting unit 14
(see FIGS. 8A to 8C), the electronics unit 16 is configured to
releasably mate with the mounting unit 14 in a manner similar to
that described above with reference to the applicator body base 60.
The electronics unit 16 includes contacts on its backside (not
shown) configured to electrically connect with the contacts 28,
such as are described in more detail with reference to FIGS. 2
through 4. In one embodiment, the electronics unit 16 is configured
with programming, for example initialization, calibration reset,
failure testing, or the like, each time it is initially inserted
into the mounting unit 14 and/or each time it initially
communicates with the sensor 32.
Mounting Unit
[0095] FIG. 2 is a perspective view of a sensor system of a
preferred embodiment, shown in its functional position, including a
mounting unit and an electronics unit matingly engaged therein.
FIGS. 8 to 10 illustrate the sensor is its functional position for
measurement of an analyte concentration in a host.
[0096] In preferred embodiments, the mounting unit 14, also
referred to as a housing, comprises a base 24 adapted for fastening
to a host's skin. The base can be formed from a variety of hard or
soft materials, and preferably comprises a low profile for
minimizing protrusion of the device from the host during use. In
some embodiments, the base 24 is formed at least partially from a
flexible material, which is believed to provide numerous advantages
over conventional transcutaneous sensors, which, unfortunately, can
suffer from motion-related artifacts associated with the host's
movement when the host is using the device. For example, when a
transcutaneous analyte sensor is inserted into the host, various
movements of the sensor (for example, relative movement between the
in vivo portion and the ex vivo portion, movement of the skin,
and/or movement within the host (dermis or subcutaneous)) create
stresses on the device and can produce noise in the sensor signal.
It is believed that even small movements of the skin can translate
to discomfort and/or motion-related artifact, which can be reduced
or obviated by a flexible or articulated base. Thus, by providing
flexibility and/or articulation of the device against the host's
skin, better conformity of the sensor system 10 to the regular use
and movements of the host can be achieved. Flexibility or
articulation is believed to increase adhesion (with the use of an
adhesive pad) of the mounting unit 14 onto the skin, thereby
decreasing motion-related artifact that can otherwise translate
from the host's movements and reduced sensor performance.
[0097] FIG. 3 is an exploded perspective view of a sensor system of
a preferred embodiment, showing a mounting unit, an associated
contact subassembly, and an electronics unit. In some embodiments,
the contacts 28 are mounted on or in a subassembly hereinafter
referred to as a contact subassembly 26 (see FIG. 4), which
includes a contact holder 34 configured to fit within the base 24
of the mounting unit 14 and a hinge 38 that allows the contact
subassembly 26 to pivot between a first position (for insertion)
and a second position (for use) relative to the mounting unit 14,
which is described in more detail with reference to FIGS. 10 and
11. The term "hinge" as used herein is a broad term and is used in
its ordinary sense, including, without limitation, to refer to any
of a variety of pivoting, articulating, and/or hinging mechanisms,
such as an adhesive hinge, a sliding joint, and the like; the term
hinge does not necessarily imply a fulcrum or fixed point about
which the articulation occurs.
[0098] In certain embodiments, the mounting unit 14 is provided
with an adhesive pad 8, preferably disposed on the mounting unit's
back surface and preferably including a releasable backing layer 9.
Thus, removing the backing layer 9 and pressing the base portion 24
of the mounting unit onto the host's skin adheres the mounting unit
14 to the host's skin. Additionally or alternatively, an adhesive
pad can be placed over some or all of the sensor system after
sensor insertion is complete to ensure adhesion, and optionally to
ensure an airtight seal or watertight seal around the wound
exit-site (or sensor insertion site) (not shown). Appropriate
adhesive pads can be chosen and designed to stretch, elongate,
conform to, and/or aerate the region (e.g., host's skin).
[0099] In preferred embodiments, the adhesive pad 8 is formed from
spun-laced, open- or closed-cell foam, and/or non-woven fibers, and
includes an adhesive disposed thereon, however a variety of
adhesive pads appropriate for adhesion to the host's skin can be
used, as is appreciated by one skilled in the art of medical
adhesive pads. In some embodiments, a double-sided adhesive pad is
used to adhere the mounting unit to the host's skin. In other
embodiments, the adhesive pad includes a foam layer, for example, a
layer wherein the foam is disposed between the adhesive pad's side
edges and acts as a shock absorber.
[0100] In some embodiments, the surface area of the adhesive pad 8
is greater than the surface area of the mounting unit's back
surface. Alternatively, the adhesive pad can be sized with
substantially the same surface area as the back surface of the base
portion. Preferably, the adhesive pad has a surface area on the
side to be mounted on the host's skin that is greater than about 1,
1.25, 1.5, 1.75, 2, 2.25, or 2.5, times the surface area of the
back surface 25 of the mounting unit base 24. Such a greater
surface area can increase adhesion between the mounting unit and
the host's skin, minimize movement between the mounting unit and
the host's skin, and/or protect the wound exit-site (sensor
insertion site) from environmental and/or biological contamination.
In some alternative embodiments, however, the adhesive pad can be
smaller in surface area than the back surface assuming a sufficient
adhesion can be accomplished.
[0101] In some embodiments, the adhesive pad 8 is substantially the
same shape as the back surface 25 of the base 24, although other
shapes can also be advantageously employed, for example,
butterfly-shaped, round, square, or rectangular. The adhesive pad
backing can be designed for two-step release, for example, a
primary release wherein only a portion of the adhesive pad is
initially exposed to allow adjustable positioning of the device,
and a secondary release wherein the remaining adhesive pad is later
exposed to firmly and securely adhere the device to the host's skin
once appropriately positioned. The adhesive pad is preferably
waterproof. Preferably, a stretch-release adhesive pad is provided
on the back surface of the base portion to enable easy release from
the host's skin at the end of the useable life of the sensor, as is
described in more detail with reference to FIGS. 9A to 9C.
[0102] In some circumstances, it has been found that a conventional
bond between the adhesive pad and the mounting unit may not be
sufficient, for example, due to humidity that can cause release of
the adhesive pad from the mounting unit. Accordingly, in some
embodiments, the adhesive pad can be bonded using a bonding agent
activated by or accelerated by an ultraviolet, acoustic, radio
frequency, or humidity cure. In some embodiments, a eutectic bond
of first and second composite materials can form a strong adhesion.
In some embodiments, the surface of the mounting unit can be
pretreated utilizing ozone, plasma, chemicals, or the like, in
order to enhance the bondability of the surface.
[0103] A bioactive agent is preferably applied locally at the
insertion site prior to or during sensor insertion. Suitable
bioactive agents include those which are known to discourage or
prevent bacterial growth and infection, for example,
anti-inflammatory agents, antimicrobials, antibiotics, or the like.
It is believed that the diffusion or presence of a bioactive agent
can aid in prevention or elimination of bacteria adjacent to the
exit-site. Additionally or alternatively, the bioactive agent can
be integral with or coated on the adhesive pad, or no bioactive
agent at all is employed
[0104] FIG. 4 is an exploded perspective view of the contact
subassembly 26 in one embodiment, showing its individual
components. Preferably, a watertight (waterproof or
water-resistant) sealing member 36, also referred to as a sealing
material, fits within a contact holder 34 and provides a watertight
seal configured to surround the electrical connection at the
electrode terminals within the mounting unit in order to protect
the electrodes (and the respective operable connection with the
contacts of the electronics unit 16) from damage due to moisture,
humidity, dirt, and other external environmental factors. In one
embodiment, the sealing member 36 is formed from an elastomeric
material, such as silicone; however, a variety of other elastomeric
or sealing materials can also be used. In alternative embodiments,
the seal is designed to form an interference fit with the
electronics unit and can be formed from a variety of materials, for
example, flexible plastics or noble metals. One of ordinary skill
in the art appreciates that a variety of designs can be employed to
provide a seal surrounding the electrical contacts described
herein. For example, the contact holder 34 can be integrally
designed as a part of the mounting unit, rather than as a separate
piece thereof. Additionally or alternatively, a sealant can be
provided in or around the sensor (e.g., within or on the contact
subassembly or sealing member), such as is described in more detail
with reference to FIGS. 11A and 11B.
[0105] In the illustrated embodiment, the sealing member 36 is
formed with a raised portion 37 surrounding the contacts 28. The
raised portion 37 enhances the interference fit surrounding the
contacts 28 when the electronics unit 16 is mated to the mounting
unit 14. Namely, the raised portion surrounds each contact and
presses against the electronics unit 16 to form a tight seal around
the electronics unit.
[0106] Contacts 28 fit within the seal 36 and provide for
electrical connection between the sensor 32 and the electronics
unit 16. In general, the contacts are designed to ensure a stable
mechanical and electrical connection of the electrodes that form
the sensor 32 (see FIG. 5A to 5C) to mutually engaging contacts 28
thereon. A stable connection can be provided using a variety of
known methods, for example, domed metallic contacts, cantilevered
fingers, pogo pins, or the like, as is appreciated by one skilled
in the art.
[0107] In preferred embodiments, the contacts 28 are formed from a
conductive elastomeric material, such as a carbon black elastomer,
through which the sensor 32 extends (see FIGS. 10B and 11B).
Conductive elastomers are advantageously employed because their
resilient properties create a natural compression against mutually
engaging contacts, forming a secure press fit therewith. In some
embodiments, conductive elastomers can be molded in such a way that
pressing the elastomer against the adjacent contact performs a
wiping action on the surface of the contact, thereby creating a
cleaning action during initial connection. Additionally, in
preferred embodiments, the sensor 32 extends through the contacts
28 wherein the sensor is electrically and mechanically secure by
the relaxation of elastomer around the sensor (see FIGS. 7A to
7D).
[0108] In an alternative embodiment, a conductive, stiff plastic
forms the contacts, which are shaped to comply upon application of
pressure (for example, a leaf-spring shape). Contacts of such a
configuration can be used instead of a metallic spring, for
example, and advantageously avoid the need for crimping or
soldering through compliant materials; additionally, a wiping
action can be incorporated into the design to remove contaminants
from the surfaces during connection. Non-metallic contacts can be
advantageous because of their seamless manufacturability,
robustness to thermal compression, non-corrosive surfaces, and
native resistance to electrostatic discharge (ESD) damage due to
their higher-than-metal resistance.
Sensor
[0109] Preferably, the sensor 32 includes a distal portion 42, also
referred to as the in vivo portion, adapted to extend out of the
mounting unit for insertion under the host's skin, and a proximal
portion 40, also referred to as an ex vivo portion, adapted to
remain above the host's skin after sensor insertion and to operably
connect to the electronics unit 16 via contacts 28. Preferably, the
sensor 32 includes two or more electrodes: a working electrode 44
and at least one additional electrode, which can function as a
counter electrode and/or reference electrode, hereinafter referred
to as the reference electrode 46. A membrane system is preferably
deposited over the electrodes, such as described in more detail
with reference to FIGS. 5A to 5C, below.
[0110] FIG. 5A is an expanded cutaway view of a proximal portion 40
of the sensor in one embodiment, showing working and reference
electrodes. In the illustrated embodiments, the working and
reference electrodes 44, 46 extend through the contacts 28 to form
electrical connection therewith (see FIGS. 10B and 11B). Namely,
the working electrode 44 is in electrical contact with one of the
contacts 28 and the reference electrode 46 is in electrical contact
with the other contact 28, which in turn provides for electrical
connection with the electronics unit 16 when it is mated with the
mounting unit 14. Mutually engaging electrical contacts permit
operable connection of the sensor 32 to the electronics unit 16
when connected to the mounting unit 14, however other methods of
electrically connecting the electronics unit 16 to the sensor 32
are also possible. In some alternative embodiments, for example,
the reference electrode can be configured to extend from the sensor
and connect to a contact at another location on the mounting unit
(e.g., non-coaxially). Detachable connection between the mounting
unit 14 and electronics unit 16 provides improved
manufacturability, namely, the relatively inexpensive mounting unit
14 can be disposed of when replacing the sensor system after its
usable life, while the relatively more expensive electronics unit
16 can be reused with multiple sensor systems.
[0111] In alternative embodiments, the contacts 28 are formed into
a variety of alternative shapes and/or sizes. For example, the
contacts 28 can be discs, spheres, cuboids, and the like.
Furthermore, the contacts 28 can be designed to extend from the
mounting unit in a manner that causes an interference fit within a
mating cavity or groove of the electronics unit, forming a stable
mechanical and electrical connection therewith.
[0112] FIG. 5B is an expanded cutaway view of a distal portion of
the sensor in one embodiment, showing working and reference
electrodes. In preferred embodiments, the sensor is formed from a
working electrode 44 and a reference electrode 46 helically wound
around the working electrode 44. An insulator 45 is disposed
between the working and reference electrodes to provide necessary
electrical insulation there between. Certain portions of the
electrodes are exposed to enable electrochemical reaction thereon,
for example, a window 43 can be formed in the insulator to expose a
portion of the working electrode 44 for electrochemical
reaction.
[0113] In preferred embodiments, each electrode is formed from a
fine wire with a diameter of from about 0.001 or less to about
0.010 inches or more, for example, and is formed from, e.g., a
plated insulator, a plated wire, or bulk electrically conductive
material. Although the illustrated electrode configuration and
associated text describe one preferred method of forming a
transcutaneous sensor, a variety of known transcutaneous sensor
configurations can be employed with the transcutaneous analyte
sensor system of the preferred embodiments, such as are described
in U.S. Pat. No. 6,695,860 to Ward et al., U.S. Pat. No. 6,565,509
to Say et al., U.S. Pat. No. 6,248,067 to Causey III, et al., and
U.S. Pat. No. 6,514,718 to Heller et al.
[0114] In preferred embodiments, the working electrode comprises a
wire formed from a conductive material, such as platinum,
platinum-iridium, palladium, graphite, gold, carbon, conductive
polymer, alloys, or the like. Although the electrodes can by formed
by a variety of manufacturing techniques (bulk metal processing,
deposition of metal onto a substrate, or the like), it can be
advantageous to form the electrodes from plated wire (e.g.,
platinum on steel wire) or bulk metal (e.g., platinum wire). It is
believed that electrodes formed from bulk metal wire provide
superior performance (e.g., in contrast to deposited electrodes),
including increased stability of assay, simplified
manufacturability, resistance to contamination (e.g., which can be
introduced in deposition processes), and improved surface reaction
(e.g., due to purity of material) without peeling or
delamination.
[0115] The working electrode 44 is configured to measure the
concentration of an analyte. In an enzymatic electrochemical sensor
for detecting glucose, for example, the working electrode measures
the hydrogen peroxide produced by an enzyme catalyzed reaction of
the analyte being detected and creates a measurable electronic
current For example, in the detection of glucose wherein glucose
oxidase produces hydrogen peroxide as a byproduct, hydrogen
peroxide reacts with the surface of the working electrode producing
two protons (2H.sup.+), two electrons (2e.sup.-) and one molecule
of oxygen (02), which produces the electronic current being
detected.
[0116] In preferred embodiments, the working electrode 44 is
covered with an insulating material 45, for example, a
non-conductive polymer. Dip-coating, spray-coating,
vapor-deposition, or other coating or deposition techniques can be
used to deposit the insulating material on the working electrode.
In one embodiment, the insulating material comprises parylene,
which can be an advantageous polymer coating for its strength,
lubricity, and electrical insulation properties. Generally,
parylene is produced by vapor deposition and polymerization of
para-xylylene (or its substituted derivatives). However, any
suitable insulating material can be used, for example, fluorinated
polymers, polyethyleneterephthalate, polyurethane, polyimide, other
nonconducting polymers, or the like. Glass or ceramic materials can
also be employed. Other materials suitable for use include surface
energy modified coating systems such as are marketed under the
trade names AMC18, AMC148, AMC141, and AMC321 by Advanced Materials
Components Express of Bellafonte, Pa. In some alternative
embodiments, however, the working electrode may not require a
coating of insulator.
[0117] The reference electrode 46, which can function as a
reference electrode alone, or as a dual reference and counter
electrode, is formed from silver, silver/silver chloride, or the
like. Preferably, the reference electrode 46 is juxtapositioned
and/or twisted with or around the working electrode 44; however
other configurations are also possible. In the illustrated
embodiments, the reference electrode 46 is helically wound around
the working electrode 44. The assembly of wires is then optionally
coated or adhered together with an insulating material, similar to
that described above, so as to provide an insulating
attachment.
[0118] In embodiments wherein an outer insulator is disposed, a
portion of the coated assembly structure can be stripped or
otherwise removed, for example, by hand, excimer lasing, chemical
etching, laser ablation, grit-blasting (e.g., with sodium
bicarbonate or other suitable grit), or the like, to expose the
electroactive surfaces. Alternatively, a portion of the electrode
can be masked prior to depositing the insulator in order to
maintain an exposed electroactive surface area. In one exemplary
embodiment, grit blasting is implemented to expose the
electroactive surfaces, preferably utilizing a grit material that
is sufficiently hard to ablate the polymer material, while being
sufficiently soft so as to minimize or avoid damage to the
underlying metal electrode (e.g., a platinum electrode). Although a
variety of "grit" materials can be used (e.g., sand, talc, walnut
shell, ground plastic, sea salt, and the like), in some preferred
embodiments, sodium bicarbonate is an advantageous grit-material
because it is sufficiently hard to ablate, e.g., a parylene coating
without damaging, e.g., an underlying platinum conductor. One
additional advantage of sodium bicarbonate blasting includes its
polishing action on the metal as it strips the polymer layer,
thereby eliminating a cleaning step that might otherwise be
necessary.
[0119] In the embodiment illustrated in FIG. 5B, a radial window 43
is formed through the insulating material 45 to expose a
circumferential electroactive surface of the working electrode.
Additionally, sections 41 of electroactive surface of the reference
electrode are exposed. For example, the 41 sections of
electroactive surface can be masked during deposition of an outer
insulating layer or etched after deposition of an outer insulating
layer.
[0120] In some applications, cellular attack or migration of cells
to the sensor can cause reduced sensitivity and/or function of the
device, particularly after the first day of implantation. However,
when the exposed electroactive surface is distributed
circumferentially about the sensor (e.g., as in a radial window),
the available surface area for reaction can be sufficiently
distributed so as to minimize the effect of local cellular invasion
of the sensor on the sensor signal. Alternatively, a tangential
exposed electroactive window can be formed, for example, by
stripping only one side of the coated assembly structure. In other
alternative embodiments, the window can be provided at the tip of
the coated assembly structure such that the electroactive surfaces
are exposed at the tip of the sensor. Other methods and
configurations for exposing electroactive surfaces can also be
employed.
[0121] In some embodiments, the working electrode has a diameter of
from about 0.001 inches or less to about 0.010 inches or more,
preferably from about 0.002 inches to about 0.008 inches, and more
preferably from about 0.004 inches to about 0.005 inches. The
length of the window can be from about 0.1 mm (about 0.004 inches)
or less to about 2 mm (about 0.078 inches) or more, and preferably
from about 0.5 mm (about 0.02 inches) to about 0.75 mm (0.03
inches). In such embodiments, the exposed surface area of the
working electrode is preferably from about 0.000013 in.sup.2
(0.0000839 cm.sup.2) or less to about 0.0025 in.sup.2 (0.016129
cm.sup.2) or more (assuming a diameter of from about 0.001 inches
to about 0.010 inches and a length of from about 0.004 inches to
about 0.078 inches). The preferred exposed surface area of the
working electrode is selected to produce an analyte signal with a
current in the picoAmp range, such as is described in more detail
elsewhere herein. However, a current in the picoAmp range can be
dependent upon a variety of factors, for example the electronic
circuitry design (e.g., sample rate, current draw, A/D converter
bit resolution, etc.), the membrane system (e.g., permeability of
the analyte through the membrane system), and the exposed surface
area of the working electrode. Accordingly, the exposed
electroactive working electrode surface area can be selected to
have a value greater than or less than the above-described ranges
taking into consideration alterations in the membrane system and/or
electronic circuitry. In preferred embodiments of a glucose sensor,
it can be advantageous to minimize the surface area of the working
electrode while maximizing the diffusivity of glucose in order to
optimize the signal-to-noise ratio while maintaining sensor
performance in both high and low glucose concentration ranges.
[0122] In some alternative embodiments, the exposed surface area of
the working (and/or other) electrode can be increased by altering
the cross-section of the electrode itself. For example, in some
embodiments the cross-section of the working electrode can be
defined by a cross, star, cloverleaf, ribbed, dimpled, ridged,
irregular, or other non-circular configuration; thus, for any
predetermined length of electrode, a specific increased surface
area can be achieved (as compared to the area achieved by a
circular cross-section). Increasing the surface area of the working
electrode can be advantageous in providing an increased signal
responsive to the analyte concentration, which in turn can be
helpful in improving the signal-to-noise ratio, for example.
[0123] In some alternative embodiments, additional electrodes can
be included within the assembly, for example, a three-electrode
system (working, reference, and counter electrodes) and/or an
additional working electrode (e.g., an electrode which can be used
to generate oxygen, which is configured as a baseline subtracting
electrode, or which is configured for measuring additional
analytes). Co-pending U.S. patent application Ser. No. 11/007,635,
filed Dec. 7, 2004 and entitled "SYSTEMS AND METHODS FOR IMPROVING
ELECTROCHEMICAL ANALYTE SENSORS" and U.S. patent application Ser.
No. 11/004,561, filed Dec. 3, 2004 and entitled "CALIBRATION
TECHNIQUES FOR A CONTINUOUS ANALYTE SENSOR" describe some systems
and methods for implementing and using additional working, counter,
and/or reference electrodes. In one implementation wherein the
sensor comprises two working electrodes, the two working electrodes
are juxtapositioned (e.g., extend parallel to each other), around
which the reference electrode is disposed (e.g., helically wound).
In some embodiments wherein two or more working electrodes are
provided, the working electrodes can be formed in a double-,
triple-, quad-, etc. helix configuration along the length of the
sensor (for example, surrounding a reference electrode, insulated
rod, or other support structure.) The resulting electrode system
can be configured with an appropriate membrane system, wherein the
first working electrode is configured to measure a first signal
comprising glucose and baseline and the additional working
electrode is configured to measure a baseline signal consisting of
baseline only (e.g., configured to be substantially similar to the
first working electrode without an enzyme disposed thereon.) In
this way, the baseline signal can be subtracted from the first
signal to produce a glucose-only signal that is substantially not
subject to fluctuations in the baseline and/or interfering species
on the signal.
[0124] Although the preferred embodiments illustrate one electrode
configuration including one bulk metal wire helically wound around
another bulk metal wire, other electrode configurations are also
contemplated. In an alternative embodiment, the working electrode
comprises a tube with a reference electrode disposed or coiled
inside, including an insulator there between. Alternatively, the
reference electrode comprises a tube with a working electrode
disposed or coiled inside, including an insulator there between. In
another alternative embodiment, a polymer (e.g., insulating) rod is
provided, wherein the electrodes are deposited (e.g.,
electro-plated) thereon. In yet another alternative embodiment, a
metallic (e.g., steel) rod is provided, coated with an insulating
material, onto which the working and reference electrodes are
deposited. In yet another alternative embodiment, one or more
working electrodes are helically wound around a reference
electrode.
[0125] Preferably, the electrodes and membrane systems of the
preferred embodiments are coaxially formed, namely, the electrodes
and/or membrane system all share the same central axis. While not
wishing to be bound by theory, it is believed that a coaxial design
of the sensor enables a symmetrical design without a preferred bend
radius. Namely, in contrast to prior art sensors comprising a
substantially planar configuration that can suffer from regular
bending about the plane of the sensor, the coaxial design of the
preferred embodiments do not have a preferred bend radius and
therefore are not subject to regular bending about a particular
plane (which can cause fatigue failures and the like). However,
non-coaxial sensors can be implemented with the sensor system of
the preferred embodiments.
[0126] In addition to the above-described advantages, the coaxial
sensor design of the preferred embodiments enables the diameter of
the connecting end of the sensor (proximal portion) to be
substantially the same as that of the sensing end (distal portion)
such that the needle is able to insert the sensor into the host and
subsequently slide back over the sensor and release the sensor from
the needle, without slots or other complex multi-component
designs.
[0127] In one such alternative embodiment, the two wires of the
sensor are held apart and configured for insertion into the host in
proximal but separate locations. The separation of the working and
reference electrodes in such an embodiment can provide additional
electrochemical stability with simplified manufacture and
electrical connectivity. It is appreciated by one skilled in the
art that a variety of electrode configurations can be implemented
with the preferred embodiments.
Anchoring Mechanism
[0128] It is preferred that the sensor remains substantially
stationary within the tissue of the host, such that migration or
motion of the sensor with respect to the surrounding tissue is
minimized. Migration or motion is believed to cause inflammation at
the sensor implant site due to irritation, and can also cause noise
on the sensor signal due to motion-related artifact, for example.
Therefore, it can be advantageous to provide an anchoring mechanism
that provides support for the sensor's in vivo portion to avoid the
above-mentioned problems. Combining advantageous sensor geometry
with an advantageous anchoring minimizes additional parts and
allows for an optimally small or low profile design of the sensor.
In one embodiment the sensor includes a surface topography, such as
the helical surface topography provided by the reference electrode
surrounding the working electrode. In alternative embodiments, a
surface topography could be provided by a roughened surface, porous
surface (e.g. porous parylene), ridged surface, or the like.
Additionally (or alternatively), the anchoring can be provided by
prongs, spines, barbs, wings, hooks, a bulbous portion (for
example, at the distal end), an S-bend along the sensor, a rough
surface topography, a gradually changing diameter, combinations
thereof, or the like, which can be used alone or in combination
with the helical surface topography to stabilize the sensor within
the subcutaneous tissue.
Variable Stiffness
[0129] As described above, conventional transcutaneous devices are
believed to suffer from motion artifact associated with host
movement when the host is using the device. For example, when a
transcutaneous analyte sensor is inserted into the host, various
movements on the sensor (for example, relative movement within and
between the subcutaneous space, dermis, skin, and external portions
of the sensor) create stresses on the device, which is known to
produce artifacts on the sensor signal. Accordingly, there are
different design considerations (for example, stress
considerations) on various sections of the sensor. For example, the
distal portion 42 of the sensor can benefit in general from greater
flexibility as it encounters greater mechanical stresses caused by
movement of the tissue within the patient and relative movement
between the in vivo and ex vivo portions of the sensor. On the
other hand, the proximal portion 40 of the sensor can benefit in
general from a stiffer, more robust design to ensure structural
integrity and/or reliable electrical connections. Additionally, in
some embodiments wherein a needle is retracted over the proximal
portion 40 of the device (see FIGS. 6 to 8), a stiffer design can
minimize crimping of the sensor and/or ease in retraction of the
needle from the sensor. Thus, by designing greater flexibility into
the in vivo (distal) portion 42, the flexibility is believed to
compensate for patient movement, and noise associated therewith. By
designing greater stiffness into the ex vivo (proximal) portion 40,
column strength (for retraction of the needle over the sensor),
electrical connections, and integrity can be enhanced. In some
alternative embodiments, a stiffer distal end and/or a more
flexible proximal end can be advantageous as described in
co-pending U.S. patent Ser. No. 11/077,759, filed on even date
herewith and entitled "TRANSCUTANEOUS MEDICAL DEVICE WITH VARIABLE
STIFFNESS."
[0130] The preferred embodiments provide a distal portion 42 of the
sensor 32 designed to be more flexible than a proximal portion 40
of the sensor. The variable stiffness of the preferred embodiments
can be provided by variable pitch of any one or more helically
wound wires of the device, variable cross-section of any one or
more wires of the device, and/or variable hardening and/or
softening of any one or more wires of the device, such as is
described in more detail with reference to co-pending U.S. patent
application Ser. No. 11/077,759 described above and entitled
"TRANSCUTANEOUS MEDICAL DEVICE WITH VARIABLE STIFFNESS."
Membrane System
[0131] FIG. 5C is a cross-sectional view through the sensor on line
C-C of FIG. 5B showing the exposed electroactive surface of the
working electrode surrounded by the membrane system in one
embodiment. Preferably, a membrane system is deposited over at
least a portion of the electroactive surfaces of the sensor 32
(working electrode and optionally reference electrode) and provides
protection of the exposed electrode surface from the biological
environment, diffusion resistance (limitation) of the analyte if
needed, a catalyst for enabling an enzymatic reaction, limitation
or blocking of interferants, and/or hydrophilicity at the
electrochemically reactive surfaces of the sensor interface. Some
examples of suitable membrane systems are described in co-pending
U.S. patent application Ser. No. 10/838,912, filed May 3, 2004 and
entitled "IMPLANTABLE ANALYTE SENSOR."
[0132] In general, the membrane system includes a plurality of
domains, for example, an electrode domain 47, an interference
domain 48, an enzyme domain 49 (for example, including glucose
oxidase), and a resistance domain 50, and can include a high oxygen
solubility domain, and/or a bioprotective domain (not shown), such
as is described in more detail in U.S. patent application Ser. No.
10/838,912, and such as is described in more detail below. The
membrane system can be deposited on the exposed electroactive
surfaces using known thin film techniques (for example, spraying,
electro-depositing, dipping, or the like). In one embodiment, one
or more domains are deposited by dipping the sensor into a solution
and drawing out the sensor at a speed that provides the appropriate
domain thickness. However, the membrane system can be disposed over
(or deposited on) the electroactive surfaces using any known method
as will be appreciated by one skilled in the art.
Electrode Domain
[0133] In some embodiments, the membrane system comprises an
optional electrode domain 47. The electrode domain 47 is provided
to ensure that an electrochemical reaction occurs between the
electroactive surfaces of the working electrode and the reference
electrode, and thus the electrode domain 47 is preferably situated
more proximal to the electroactive surfaces than the enzyme domain.
Preferably, the electrode domain 47 includes a semipermeable
coating that maintains a layer of water at the electrochemically
reactive surfaces of the sensor, for example, a humectant in a
binder material can be employed as an electrode domain; this allows
for the full transport of ions in the aqueous environment. The
electrode domain can also assist in stabilizing the operation of
the sensor by overcoming electrode start-up and drifting problems
caused by inadequate electrolyte. The material that forms the
electrode domain can also protect against pH-mediated damage that
can result from the formation of a large pH gradient due to the
electrochemical activity of the electrodes.
[0134] In one embodiment, the electrode domain 47 includes a
flexible, water-swellable, hydrogel film having a "dry film"
thickness of from about 0.05 micron or less to about 20 microns or
more, more preferably from about 0.05, 0.1, 0.15, 0.2, 0.25, 0.3,
0.35, 0.4, 0.45, 0.5, 1, 1.5, 2, 2.5, 3, or 3.5 to about 4, 5, 6,
7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 19.5 microns,
and more preferably from about 2, 2.5 or 3 microns to about 3.5, 4,
4.5, or 5 microns. "Dry film" thickness refers to the thickness of
a cured film cast from a coating formulation by standard coating
techniques.
[0135] In certain embodiments, the electrode domain 47 is formed of
a curable mixture of a urethane polymer and a hydrophilic polymer.
Particularly preferred coatings are formed of a polyurethane
polymer having carboxylate functional groups and non-ionic
hydrophilic polyether segments, wherein the polyurethane polymer is
crosslinked with a water soluble carbodiimide (e.g.,
1-ethyl-3-(3-dimethylaminopropyl)carbodiimide (EDC))) in the
presence of polyvinylpyrrolidone and cured at a moderate
temperature of about 50.degree. C.
[0136] Preferably, the electrode domain 47 is deposited by spray or
dip-coating the electroactive surfaces of the sensor 32. More
preferably, the electrode domain is formed by dip-coating the
electroactive surfaces in an electrode solution and curing the
domain for a time of from about 15 to about 30 minutes at a
temperature of from about 40 to about 55.degree. C. (and can be
accomplished under vacuum (e.g., 20 to 30 mmHg)). In embodiments
wherein dip-coating is used to deposit the electrode domain, a
preferred insertion rate of from about 1 to about 3 inches per
minute, with a preferred dwell time of from about 0.5 to about 2
minutes, and a preferred withdrawal rate of from about 0.25 to
about 2 inches per minute provide a functional coating. However,
values outside of those set forth above can be acceptable or even
desirable in certain embodiments, for example, dependent upon
viscosity and surface tension as is appreciated by one skilled in
the art. In one embodiment, the electroactive surfaces of the
electrode system are dip-coated one time (one layer) and cured at
50.degree. C. under vacuum for 20 minutes.
[0137] Although an independent electrode domain is described
herein, in some embodiments, sufficient hydrophilicity can be
provided in the interference domain and/or enzyme domain (the
domain adjacent to the electroactive surfaces) so as to provide for
the full transport of ions in the aqueous environment (e.g. without
a distinct electrode domain).
Interference Domain
[0138] In some embodiments, an optional interference domain 48 is
provided, which generally includes a polymer domain that restricts
the flow of one or more interferants. In some embodiments, the
interference domain 48 functions as a molecular sieve that allows
analytes and other substances that are to be measured by the
electrodes to pass through, while preventing passage of other
substances, including interferants such as ascorbate and urea (see
U.S. Pat. No. 6,001,067 to Shults). Some known interferants for a
glucose-oxidase based electrochemical sensor include acetaminophen,
ascorbic acid, bilirubin, cholesterol, creatinine, dopamine,
ephedrine, ibuprofen, L-dopa, methyldopa, salicylate, tetracycline,
tolazamide, tolbutamide, triglycerides, and uric acid.
[0139] Several polymer types that can be utilized as a base
material for the interference domain 48 include polyurethanes,
polymers having pendant ionic groups, and polymers having
controlled pore size, for example. In one embodiment, the
interference domain includes a thin, hydrophobic membrane that is
non-swellable and restricts diffusion of low molecular weight
species. The interference domain 48 is permeable to relatively low
molecular weight substances, such as hydrogen peroxide, but
restricts the passage of higher molecular weight substances,
including glucose and ascorbic acid. Other systems and methods for
reducing or eliminating interference species that can be applied to
the membrane system of the preferred embodiments are described in
co-pending U.S. patent application Ser. No. 10/896,312 filed Jul.
21, 2004 and entitled "ELECTRODE SYSTEMS FOR ELECTROCHEMICAL
SENSORS," Ser. No. 10/991,353, filed Nov. 16, 2004 and entitled,
"AFFINITY DOMAIN FOR AN ANALYTE SENSOR," No. Ser. No. 11/007,635,
filed Dec. 7, 2004 and entitled "SYSTEMS AND METHODS FOR IMPROVING
ELECTROCHEMICAL ANALYTE SENSORS" and No. Ser. No. 11/004,561, filed
Dec. 3, 2004 and entitled, "CALIBRATION TECHNIQUES FOR A CONTINUOUS
ANALYTE SENSOR." In some alternative embodiments, a distinct
interference domain is not included.
[0140] In preferred embodiments, the interference domain 48 is
deposited onto the electrode domain (or directly onto the
electroactive surfaces when a distinct electrode domain is not
included) for a domain thickness of from about 0.05 micron or less
to about 20 microns or more, more preferably from about 0.05, 0.1,
0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 1, 1.5, 2, 2.5, 3, or
3.5 to about 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18,
19, or 19.5 microns, and more preferably from about 2, 2.5 or 3
microns to about 3.5, 4, 4.5, or 5 microns. Thicker membranes can
also be useful, but thinner membranes are generally preferred
because they have a lower impact on the rate of diffusion of
hydrogen peroxide from the enzyme membrane to the electrodes.
Unfortunately, the thin thickness of the interference domains
conventionally used can introduce variability in the membrane
system processing. For example, if too much or too little
interference domain is incorporated within a membrane system, the
performance of the membrane can be adversely affected.
Enzyme Domain
[0141] In preferred embodiments, the membrane system further
includes an enzyme domain 49 disposed more distally situated from
the electroactive surfaces than the interference domain 48 (or
electrode domain 47 when a distinct interference is not included).
In some embodiments, the enzyme domain is directly deposited onto
the electroactive surfaces (when neither an electrode or
interference domain is included). In the preferred embodiments, the
enzyme domain 49 provides an enzyme to catalyze the reaction of the
analyte and its co-reactant, as described in more detail below.
Preferably, the enzyme domain includes glucose oxidase, however
other oxidases, for example, galactose oxidase or uricase oxidase,
can also be used.
[0142] For an enzyme-based electrochemical glucose sensor to
perform well, the sensor's response is preferably limited by
neither enzyme activity nor co-reactant concentration. Because
enzymes, including glucose oxidase, are subject to deactivation as
a function of time even in ambient conditions, this behavior is
compensated for in forming the enzyme domain. Preferably, the
enzyme domain 49 is constructed of aqueous dispersions of colloidal
polyurethane polymers including the enzyme. However, in alternative
embodiments the enzyme domain is constructed from an oxygen
enhancing material, for example, silicone or fluorocarbon, in order
to provide a supply of excess oxygen during transient ischemia.
Preferably, the enzyme is immobilized within the domain. See U.S.
patent application Ser. No. 10/896,639 filed on Jul. 21, 2004 and
entitled "Oxygen Enhancing Membrane Systems for Implantable
Device."
[0143] In preferred embodiments, the enzyme domain 49 is deposited
onto the interference domain for a domain thickness of from about
0.05 micron or less to about 20 microns or more, more preferably
from about 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5,
1, 1.5, 2, 2.5, 3, or 3.5 to about 4, 5, 6, 7, 8, 9, 10, 11, 12,
13, 14, 15, 16, 17, 18, 19, or 19.5 microns, and more preferably
from about 2, 2.5 or 3 microns to about 3.5, 4, 4.5, or 5 microns.
However in some embodiments, the enzyme domain is deposited onto
the electrode domain or directly onto the electroactive surfaces.
Preferably, the enzyme domain 49 is deposited by spray or dip
coating. More preferably, the enzyme domain is formed by
dip-coating the electrode domain into an enzyme domain solution and
curing the domain for from about 15 to about 30 minutes at a
temperature of from about 40 to about 55.degree. C. (and can be
accomplished under vacuum (e.g., 20 to 30 mmHg)). In embodiments
wherein dip-coating is used to deposit the enzyme domain at room
temperature, a preferred insertion rate of from about 1 inch per
minute to about 3 inches per minute, with a preferred dwell time of
from about 0.5 minutes to about 2 minutes, and a preferred
withdrawal rate of from about 0.25 inch per minute to about 2
inches per minute provide a functional coating. However, values
outside of those set forth above can be acceptable or even
desirable in certain embodiments, for example, dependent upon
viscosity and surface tension as is appreciated by one skilled in
the art. In one embodiment, the enzyme domain 49 is formed by dip
coating two times (namely, forming two layers) in a coating
solution and curing at 50.degree. C. under vacuum for 20 minutes.
However, in some embodiments, the enzyme domain can be formed by
dip-coating and/or spray-coating one or more layers at a
predetermined concentration of the coating solution, insertion
rate, dwell time, withdrawal rate, and/or desired thickness.
Resistance Domain
[0144] In preferred embodiments, the membrane system includes a
resistance domain 50 disposed more distal from the electroactive
surfaces than the enzyme domain 49. Although the following
description is directed to a resistance domain for a glucose
sensor, the resistance domain can be modified for other analytes
and co-reactants as well.
[0145] There exists a molar excess of glucose relative to the
amount of oxygen in blood; that is, for every free oxygen molecule
in extracellular fluid, there are typically more than 100 glucose
molecules present (see Updike et al., Diabetes Care
5:207-21(1982)). However, an immobilized enzyme-based glucose
sensor employing oxygen as co-reactant is preferably supplied with
oxygen in non-rate-limiting excess in order for the sensor to
respond linearly to changes in glucose concentration, while not
responding to changes in oxygen concentration. Specifically, when a
glucose-monitoring reaction is oxygen limited, linearity is not
achieved above minimal concentrations of glucose. Without a
semipermeable membrane situated over the enzyme domain to control
the flux of glucose and oxygen, a linear response to glucose levels
can be obtained only for glucose concentrations of up to about 40
mg/dL. However, in a clinical setting, a linear response to glucose
levels is desirable up to at least about 400 mg/dL.
[0146] The resistance domain 50 includes a semi permeable membrane
that controls the flux of oxygen and glucose to the underlying
enzyme domain 49, preferably rendering oxygen in a
non-rate-limiting excess. As a result, the upper limit of linearity
of glucose measurement is extended to a much higher value than that
which is achieved without the resistance domain. In one embodiment,
the resistance domain 50 exhibits an oxygen to glucose permeability
ratio of from about 50:1 or less to about 400:1 or more, preferably
about 200:1. As a result, one-dimensional reactant diffusion is
adequate to provide excess oxygen at all reasonable glucose and
oxygen concentrations found in the subcutaneous matrix (See Rhodes
et al., Anal. Chem., 66:1520-1529 (1994)).
[0147] In alternative embodiments, a lower ratio of
oxygen-to-glucose can be sufficient to provide excess oxygen by
using a high oxygen solubility domain (for example, a silicone or
fluorocarbon-based material or domain) to enhance the
supply/transport of oxygen to the enzyme domain 49. If more oxygen
is supplied to the enzyme, then more glucose can also be supplied
to the enzyme without creating an oxygen rate-limiting excess. In
alternative embodiments, the resistance domain is formed from a
silicone composition, such as is described in co-pending U.S.
application Ser. No. 10/695,636 filed Oct. 28, 2003 and entitled,
"SILICONE COMPOSITION FOR BIOCOMPATIBLE MEMBRANE."
[0148] In a preferred embodiment, the resistance domain 50 includes
a polyurethane membrane with both hydrophilic and hydrophobic
regions to control the diffusion of glucose and oxygen to an
analyte sensor, the membrane being fabricated easily and
reproducibly from commercially available materials. A suitable
hydrophobic polymer component is a polyurethane, or
polyetherurethaneurea. Polyurethane is a polymer produced by the
condensation reaction of a diisocyanate and a difunctional
hydroxyl-containing material. A polyurethaneurea is a polymer
produced by the condensation reaction of a diisocyanate and a
difunctional amine-containing material. Preferred diisocyanates
include aliphatic diisocyanates containing from about 4 to about 8
methylene units. Diisocyanates containing cycloaliphatic moieties
can also be useful in the preparation of the polymer and copolymer
components of the membranes of preferred embodiments. The material
that forms the basis of the hydrophobic matrix of the resistance
domain can be any of those known in the art as appropriate for use
as membranes in sensor devices and as having sufficient
permeability to allow relevant compounds to pass through it, for
example, to allow an oxygen molecule to pass through the membrane
from the sample under examination in order to reach the active
enzyme or electrochemical electrodes. Examples of materials which
can be used to make non-polyurethane type membranes include vinyl
polymers, polyethers, polyesters, polyamides, inorganic polymers
such as polysiloxanes and polycarbosiloxanes, natural polymers such
as cellulosic and protein based materials, and mixtures or
combinations thereof.
[0149] In a preferred embodiment, the hydrophilic polymer component
is polyethylene oxide. For example, one useful
hydrophobic-hydrophilic copolymer component is a polyurethane
polymer that includes about 20% hydrophilic polyethylene oxide. The
polyethylene oxide portions of the copolymer are thermodynamically
driven to separate from the hydrophobic portions of the copolymer
and the hydrophobic polymer component. The 20% polyethylene
oxide-based soft segment portion of the copolymer used to form the
final blend affects the water pick-up and subsequent glucose
permeability of the membrane.
[0150] In preferred embodiments, the resistance domain 50 is
deposited onto the enzyme domain 49 to yield a domain thickness of
from about 0.05 micron or less to about 20 microns or more, more
preferably from about 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4,
0.45, 0.5, 1, 1.5, 2, 2.5, 3, or 3.5 to about 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, or 19.5 microns, and more
preferably from about 2, 2.5 or 3 microns to about 3.5, 4, 4.5, or
5 microns. Preferably, the resistance domain is deposited onto the
enzyme domain by spray coating or dip coating. In certain
embodiments, spray coating is the preferred deposition technique.
The spraying process atomizes and mists the solution, and therefore
most or all of the solvent is evaporated prior to the coating
material settling on the underlying domain, thereby minimizing
contact of the solvent with the enzyme. One additional advantage of
spray-coating the resistance domain as described in the preferred
embodiments includes formation of a membrane system that
substantially blocks or resists ascorbate (a known electrochemical
interferant in hydrogen peroxide-measuring glucose sensors). While
not wishing to be bound by theory, it is believed that during the
process of depositing the resistance domain as described in the
preferred embodiments, a structural morphology is formed,
characterized in that ascorbate does not substantially permeate
there through.
[0151] In preferred embodiments, the resistance domain 50 is
deposited on the enzyme domain 49 by spray-coating a solution of
from about 1 wt. % to about 5 wt. % polymer and from about 95 wt. %
to about 99 wt. % solvent. In spraying a solution of resistance
domain material, including a solvent, onto the enzyme domain, it is
desirable to mitigate or substantially reduce any contact with
enzyme of any solvent in the spray solution that can deactivate the
underlying enzyme of the enzyme domain 49. Tetrahydrofuran (THF) is
one solvent that minimally or negligibly affects the enzyme of the
enzyme domain upon spraying. Other solvents can also be suitable
for use, as is appreciated by one skilled in the art.
[0152] Although a variety of spraying or deposition techniques can
be used, spraying the resistance domain material and rotating the
sensor at least one time by 180.degree. can provide adequate
coverage by the resistance domain. Spraying the resistance domain
material and rotating the sensor at least two times by 120 degrees
provides even greater coverage (one layer of 360.degree. coverage),
thereby ensuring resistivity to glucose, such as is described in
more detail above.
[0153] In preferred embodiments, the resistance domain 50 is
spray-coated and subsequently cured for a time of from about 15 to
about 90 minutes at a temperature of from about 40 to about
60.degree. C. (and can be accomplished under vacuum (e.g., 20 to 30
mmHg)). A cure time of up to about 90 minutes or more can be
advantageous to ensure complete drying of the resistance domain.
While not wishing to be bound by theory, it is believed that
complete drying of the resistance domain aids in stabilizing the
sensitivity of the glucose sensor signal. It reduces drifting of
the signal sensitivity over time, and complete drying is believed
to stabilize performance of the glucose sensor signal in lower
oxygen environments.
[0154] In one embodiment, the resistance domain 50 is formed by
spray-coating at least six layers (namely, rotating the sensor
seventeen times by 120.degree. for at least six layers of
360.degree. coverage) and curing at 50.degree. C. under vacuum for
60 minutes. However, the resistance domain can be formed by
dip-coating or spray-coating any layer or plurality of layers,
depending upon the concentration of the solution, insertion rate,
dwell time, withdrawal rate, and/or the desired thickness of the
resulting film.
[0155] Advantageously, sensors with the membrane system of the
preferred embodiments, including an electrode domain 47 and/or
interference domain 48, an enzyme domain 49, and a resistance
domain 50, provide stable signal response to increasing glucose
levels of from about 40 to about 400 mg/dL, and sustained function
(at least 90% signal strength) even at low oxygen levels (for
example, at about 0.6 mg/L 02). While not wishing to be bound by
theory, it is believed that the resistance domain provides
sufficient resistivity, or the enzyme domain provides sufficient
enzyme, such that oxygen limitations are seen at a much lower
concentration of oxygen as compared to prior art sensors.
[0156] In preferred embodiments, a sensor signal with a current in
the picoAmp range is preferred, which is described in more detail
elsewhere herein. However, the ability to produce a signal with a
current in the picoAmp range can be dependent upon a combination of
factors, including the electronic circuitry design (e.g., A/D
converter, bit resolution, and the like), the membrane system
(e.g., permeability of the analyte through the resistance domain,
enzyme concentration, and/or electrolyte availability to the
electrochemical reaction at the electrodes), and the exposed
surface area of the working electrode. For example, the resistance
domain can be designed to be more or less restrictive to the
analyte depending upon to the design of the electronic circuitry,
membrane system, and/or exposed electroactive surface area of the
working electrode.
[0157] Accordingly, in preferred embodiments, the membrane system
is designed with a sensitivity of from about 1 pA/mg/dL to about
100 pA/mg/dL, preferably from about 5 pA/mg/dL to 25 pA/mg/dL, and
more preferably from about 4 to about 7 pA/mg/dL. While not wishing
to be bound by any particular theory, it is believed that membrane
systems designed with a sensitivity in the preferred ranges permit
measurement of the analyte signal in low analyte and/or low oxygen
situations. Namely, conventional analyte sensors have shown reduced
measurement accuracy in low analyte ranges due to lower
availability of the analyte to the sensor and/or have shown
increased signal noise in high analyte ranges due to insufficient
oxygen necessary to react with the amount of analyte being
measured. While not wishing to be bound by theory, it is believed
that the membrane systems of the preferred embodiments, in
combination with the electronic circuitry design and exposed
electrochemical reactive surface area design, support measurement
of the analyte in the picoAmp range, which enables an improved
level of resolution and accuracy in both low and high analyte
ranges not seen in the prior art.
Mutarotase Enzyme
[0158] In some embodiments, mutarotase, an enzyme that converts
.alpha. D-glucose to .beta. D-glucose, is incorporated into the
membrane system. Mutarotase can be incorporated into the enzyme
domain and/or can be incorporated into another domain of the
membrane system. In general, glucose exists in two distinct
isomers, .alpha. and .beta., which are in equilibrium with one
another in solution and in the blood or interstitial fluid. At
equilibrium, a is present at a relative concentration of about
35.5% and .beta. is present in the relative concentration of about
64.5% (see Okuda et. al., Anal Biochem. 1971 September;
43(1):312-5). Glucose oxidase, which is a conventional enzyme used
to react with glucose in glucose sensors, reacts with .beta.
D-glucose and not with .alpha. D-glucose. Since only the .beta.
D-glucose isomer reacts with the glucose oxidase, errant readings
may occur in a glucose sensor responsive to a shift of the
equilibrium between the .alpha. D-glucose and the .beta. D-glucose.
Many compounds, such as calcium, can affect equilibrium shifts of
.alpha. D-glucose and .beta. D-glucose. For example, as disclosed
in U.S. Pat. No. 3,964,974 to Banaugh et al., compounds that exert
a mutarotation accelerating effect on a D-glucose include
histidine, aspartic acid, imidazole, glutamic acid, a hydroxyl
pyridine, and phosphate.
[0159] Accordingly, a shift in .alpha. D-glucose and .beta.
D-glucose equilibrium can cause a glucose sensor based on glucose
oxidase to err high or low. To overcome the risks associated with
errantly high or low sensor readings due to equilibrium shifts, the
sensor of the preferred embodiments can be configured to measure
total glucose in the host, including .alpha. D-glucose and .beta.
D-glucose by the incorporation of the mutarotase enzyme, which
converts .alpha. D-glucose to .beta. D-glucose.
[0160] Although sensors of some embodiments described herein
include an optional interference domain in order to block or reduce
one or more interferants, sensors with the membrane system of the
preferred embodiments, including an electrode domain 47, an enzyme
domain 48, and a resistance domain 49, have been shown to inhibit
ascorbate without an additional interference domain. Namely, the
membrane system of the preferred embodiments, including an
electrode domain 47, an enzyme domain 48, and a resistance domain
49, has been shown to be substantially non-responsive to ascorbate
in physiologically acceptable ranges. While not wishing to be bound
by theory, it is believed that the processing process of spraying
the depositing the resistance domain by spray coating, as described
herein, forms results in a structural morphology that is
substantially resistance resistant to ascorbate.
Interference-Free Membrane Systems
[0161] In general, it is believed that appropriate solvents and/or
deposition methods can be chosen for one or more of the domains of
the membrane system that form one or more transitional domains such
that interferants do not substantially permeate there through.
Thus, sensors can be built without distinct or deposited
interference domains, which are non-responsive to interferants.
While not wishing to be bound by theory, it is believed that a
simplified multilayer membrane system, more robust multilayer
manufacturing process, and reduced variability caused by the
thickness and associated oxygen and glucose sensitivity of the
deposited micron-thin interference domain can be provided.
Additionally, the optional polymer-based interference domain, which
usually inhibits hydrogen peroxide diffusion, is eliminated,
thereby enhancing the amount of hydrogen peroxide that passes
through the membrane system.
Oxygen Conduit
[0162] As described above, certain sensors depend upon an enzyme
within the membrane system through which the host's bodily fluid
passes and in which the analyte (for example, glucose) within the
bodily fluid reacts in the presence of a co-reactant (for example,
oxygen) to generate a product. The product is then measured using
electrochemical methods, and thus the output of an electrode system
functions as a measure of the analyte. For example, when the sensor
is a glucose oxidase based glucose sensor, the species measured at
the working electrode is H.sub.2O.sub.2. An enzyme, glucose
oxidase, catalyzes the conversion of oxygen and glucose to hydrogen
peroxide and gluconate according to the following reaction:
Glucose+O.sub.2.fwdarw.Gluconate+H.sub.2O.sub.2
[0163] Because for each glucose molecule reacted there is a
proportional change in the product, H.sub.2O.sub.2, one can monitor
the change in H.sub.2O.sub.2 to determine glucose concentration.
Oxidation of H.sub.2O.sub.2 by the working electrode is balanced by
reduction of ambient oxygen, enzyme generated H.sub.2O.sub.2 and
other reducible species at a counter electrode, for example. See
Fraser, D. M., "An Introduction to In Vivo Biosensing: Progress and
Problems." In "Biosensors and the Body," D. M. Fraser, ed., 1997,
pp. 1-56 John Wiley and Sons, New York))
[0164] In vivo, glucose concentration is generally about one
hundred times or more that of the oxygen concentration.
Consequently, oxygen is a limiting reactant in the electrochemical
reaction, and when insufficient oxygen is provided to the sensor,
the sensor is unable to accurately measure glucose concentration.
Thus, depressed sensor function or inaccuracy is believed to be a
result of problems in availability of oxygen to the enzyme and/or
electroactive surface(s).
[0165] Accordingly, in an alternative embodiment, an oxygen conduit
(for example, a high oxygen solubility domain formed from silicone
or fluorochemicals) is provided that extends from the ex vivo
portion of the sensor to the in vivo portion of the sensor to
increase oxygen availability to the enzyme. The oxygen conduit can
be formed as a part of the coating (insulating) material or can be
a separate conduit associated with the assembly of wires that forms
the sensor.
Porous Biointerface Materials
[0166] In alternative embodiments, the distal portion 42 includes a
porous material disposed over some portion thereof, which modifies
the host's tissue response to the sensor. In some embodiments, the
porous material surrounding the sensor advantageously enhances and
extends sensor performance and lifetime in the short term by
slowing or reducing cellular migration to the sensor and associated
degradation that would otherwise be caused by cellular invasion if
the sensor were directly exposed to the in vivo environment.
Alternatively, the porous material can provide stabilization of the
sensor via tissue ingrowth into the porous material in the long
term. Suitable porous materials include silicone,
polytetrafluoroethylene, expanded polytetrafluoroethylene,
polyethylene-co-tetrafluoroethylene, polyolefin, polyester,
polycarbonate, biostable polytetrafluoroethylene, homopolymers,
copolymers, terpolymers of polyurethanes, polypropylene (PP),
polyvinylchloride (PVC), polyvinylidene fluoride (PVDF), polyvinyl
alcohol (PVA), polybutylene terephthalate (PBT),
polymethylmethacrylate (PMMA), polyether ether ketone (PEEK),
polyamides, polyurethanes, cellulosic polymers, polysulfones and
block copolymers thereof including, for example, di-block,
tri-block, alternating, random and graft copolymers, as well as
metals, ceramics, cellulose, hydrogel polymers, poly
(2-hydroxyethyl methacrylate, pHEMA), hydroxyethyl methacrylate,
(HEMA), polyacrylonitrile-polyvinyl chloride (PAN-PVC), high
density polyethylene, acrylic copolymers, nylon, polyvinyl
difluoride, polyanhydrides, poly(l-lysine), poly (L-lactic acid),
hydroxyethylmetharcrylate, hydroxyapeptite, alumina, zirconia,
carbon fiber, aluminum, calcium phosphate, titanium, titanium
alloy, nintinol, stainless steel, and CoCr alloy, or the like, such
as are described in co-pending U.S. patent application Ser. No.
10/842,716, filed May 10, 2004 and entitled, "BIOINTERFACE
MEMBRANES INCORPORATING BIOACTIVE AGENTS" and U.S. patent
application Ser. No. 10/647,065 filed Aug. 22, 2003 and entitled
"POROUS MEMBRANES FOR USE WITH IMPLANTABLE DEVICES."
[0167] In some embodiments, the porous material surrounding the
sensor provides unique advantages in the short term (e.g., one to
14 days) that can be used to enhance and extend sensor performance
and lifetime. However, such materials can also provide advantages
in the long term too (e.g., greater than 14 days). Particularly,
the in vivo portion of the sensor (the portion of the sensor that
is implanted into the host's tissue) is encased (partially or
fully) in a porous material. The porous material can be wrapped
around the sensor (for example, by wrapping the porous material
around the sensor or by inserting the sensor into a section of
porous material sized to receive the sensor). Alternately, the
porous material can be deposited on the sensor (for example, by
electrospinning of a polymer directly thereon). In yet other
alternative embodiments, the sensor is inserted into a selected
section of porous biomaterial. Other methods for surrounding the in
vivo portion of the sensor with a porous material can also be used
as is appreciated by one skilled in the art.
[0168] The porous material surrounding the sensor advantageously
slows or reduces cellular migration to the sensor and associated
degradation that would otherwise be caused by cellular invasion if
the sensor were directly exposed to the in vivo environment.
Namely, the porous material provides a barrier that makes the
migration of cells towards the sensor more tortuous and therefore
slower (providing short term advantages). It is believed that this
reduces or slows the sensitivity loss normally observed in a
short-term sensor over time.
[0169] In an embodiment wherein the porous material is a high
oxygen solubility material, such as porous silicone, the high
oxygen solubility porous material surrounds some of or the entire
in vivo portion 42 of the sensor. High oxygen solubility materials
are materials that dynamically retain a high availability of oxygen
that can be used to compensate for the local oxygen deficit during
times of transient ischemia (e.g., silicone and fluorocarbons). It
is believed that some signal noise normally seen by a conventional
sensor can be attributed to an oxygen deficit. In one exemplary
embodiment, porous silicone surrounds the sensor and thereby
effectively increases the concentration of oxygen local (proximal)
to the sensor. Thus, an increase in oxygen availability proximal to
the sensor as achieved by this embodiment ensures that an excess of
oxygen over glucose is provided to the sensor; thereby reducing the
likelihood of oxygen limited reactions therein. Accordingly, by
providing a high oxygen solubility material (e.g., porous silicone)
surrounding the in vivo portion of the sensor, it is believed that
increased oxygen availability, reduced signal noise, longevity, and
ultimately enhanced sensor performance can be achieved.
Bioactive Agents
[0170] In some alternative embodiments, a bioactive agent is
incorporated into the above described porous material and/or
membrane system, such as is described in co-pending U.S. patent
application Ser. No. 10/842,716, which diffuses out into the
environment adjacent to the sensing region. Additionally or
alternately, a bioactive agent can be administered locally at the
exit-site or implantation-site. Suitable bioactive agents are those
that modify the host's tissue response to the sensor, for example
anti-inflammatory agents, anti-infective agents, anesthetics,
inflammatory agents, growth factors, immunosuppressive agents,
antiplatelet agents, anti-coagulants, anti-proliferates, ACE
inhibitors, cytotoxic agents, anti-barrier cell compounds,
vascularization-inducing compounds, anti-sense molecules, or
mixtures thereof, such as are described in more detail in
co-pending U.S. patent application Ser. No. 10/842,716.
[0171] In embodiments wherein the porous material is designed to
enhance short-term (e.g., between about 1 and 14 days) lifetime or
performance of the sensor, a suitable bioactive agent can be chosen
to ensure that tissue ingrowth does not substantially occur within
the pores of the porous material. Namely, by providing a tissue
modifying bioactive agent, such as an anti-inflammatory agent (for
example, Dexamethasone), substantially tissue ingrowth can be
inhibited, at least in the short term, in order to maintain
sufficient glucose transport through the pores of the porous
material to maintain a stable sensitivity.
[0172] In embodiments wherein the porous material is designed to
enhance long-term (e.g., between about a day to a year or more)
lifetime or performance of the sensor, a suitable bioactive agent,
such as a vascularization-inducing compound or anti-barrier cell
compound, can be chosen to encourage tissue ingrowth without
barrier cell formation.
[0173] In some alternative embodiments, the in vivo portion of the
sensor is designed with porosity there through, for example, a
design wherein the sensor wires are configured in a mesh, loose
helix configuration (namely, with spaces between the wires), or
with micro-fabricated holes there through. Porosity within the
sensor modifies the host's tissue response to the sensor, because
tissue ingrowth into and/or through the in vivo portion of the
sensor increases stability of the sensor and/or improves host
acceptance of the sensor, thereby extending the lifetime of the
sensor in vivo.
[0174] In some alternative embodiments, the sensor is manufactured
partially or wholly using a continuous reel-to-reel process,
wherein one or more manufacturing steps are automated. In such
embodiments, a manufacturing process can be provided substantially
without the need for manual mounting and fixturing steps and
substantially without the need human interaction. A process can be
utilized wherein a plurality of sensors of the preferred
embodiments, including the electrodes, insulator, and membrane
system, are continuously manufactured in a semi-automated or
automated process.
[0175] In one embodiment, a plurality of twisted pairs are
continuously formed into a coil, wherein a working electrode is
coated with an insulator material around which a plurality of
reference electrodes are wound. The plurality of twisted pairs are
preferably indexed and subsequently moved from one station to the
next whereby the membrane system is serially deposited according to
the preferred embodiments. Preferably, the coil is continuous and
remains as such during the entire sensor fabrication process,
including winding of the electrodes, insulator application, and
membrane coating processes. After drying of the membrane system,
each individual sensor is cut from the continuous coil.
[0176] A continuous reel-to-reel process for manufacturing the
sensor eliminates possible sensor damage due to handling by
eliminating handling steps, and provides faster manufacturing due
to faster trouble shooting by isolation when a product fails.
Additionally, a process run can be facilitated because of
elimination of steps that would otherwise be required (e.g., steps
in a manual manufacturing process.) Finally, increased or improved
product consistency due to consistent processes within a controlled
environment can be achieved in a machine or robot driven
operation.
[0177] In one alternative embodiment, a continuous manufacturing
process is contemplated that utilizes physical vapor deposition in
a vacuum to form the sensor. Physical vapor deposition can be used
to coat one or more insulating layers onto the electrodes, and
further can be used to deposit the membrane system thereon. While
not wishing to be bound by theory, it is believed that by
implementing physical vapor deposition to form some portions or the
entire sensor of the preferred embodiments, simplified
manufacturing, consistent deposition, and overall increased
reproducibility can be achieved.
Applicator
[0178] FIG. 6 is an exploded side view of an applicator, showing
the components that enable sensor and needle insertion. In this
embodiment, the applicator 12 includes an applicator body 18 that
aides in aligning and guiding the applicator components.
Preferably, the applicator body 18 includes an applicator body base
60 that matingly engages the mounting unit 14 and an applicator
body cap 62 that enables appropriate relationships (for example,
stops) between the applicator components.
[0179] The guide tube subassembly 20 includes a guide tube carrier
64 and a guide tube 66. In some embodiments, the guide tube is a
cannula. The guide tube carrier 64 slides along the applicator body
18 and maintains the appropriate relative position of the guide
tube 66 during insertion and subsequent retraction. For example,
prior to and during insertion of the sensor, the guide tube 66
extends through the contact subassembly 26 to maintain an opening
that enables easy insertion of the needle there through (see FIGS.
7A to 7D). During retraction of the sensor, the guide tube
subassembly 20 is pulled back, engaging with and causing the needle
and associated moving components to retract back into the
applicator 12 (See FIGS. 7C and 7D).
[0180] A needle subassembly 68 is provided that includes a needle
carrier 70 and needle 72. The needle carrier 70 cooperates with the
other applicator components and carries the needle 72 between its
extended and retracted positions. The needle can be of any
appropriate size that can encompass the sensor 32 and aid in its
insertion into the host. Preferred sizes include from about 32
gauge or less to about 18 gauge or more, more preferably from about
28 gauge to about 25 gauge, to provide a comfortable insertion for
the host. Referring to the inner diameter of the needle,
approximately 0.006 inches to approximately 0.023 inches is
preferable, and 0.013 inches is most preferable. The needle carrier
70 is configured to engage with the guide tube carrier 64, while
the needle 72 is configured to slidably nest within the guide tube
66, which allows for easy guided insertion (and retraction) of the
needle through the contact subassembly 26.
[0181] A push rod subassembly 74 is provided that includes a push
rod carrier 76 and a push rod 78. The push rod carrier 76
cooperates with other applicator components to ensure that the
sensor is properly inserted into the host's skin, namely the push
rod carrier 76 carries the push rod 78 between its extended and
retracted positions. In this embodiment, the push rod 78 is
configured to slidably nest within the needle 72, which allows for
the sensor 32 to be pushed (released) from the needle 72 upon
retraction of the needle, which is described in more detail with
reference to FIGS. 7A through 7D. In some embodiments, a slight
bend or serpentine shape is designed into or allowed in the sensor
in order to maintain the sensor within the needle by interference.
While not wishing to be bound by theory, it is believed that a
slight friction fit of the sensor within the needle minimizes
motion of the sensor during withdrawal of the needle and maintains
the sensor within the needle prior to withdrawal of the needle.
[0182] A plunger subassembly 22 is provided that includes a plunger
80 and plunger cap 82. The plunger subassembly 22 cooperates with
other applicators components to ensure proper insertion and
subsequent retraction of the applicator components. In this
embodiment, the plunger 80 is configured to engage with the push
rod to ensure the sensor remains extended (namely, in the host)
during retraction, such as is described in more detail with
reference to FIG. 7C.
Sensor Insertion
[0183] FIGS. 7A through 7D are schematic side cross-sectional views
that illustrate the applicator components and their cooperating
relationships at various stages of sensor insertion. FIG. 7A
illustrates the needle and sensor loaded prior to sensor insertion.
FIG. 7B illustrates the needle and sensor after sensor insertion.
FIG. 7C illustrates the sensor and needle during needle retraction.
FIG. 7D illustrates the sensor remaining within the contact
subassembly after needle retraction. Although the embodiments
described herein suggest manual insertion and/or retraction of the
various components, automation of one or more of the stages can
also be employed. For example, spring-loaded mechanisms that can be
triggered to automatically insert and/or retract the sensor,
needle, or other cooperative applicator components can be
implemented.
[0184] Referring to FIG. 7A, the sensor 32 is shown disposed within
the needle 72, which is disposed within the guide tube 66. In this
embodiment, the guide tube 66 is provided to maintain an opening
within the contact subassembly 26 and/or contacts 28 to provide
minimal friction between the needle 72 and the contact subassembly
26 and/or contacts 28 during insertion and retraction of the needle
72. However, the guide tube is an optional component, which can be
advantageous in some embodiments wherein the contact subassembly 26
and/or the contacts 28 are formed from an elastomer or other
material with a relatively high friction coefficient, and which can
be omitted in other embodiments wherein the contact subassembly 26
and or the contacts 28 are formed from a material with a relatively
low friction coefficient (for example, hard plastic or metal). A
guide tube, or the like, can be preferred in embodiments wherein
the contact subassembly 26 and/or the contacts 28 are formed from a
material designed to frictionally hold the sensor 32 (see FIG. 7D),
for example, by the relaxing characteristics of an elastomer, or
the like. In these embodiments, the guide tube is provided to ease
insertion of the needle through the contacts, while allowing for a
frictional hold of the contacts on the sensor 32 upon subsequent
needle retraction. Stabilization of the sensor in or on the
contacts 28 is described in more detail with reference to FIG. 7D
and following. Although FIG. 7A illustrates the needle and sensor
inserted into the contacts subassembly as the initial loaded
configuration, alternative embodiments contemplate a step of
loading the needle through the guide tube 66 and/or contacts 28
prior to sensor insertion.
[0185] Referring to FIG. 7B, the sensor 32 and needle 72 are shown
in an extended position. In this stage, the pushrod 78 has been
forced to a forward position, for example by pushing on the plunger
shown in FIG. 6, or the like. The plunger 22 (FIG. 6) is designed
to cooperate with other of the applicator components to ensure that
sensor 32 and the needle 72 extend together to a forward position
(as shown); namely, the push rod 78 is designed to cooperate with
other of the applicator components to ensure that the sensor 32
maintains the forward position simultaneously within the needle
72.
[0186] Referring to FIG. 7C, the needle 72 is shown during the
retraction process. In this stage, the push rod 78 is held in its
extended (forward) position in order to maintain the sensor 32 in
its extended (forward) position until the needle 72 has
substantially fully retracted from the contacts 28. Simultaneously,
the cooperating applicator components retract the needle 72 and
guide tube 66 backward by a pulling motion (manual or automated)
thereon. In preferred embodiments, the guide tube carrier 64 (FIG.
6) engages with cooperating applicator components such that a
backward (retraction) motion applied to the guide tube carrier
retracts the needle 72 and guide tube 66, without (initially)
retracting the push rod 78. In an alternative embodiment, the push
rod 78 can be omitted and the sensor 32 held it its forward
position by a cam, elastomer, or the like, which is in contact with
a portion of the sensor while the needle moves over another portion
of the sensor. One or more slots can be cut in the needle to
maintain contact with the sensor during needle retraction.
[0187] Referring to FIG. 7D, the needle 72, guide tube 66, and push
rod 78 are all retracted from contact subassembly 26, leaving the
sensor 32 disposed therein. The cooperating applicator components
are designed such that when the needle 72 has substantially cleared
from the contacts 28 and/or contact subassembly 26, the push rod 78
is retracted along with the needle 72 and guide tube 66. The
applicator 12 can then be released (manually or automatically) from
the contacts 28, such as is described in more detail elsewhere
herein, for example with reference to FIGS. 8C and 9A.
[0188] The preferred embodiments are generally designed with
elastomeric contacts to ensure a retention force that retains the
sensor 32 within the mounting unit 14 and to ensure stable
electrical connection of the sensor 32 and its associated contacts
28. Although the illustrated embodiments and associated text
describe the sensor 32 extending through the contacts 28 to form a
friction fit therein, a variety of alternatives are contemplated.
In one alternative embodiment, the sensor is configured to be
disposed adjacent to the contacts (rather than between the
contacts). The contacts can be constructed in a variety of known
configurations, for example, metallic contacts, cantilevered
fingers, pogo pins, or the like, which are configured to press
against the sensor after needle retraction.
[0189] The illustrated embodiments are designed with coaxial
contacts 28; namely, the contacts 28 are configured to contact the
working and reference electrodes 44, 46 axially along the distal
portion 42 of the sensor 32 (see FIG. 5A). As shown in FIG. 5A, the
working electrode 44 extends farther than the reference electrode
46, which allows coaxial connection of the electrodes 44, 46 with
the contacts 28 at locations spaced along the distal portion of the
sensor (see also FIGS. 9B and 10B). Although the illustrated
embodiments employ a coaxial design, other designs are contemplated
within the scope of the preferred embodiments. For example, the
reference electrode can be positioned substantially adjacent to
(but spaced apart from) the working electrode at the distal portion
of the sensor. In this way, the contacts 28 can be designed
side-by-side rather than co-axially along the axis of the
sensor.
[0190] FIGS. 8A to 8C are side views of an applicator and mounting,
showing various stages of sensor insertion. FIG. 8A is a side view
of the applicator matingly engaged to the mounting unit prior to
sensor insertion. FIG. 8B is a side view of the mounting unit and
applicator after the plunger subassembly has been pushed, extending
the needle and sensor from the mounting unit (namely, through the
host's skin). FIG. 8C is a side view of the mounting unit and
applicator after the guide tube subassembly has been retracted,
retracting the needle back into the applicator. Although the
drawings and associated text illustrate and describe embodiments
wherein the applicator is designed for manual insertion and/or
retraction, automated insertion and/or retraction of the
sensor/needle, for example, using spring-loaded components, can
alternatively be employed.
[0191] The preferred embodiments advantageously provide a system
and method for easy insertion of the sensor and subsequent
retraction of the needle in a single push-pull motion. Because of
the mechanical latching system of the applicator, the user provides
a continuous force on the plunger cap 82 and guide tube carrier 64
that inserts and retracts the needle in a continuous motion. When a
user grips the applicator, his or her fingers grasp the guide tube
carrier 64 while his or her thumb (or another finger) is positioned
on the plunger cap 82. The user squeezes his or her fingers and
thumb together continuously, which causes the needle to insert (as
the plunger slides forward) and subsequently retract (as the guide
tube carrier slides backward) due to the system of latches located
within the applicator (FIGS. 6 to 8) without any necessary change
of grip or force, leaving the sensor implanted in the host. In some
embodiments, a continuous torque, when the applicator components
are configured to rotatingly engage one another, can replace the
continuous force. Some prior art sensors, in contrast to the
sensors of the preferred embodiments, suffer from complex,
multi-step, or multi-component insertion and retraction steps to
insert and remove the needle from the sensor system.
[0192] FIG. 8A shows the mounting unit and applicator in the ready
position. The sensor system can be shipped in this configuration,
or the user can be instructed to mate the applicator 12 with the
mounting unit 14 prior to sensor insertion. The insertion angle
.alpha. is preferably fixed by the mating engagement of the
applicator 12. In the illustrated embodiment, the insertion angle
.alpha. is fixed in the applicator 12 by the angle of the
applicator body base 60 with the shaft of the applicator body 18.
However, a variety of systems and methods of ensuring proper
placement can be implemented. Proper placement ensures that at
least a portion of the sensor 32 extends below the dermis of the
host upon insertion. In alternative embodiments, the sensor system
10 is designed with a variety of adjustable insertion angles. A
variety of insertion angles can be advantageous to accommodate a
variety of insertion locations and/or individual dermis
configurations (for example, thickness of the dermis). In preferred
embodiments, the insertion angle .alpha. is from about 0 to about
90 degrees, more preferably from about 30 to about 60 degrees, and
even more preferably about 45 degrees.
[0193] In practice, the mounting unit is placed at an appropriate
location on the host's skin, for example, the skin of the arm,
thigh, or abdomen. Thus, removing the backing layer 9 from the
adhesive pad 8 and pressing the base portion of the mounting unit
on the skin adheres the mounting unit to the host's skin.
[0194] FIG. 8B shows the mounting unit and applicator after the
needle 72 has been extended from the mounting unit 14 (namely,
inserted into the host) by pushing the push rod subassembly 22 into
the applicator 12. In this position, the sensor 32 is disposed
within the needle 72 (namely, in position within the host), and
held by the cooperating applicator components. In alternative
embodiments, the mounting unit and/or applicator can be configured
with the needle/sensor initially extended. In this way, the
mechanical design can be simplified and the plunger-assisted
insertion step can be eliminated or modified. The needle can be
simply inserted by a manual force to puncture the host's skin, and
only one (pulling) step is required on the applicator, which
removes the needle from the host's skin.
[0195] FIG. 8C shows the mounting unit and applicator after the
needle 72 has been retracted into the applicator 12, exposing the
sensor 32 to the host's tissue. During needle retraction, the push
rod subassembly maintains the sensor in its extended position
(namely, within the host). In preferred embodiments, retraction of
the needle irreversibly locks the needle within the applicator so
that it cannot be accidentally and/or intentionally released,
reinserted, or reused. The applicator is preferably configured as a
disposable device to reduce or eliminate a possibility of exposure
of the needle after insertion into the host. However a reusable or
reloadable applicator is also contemplated in some alternative
embodiments. After needle retraction, the applicator 12 can be
released from the mounting unit, for example, by pressing the
release latch(es) 30, and the applicator disposed of appropriately.
In alternative embodiments, other mating and release configurations
can be implemented between the mounting unit and the applicator, or
the applicator can automatically release from the mounting unit
after sensor insertion and subsequent needle retraction. In one
alternative embodiment, a retention hold (e.g., ball and detent
configuration) holds and releases the electronics unit (or
applicator).
[0196] In one alternative embodiment, the mounting unit is
configured to releasably mate with the applicator and electronics
unit, such that when the applicator is releasably mated to the
mounting unit (e.g., after sensor insertion), the electronics unit
is configured to slide into the mounting unit, thereby triggering
release of the applicator and simultaneous mating of the
electronics unit to the mounting unit. Cooperating mechanical
components, for example, sliding ball and detent type
configurations, can be used to accomplish the simultaneous mating
of electronics unit and release of the applicator.
[0197] In some embodiments, the sensor 32 exits the base of the
mounting unit 14 at a location distant from an edge of the base. In
some embodiments, the sensor 32 exits the base of the mounting unit
14 at a location substantially closer to the center than the edges
thereof. While not wishing to be bound by theory, it is believed
that by providing an exit port for the sensor 32 located away from
the edges, the sensor 32 can be protected from motion between the
body and the mounting unit, snagging of the sensor by an external
source, and/or environmental contaminants that can migrate under
the edges of the mounting unit. In some embodiments, the sensor
exits the mounting unit away from an outer edge of the device. In
some alternative embodiments, however, the sensor exits the
mounting unit 14 at an edge or near an edge of the device. In some
embodiments, the mounting unit is configured such that the exit
port (location) of the sensor is adjustable; thus, in embodiments
wherein the depth of the sensor insertion is adjustable,
six-degrees of freedom can thereby be provided.
Extensible Adhesive Pad
[0198] In certain embodiments, an adhesive pad is used with the
sensor system. A variety of design parameters are desirable when
choosing an adhesive pad for the mounting unit. For example: 1) the
adhesive pad can be strong enough to maintain full contact at all
times and during all movements (devices that release even slightly
from the skin have a greater risk of contamination and infection),
2) the adhesive pad can be waterproof or water permeable such that
the host can wear the device even while heavily perspiring,
showering, or even swimming in some cases, 3) the adhesive pad can
be flexible enough to withstand linear and rotational forces due to
host movements, 4) the adhesive pad can be comfortable for the
host, 5) the adhesive pad can be easily releasable to minimize host
pain, 6) and/or the adhesive pad can be easily releasable so as to
protect the sensor during release. Unfortunately, these design
parameters are difficult to simultaneously satisfy using known
adhesive pads, for example, strong medical adhesive pads are
available but are usually non-precise (for example, requiring
significant "ripping" force during release) and can be painful
during release due to the strength of their adhesion.
[0199] Therefore, the preferred embodiments provide an adhesive pad
8' for mounting the mounting unit onto the host, including a
sufficiently strong medical adhesive pad that satisfies one or more
strength and flexibility requirements described above, and further
provides a for easy, precise and pain-free release from the host's
skin. FIG. 9A is a side view of the sensor assembly, illustrating
the sensor implanted into the host with mounting unit adhered to
the host's skin via an adhesive pad in one embodiment. Namely, the
adhesive pad 8' is formed from an extensible material that can be
removed easily from the host's skin by stretching it lengthwise in
a direction substantially parallel to (or up to about 35 degrees
from) the plane of the skin. It is believed that this easy,
precise, and painless removal is a function of both the high
extensibility and easy stretchability of the adhesive pad.
[0200] In one embodiment, the extensible adhesive pad includes a
polymeric foam layer or is formed from adhesive pad foam. It is
believed that the conformability and resiliency of foam aids in
conformation to the skin and flexibility during movement of the
skin. In another embodiment, a stretchable solid adhesive pad, such
as a rubber-based or an acrylate-based solid adhesive pad can be
used. In another embodiment, the adhesive pad comprises a film,
which can aid in increasing load bearing strength and rupture
strength of the adhesive pad
[0201] FIGS. 9B to 9C illustrate initial and continued release of
the mounting unit from the host's skin by stretching the extensible
adhesive pad in one embodiment. To release the device, the backing
adhesive pad is pulled in a direction substantially parallel to (or
up to about 35 degrees from) the plane of the device.
Simultaneously, the extensible adhesive pad stretches and releases
from the skin in a relatively easy and painless manner.
[0202] In one implementation, the mounting unit is bonded to the
host's skin via a single layer of extensible adhesive pad 8', which
is illustrated in FIGS. 9A to 9C. The extensible adhesive pad
includes a substantially non-extensible pull-tab 52, which can
include a light adhesive pad layer that allows it to be held on the
mounting unit 14 prior to release. Additionally, the adhesive pad
can further include a substantially non-extensible holding tab 54,
which remains attached to the mounting unit during release
stretching to discourage complete and/or uncontrolled release of
the mounting unit from the skin.
[0203] In one alternative implementation, the adhesive pad 8'
includes two-sides, including the extensible adhesive pad and a
backing adhesive pad (not shown). In this embodiment, the backing
adhesive pad is bonded to the mounting unit's back surface 25 while
the extensible adhesive pad 8' is bonded to the host's skin. Both
adhesive pads provide sufficient strength, flexibility, and
waterproof or water permeable characteristics appropriate for their
respective surface adhesion. In some embodiments, the backing and
extensible adhesive pads are particularly designed with an
optimized bond for their respective bonding surfaces (namely, the
mounting unit and the skin).
[0204] In another alternative implementation, the adhesive pad 8'
includes a double-sided extensible adhesive pad surrounding a
middle layer or backing layer (not shown). The backing layer can
comprise a conventional backing film or can be formed from foam to
enhance comfort, conformability, and flexibility. Preferably, each
side of the double-sided adhesive pad is respectively designed for
appropriate bonding surface (namely, the mounting unit and skin). A
variety of alternative stretch-release configurations are possible.
Controlled release of one or both sides of the adhesive pad can be
facilitated by the relative lengths of each adhesive pad side, by
incorporation of a non-adhesive pad zone, or the like.
[0205] FIGS. 10A and 10B are perspective and side cross-sectional
views, respectively, of the mounting unit immediately following
sensor insertion and release of the applicator from the mounting
unit. In one embodiment, such as illustrated in FIGS. 10A and 10B,
the contact subassembly 26 is held in its insertion position,
substantially at the insertion angle .alpha. of the sensor.
Maintaining the contact subassembly 26 at the insertion angle
.alpha. during insertion enables the sensor 32 to be easily
inserted straight through the contact subassembly 26. The contact
subassembly 26 further includes a hinge 38 that allows movement of
the contact subassembly 26 from an angled to a flat position. The
term "hinge," as used herein, is a broad term and is used in its
ordinary sense, including, without limitation, a mechanism that
allows articulation of two or more parts or portions of a device.
The term is broad enough to include a sliding hinge, for example, a
ball and detent type hinging mechanism.
[0206] Although the illustrated embodiments describe a fixed
insertion angle designed into the applicator, alternative
embodiments can design the insertion angle into other components of
the system. For example, the insertion angle can be designed into
the attachment of the applicator with the mounting unit, or the
like. In some alternative embodiments, a variety of adjustable
insertion angles can be designed into the system to provide for a
variety of host dermis configurations.
[0207] FIG. 10B illustrates the sensor 32 extending from the
mounting unit 14 by a preselected distance, which defines the depth
of insertion of the sensor into the host. The dermal and
subcutaneous make-up of animals and humans is variable and a fixed
depth of insertion may not be appropriate for all implantations.
Accordingly, in an alternative embodiment, the distance that the
sensor extends from the mounting unit is adjustable to accommodate
a variety of host body-types. For example, the applicator 12 can be
designed with a variety of adjustable settings, which control the
distance that the needle 72 (and therefore the sensor 32) extends
upon sensor insertion. One skilled in the art appreciates a variety
of means and mechanisms can be employed to accommodate adjustable
sensor insertion depths, which are considered within the scope of
the preferred embodiments. The preferred insertion depth is from
about 0.1 mm or less to about 2 cm or more, preferably from about
0.15, 0.2, 0.25, 0.3, 0.35, 0.4, or 0.45 mm to about 0.5, 0.6, 0.7,
0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, or 1.9 cm.
[0208] FIGS. 11A and 11B are perspective and side cross-sectional
views, respectively, of the mounting unit after articulating the
contact subassembly to its functional position (which is also
referred to as an inserted, implanted, or sensing position). The
hinge 38 enables the contact subassembly 26 to tilt from its
insertion position (FIG. 10) to its functional position (FIG. 11)
by pressing downward on the contact subassembly, for example.
Certain embodiments provide this pivotal movement via two separate
pieces (the contact subassembly 26 and the mounting unit 14
connected by a hinge, for example, a mechanical or adhesive pad
joint or hinge. A variety of pivoting, articulating, and/or hinging
mechanisms can be employed with the sensors of preferred
embodiments. For example, the hinge can be formed as a part of the
contact subassembly 26. The contact subassembly can be formed from
a flexible piece of material (such as silicone, urethane rubber, or
other flexible or elastomeric material), wherein the material is
sufficiently flexible to enable bending or hinging of the contact
subassembly from an angle appropriate for insertion (FIGS. 10A and
10B) to a lower functional configuration (FIGS. 11A and 11B).
[0209] The relative pivotal movement of the contact subassembly is
advantageous, for example, for enabling the design of a low profile
device while providing support for an appropriate needle insertion
angle. In its insertion position, the sensor system is designed for
easy sensor insertion while forming a stable electrical connection
with the associated contacts 28. In its functional position, the
sensor system maintains a low profile for convenience, comfort, and
discreetness during use. Thus, the sensor systems of preferred
embodiments are advantageously designed with a hinging
configuration to provide an optimum guided insertion angle while
maintaining a low profile device during sensor use.
[0210] In some embodiments, a shock-absorbing member or feature is
incorporated into the design of the sensor and configured to absorb
movement of the in vivo and/or ex vivo portion of the sensor.
Conventional analyte sensors can suffer from motion-related
artifact associated with host movement when the host is using the
device. For example, when a transcutaneous analyte sensor is
inserted into the host, various movements on the sensor (for
example, relative movement between the in vivo portion and the ex
vivo portion and/or movement within the host) create stresses on
the device and can produce noise in the sensor signal. Accordingly
in some embodiments, a shock-absorbing member is located on the
sensor/mounting unit in a location that absorbs stresses associated
with the above-described movement.
[0211] In the preferred embodiments, the sensor 32 bends from a
substantially straight to substantially bent configuration upon
pivoting of the contact subassembly from the insertion to
functional position. The substantially straight sensor
configuration during insertion advantageously provides ease of
sensor insertion, while the substantial bend in the sensor in its
functional position advantageously provides stability on the
proximal end of the sensor with flexibility/mobility on the distal
end of the sensor. Additionally, motion within the mounting unit
(e.g., caused by external forces to the mounting unit, movement of
the skin, and the like) does not substantially translate to the in
vivo portion of the sensor. Namely, the bend formed within the
sensor 32 functions to break column strength, causing flexion that
effectively absorbs movements on the sensor during use.
Additionally, the sensor can be designed with a length such that
when the contact subassembly 26 is pivoted to its functional
position (FIG. 10B), the sensor pushes forward and flexes, allowing
it to absorb motion between the in vivo and ex vivo portions of the
sensor. It is believed that both of the above advantages minimize
motion artifact on the sensor signal and/or minimize damage to the
sensor caused by movement, both of which (motion artifact and
damage) have been observed in conventional transcutaneous
sensors.
[0212] In some alternative embodiments, the shock-absorbing member
can be an expanding and contracting member, such as a spring,
accordion, telescoping, or bellows-type device. In general, the
shock absorbing member can be located such that relative movement
between the sensor, the mounting unit, and the host is absorbed
without (or minimally) affecting the connection of the sensor to
the mounting unit and/or the sensor stability within the
implantation site; for example, the shock-absorbing member can be
formed as a part of or connected to the sensor 32.
[0213] FIGS. 12A to 12C are perspective and side views of a sensor
system including the mounting unit 14 and electronics unit 16
attached thereto. After sensor insertion, the transcutaneous
analyte sensor system 10 measures a concentration of an analyte or
a substance indicative of the concentration or presence of the
analyte as described above. Although the examples are directed to a
glucose sensor, the analyte sensor can be a sensor capable of
determining the level of any suitable analyte in the body, for
example, oxygen, lactase, insulin, hormones, cholesterol,
medicaments, viruses, or the like. Once the electronics unit 16 is
connected to the mounting unit 14, the sensor 32 is able to measure
levels of the analyte in the host.
[0214] Detachable connection between the mounting unit 14 and
electronics unit 16 provides improved manufacturability, namely,
the relatively inexpensive mounting unit 14 can be disposed of when
replacing the sensor system after its usable life, while the
relatively more expensive electronics unit 16 can be reusable with
multiple sensor systems. In certain embodiments, the electronics
unit 16 is configured with programming, for example,
initialization, calibration reset, failure testing, or the like,
each time it is initially inserted into the cavity and/or each time
it initially communicates with the sensor 32. However, an integral
(non-detachable) electronics unit can be configured as is
appreciated by one skilled in the art.
[0215] Referring to the mechanical fit between the mounting unit 14
and the electronics unit 16 (and/or applicator 12), a variety of
mechanical joints are contemplated, for example, snap fit,
interference fit, or slide fit. In the illustrated embodiment of
FIGS. 12A to 12C, tabs 120 are provided on the mounting unit 14
and/or electronics unit 16 that enable a secure connection there
between. The tabs 120 of the illustrated embodiment can improve
ease of mechanical connection by providing alignment of the
mounting unit and electronics unit and additional rigid support for
force and counter force by the user (e.g., fingers) during
connection. However, other configurations with or without guiding
tabs are contemplated, such as illustrated in FIGS. 10 and 11, for
example.
[0216] In some circumstances, a drift of the sensor signal can
cause inaccuracies in sensor performance and/or require
re-calibration of the sensor. Accordingly, it can be advantageous
to provide a sealant, whereby moisture (e.g., water and water
vapor) cannot substantially penetrate to the sensor and its
connection to the electrical contacts. The sealant described herein
can be used alone or in combination with the sealing member 36
described in more detail above, to seal the sensor from moisture in
the external environment.
[0217] Preferably, the sealant fills in holes, crevices, or other
void spaces between the mounting unit 14 and electronics unit 16
and/or around the sensor 32 within the mounting unit 32. For
example, the sealant can surround the sensor in the portion of the
sensor 32 that extends through the contacts 28. Additionally, the
sealant can be disposed within the additional void spaces, for
example a hole 122 that extends through the sealing member 36.
[0218] Preferably, the sealant comprises a water impermeable
material or compound, for example, oil, grease, or gel. In one
exemplary embodiment, the sealant comprises petroleum jelly and is
used to provide a moisture barrier surrounding the sensor 32. In
one experiment, petroleum jelly was liquefied by heating, after
which a sensor 32 was immersed into the liquefied petroleum jelly
to coat the outer surfaces thereof. The sensor was then assembled
into a housing and inserted into a host, during which deployment
the sensor was inserted through the electrical contacts 28 and the
petroleum jelly conforming there between. Sensors incorporating
petroleum jelly, such as described above, when compared to sensors
without the petroleum jelly moisture barrier exhibited less or no
signal drift over time when studied in a humid or submersed
environment. While not wishing to be bound by theory, it is
believed that incorporation of a moisture barrier surrounding the
sensor, especially between the sensor and its associated electrical
contacts, reduces or eliminates the effects of humidity on the
sensor signal. The viscosity of grease or oil-based moisture
barriers allows penetration into and through even small cracks or
crevices within the sensor and mounting unit, displacing moisture
and thereby increasing the sealing properties thereof. U.S. Pat.
Nos. 4,259,540 and 5,285,513 disclose materials suitable for use as
a water impermeable material (sealant).
[0219] Referring to the electrical fit between the sensor 32 and
the electronics unit 16, contacts 28 (through which the sensor
extends) are configured to electrically connect with mutually
engaging contacts on the electronics unit 16. A variety of
configurations are contemplated; however, the mutually engaging
contacts operatively connect upon detachable connection of the
electronics unit 16 with the mounting unit 14, and are
substantially sealed from external moisture by sealing member 36.
Even with the sealing member, some circumstances may exist wherein
moisture can penetrate into the area surrounding the sensor 32 and
or contacts, for example, exposure to a humid or wet environment
(e.g., caused by sweat, showering, or other environmental causes).
It has been observed that exposure of the sensor to moisture can be
a cause of baseline signal drift of the sensor over time. For
example in a glucose sensor, the baseline is the component of a
glucose sensor signal that is not related to glucose (the amount of
signal if no glucose is present), which is ideally constant over
time. However, some circumstances my exist wherein the baseline can
fluctuate over time, also referred to as drift, which can be
caused, for example, by changes in a host's metabolism, cellular
migration surrounding the sensor, interfering species, humidity in
the environment, and the like.
[0220] In some embodiments, the mounting unit is designed to
provide ventilation (e.g., a vent hole 124) between the exit-site
and the sensor. In certain embodiments, a filter (not shown) is
provided in the vent hole 124 that allows the passage of air, while
preventing contaminants from entering the vent hole 124 from the
external environment. While not wishing to be bound by theory, it
is believed that ventilation to the exit-site (or to the sensor 32)
can reduce or eliminate trapped moisture or bacteria, which can
otherwise increase the growth and/or lifetime of bacteria adjacent
to the sensor.
[0221] In some alternative embodiments, a sealing material is
provided, which seals the needle and/or sensor from contamination
of the external environment during and after sensor insertion. For
example, one problem encountered in conventional transcutaneous
devices is infection of the exit-site of the wound. For example,
bacteria or contaminants can migrate from ex vivo, for example, any
ex vivo portion of the device or the ex vivo environment, through
the exit-site of the needle/sensor, and into the subcutaneous
tissue, causing contamination and infection. Bacteria and/or
contaminants can originate from handling of the device, exposed
skin areas, and/or leakage from the mounting unit (external to) on
the host. In many conventional transcutaneous devices, there exists
some path of migration for bacteria and contaminants to the
exit-site, which can become contaminated during sensor insertion or
subsequent handling or use of the device. Furthermore, in some
embodiments of a transcutaneous analyte sensor, the
insertion-aiding device (for example, needle) is an integral part
of the mounting unit; namely, the device stores the insertion
device after insertion of the sensor, which is isolated from the
exit-site (namely, point-of-entry of the sensor) after
insertion.
[0222] Accordingly, these alternative embodiments provide a sealing
material on the mounting unit, interposed between the housing and
the skin, wherein the needle and/or sensor are adapted to extend
through, and be sealed by, the sealing material. The sealing
material is preferably formed from a flexible material that
substantially seals around the needle/sensor. Appropriate flexible
materials include malleable materials, elastomers, gels, greases,
or the like (e.g., see U.S. Pat. Nos. 4,259,540 and 5,285,513).
However, not all embodiments include a sealing material, and in
some embodiments a clearance hole or other space surrounding the
needle and/or sensor is preferred.
[0223] In one embodiment, the base 24 of the mounting unit 14 is
formed from a flexible material, for example silicone, which by its
elastomeric properties seals the needle and/or sensor at the exit
port 126, such as is illustrated in FIGS. 11A and 11B. Thus,
sealing material can be formed as a unitary or integral piece with
the back surface 25 of the mounting unit 14, or with an adhesive
pad 8 on the back surface of the mounting unit, however
alternatively can be a separate part secured to the device. In some
embodiments, the sealing material can extend through the exit port
126 above or below the plane of the adhesive pad surface, or the
exit port 126 can comprise a septum seal such as those used in the
medical storage and disposal industries (for example, silica gel
sandwiched between upper and lower seal layers, such as layers
comprising chemically inert materials such as PTFE). A variety of
known septum seals can be implemented into the exit port of the
preferred embodiments described herein. Whether the sealing
material is integral with or a separate part attached to the
mounting unit 14, the exit port 126 is advantageously sealed so as
to reduce or eliminate the migration of bacteria or other
contaminants to or from the exit-site of the wound and/or within
the mounting unit.
[0224] During use, a host or caretaker positions the mounting unit
at the appropriate location on or near the host's skin and prepares
for sensor insertion. During insertion, the needle aids in sensor
insertion, after which the needle is retracted into the mounting
unit leaving the sensor in the subcutaneous tissue. In this
embodiment, the exit-port 126 includes a layer of sealing material,
such as a silicone membrane, that encloses the exit-port in a
configuration that protects the exit-site from contamination that
can migrate from the mounting unit or spacing external to the
exit-site. Thus, when the sensor 32 and/or needle 72 extend
through, for example, an aperture or a puncture in the sealing
material, to provide communication between the mounting unit and
subcutaneous space, a seal is formed there between. Elastomeric
sealing materials can be advantageous in some embodiments because
the elasticity provides a conforming seal between the needle/sensor
and the mounting unit and/or because the elasticity provides
shock-absorbing qualities allowing relative movement between the
device and the various layers of the host's tissue, for
example.
[0225] In some alternative embodiments, the sealing material
includes a bioactive agent incorporated therein. Suitable bioactive
agents include those which are known to discourage or prevent
bacteria and infection, for example, anti-inflammatory,
antimicrobials, antibiotics, or the like. It is believed that
diffusion or presence of a bioactive agent can aid in prevention or
elimination of bacteria adjacent to the exit-site.
[0226] In practice, after the sensor 32 has been inserted into the
host's tissue, and an electrical connection formed by mating the
electronics unit 16 to the mounting unit 14, the sensor measures an
analyte concentration continuously or continually, for example, at
an interval of from about fractions of a second to about 10 minutes
or more.
Sensor Electronics
[0227] The following description of sensor electronics associated
with the electronics unit is applicable to a variety of continuous
analyte sensors, such as non-invasive, minimally invasive, and/or
invasive (e.g., transcutaneous and wholly implantable) sensors. For
example, the sensor electronics and data processing as well as the
receiver electronics and data processing described below can be
incorporated into the wholly implantable glucose sensor disclosed
in co-pending U.S. patent application Ser. No. 10/838,912, filed
May 3, 2004 and entitled "IMPLANTABLE ANALYTE SENSOR" and U.S.
patent application Ser. No. 10/885,476 filed Jul. 6, 2004 and
entitled, "SYSTEMS AND METHODS FOR MANUFACTURE OF AN
ANALYTE-MEASURING DEVICE INCLUDING A MEMBRANE SYSTEM".
[0228] FIG. 13 is a block diagram that illustrates the electronics
132 associated with the sensor system 10 in one embodiment. In this
embodiment, a potentiostat 134 is shown, which is operably
connected to an electrode system (such as described above) and
provides a voltage to the electrodes, which biases the sensor to
enable measurement of an current signal indicative of the analyte
concentration in the host (also referred to as the analog portion).
In some embodiments, the potentiostat includes a resistor (not
shown) that translates the current into voltage. In some
alternative embodiments, a current to frequency converter is
provided that is configured to continuously integrate the measured
current, for example, using a charge counting device.
[0229] An A/D converter 136 digitizes the analog signal into a
digital signal, also referred to as "counts" for processing.
Accordingly, the resulting raw data stream in counts, also referred
to as raw sensor data, is directly related to the current measured
by the potentiostat 84.
[0230] A processor module 138 includes the central control unit
that controls the processing of the sensor electronics 132. In some
embodiments, the processor module includes a microprocessor,
however a computer system other than a microprocessor can be used
to process data as described herein, for example an ASIC can be
used for some or all of the sensor's central processing. The
processor typically provides semi-permanent storage of data, for
example, storing data such as sensor identifier (ID) and
programming to process data streams (for example, programming for
data smoothing and/or replacement of signal artifacts such as is
described in co-pending U.S. patent application Ser. No.
10/648,849, filed Aug. 22, 2003, and entitled, "SYSTEMS AND METHODS
FOR REPLACING SIGNAL ARTIFACTS IN A GLUCOSE SENSOR DATA STREAM").
The processor additionally can be used for the system's cache
memory, for example for temporarily storing recent sensor data. In
some embodiments, the processor module comprises memory storage
components such as ROM, RAM, dynamic-RAM, static-RAM, non-static
RAM, EEPROM, rewritable ROMs, flash memory, or the like.
[0231] In some embodiments, the processor module comprises a
digital filter, for example, an IIR or FIR filter, configured to
smooth the raw data stream from the A/D converter. Generally,
digital filters are programmed to filter data sampled at a
predetermined time interval (also referred to as a sample rate.) In
some embodiments, wherein the potentiostat is configured to measure
the analyte at discrete time intervals, these time intervals
determine the sample rate of the digital filter. In some
alternative embodiments, wherein the potentiostat is configured to
continuously measure the analyte, for example, using a
current-to-frequency converter as described above, the processor
module can be programmed to request a digital value from the A/D
converter at a predetermined time interval, also referred to as the
acquisition time. In these alternative embodiments, the values
obtained by the processor are advantageously averaged over the
acquisition time due the continuity of the current measurement.
Accordingly, the acquisition time determines the sample rate of the
digital filter. In preferred embodiments, the processor module is
configured with a programmable acquisition time, namely, the
predetermined time interval for requesting the digital value from
the A/D converter is programmable by a user within the digital
circuitry of the processor module. An acquisition time of from
about 2 seconds to about 512 seconds is preferred; however any
acquisition time can be programmed into the processor module. A
programmable acquisition time is advantageous in optimizing noise
filtration, time lag, and processing/battery power.
[0232] Preferably, the processor module is configured to build the
data packet for transmission to an outside source, for example, an
RF transmission to a receiver as described in more detail below.
Generally, the data packet comprises a plurality of bits that can
include a sensor ID code, raw data, filtered data, and/or error
detection or correction. The processor module can be configured to
transmit any combination of raw and/or filtered data.
[0233] In some embodiments, the processor module further comprises
a transmitter portion that determines the transmission interval of
the sensor data to a receiver, or the like. In some embodiments,
the transmitter portion, which determines the interval of
transmission, is configured to be programmable. In one such
embodiment, a coefficient can be chosen (e.g., a number of from
about 1 to about 100, or more), wherein the coefficient is
multiplied by the acquisition time (or sampling rate), such as
described above, to define the transmission interval of the data
packet. Thus, in some embodiments, the transmission interval is
programmable between about 2 seconds and about 850 minutes, more
preferably between about 30 second and 5 minutes; however, any
transmission interval can be programmable or programmed into the
processor module. However, a variety of alternative systems and
methods for providing a programmable transmission interval can also
be employed. By providing a programmable transmission interval,
data transmission can be customized to meet a variety of design
criteria (e.g., reduced battery consumption, timeliness of
reporting sensor values, etc.)
[0234] Conventional glucose sensors measure current in the nanoAmp
range. In contrast to conventional glucose sensors, the preferred
embodiments are configured to measure the current flow in the
picoAmp range, and in some embodiments, femtoAmps. Namely, for
every unit (mg/dL) of glucose measured, at least one picoAmp of
current is measured. Preferably, the analog portion of the A/D
converter 136 is configured to continuously measure the current
flowing at the working electrode and to convert the current
measurement to digital values representative of the current. In one
embodiment, the current flow is measured by a charge counting
device (e.g., a capacitor). Thus, a signal is provided, whereby a
high sensitivity maximizes the signal received by a minimal amount
of measured hydrogen peroxide (e.g., minimal glucose requirements
without sacrificing accuracy even in low glucose ranges), reducing
the sensitivity to oxygen limitations in vivo (e.g., in
oxygen-dependent glucose sensors).
[0235] A battery 144 is operably connected to the sensor
electronics 132 and provides the power for the sensor. In one
embodiment, the battery is a lithium manganese dioxide battery;
however, any appropriately sized and powered battery can be used
(for example, AAA, nickel-cadmium, zinc-carbon, alkaline, lithium,
nickel-metal hydride, lithium-ion, zinc-air, zinc-mercury oxide,
silver-zinc, and/or hermetically-sealed). In some embodiments, the
battery is rechargeable, and/or a plurality of batteries can be
used to power the system. The sensor can be transcutaneously
powered via an inductive coupling, for example. In some
embodiments, a quartz crystal 96 is operably connected to the
processor 138 and maintains system time for the computer system as
a whole, for example for the programmable acquisition time within
the processor module.
[0236] Optional temperature probe 140 is shown, wherein the
temperature probe is located on the electronics assembly or the
glucose sensor itself. The temperature probe can be used to measure
ambient temperature in the vicinity of the glucose sensor. This
temperature measurement can be used to add temperature compensation
to the calculated glucose value.
[0237] An RF module 148 is operably connected to the processor 138
and transmits the sensor data from the sensor to a receiver within
a wireless transmission 150 via antenna 152. In some embodiments, a
second quartz crystal 154 provides the time base for the RF carrier
frequency used for data transmissions from the RF transceiver. In
some alternative embodiments, however, other mechanisms, such as
optical, infrared radiation (IR), ultrasonic, or the like, can be
used to transmit and/or receive data.
[0238] In the RF telemetry module of the preferred embodiments, the
hardware and software are designed for low power requirements to
increase the longevity of the device (for example, to enable a life
of from about 3 to about 24 months, or more) with maximum RF
transmittance from the in vivo environment to the ex vivo
environment for wholly implantable sensors (for example, a distance
of from about one to ten meters or more). Preferably, a high
frequency carrier signal of from about 402 MHz to about 433 MHz is
employed in order to maintain lower power requirements.
Additionally, in wholly implantable devices, the carrier frequency
is adapted for physiological attenuation levels, which is
accomplished by tuning the RF module in a simulated in vivo
environment to ensure RF functionality after implantation;
accordingly, the preferred glucose sensor can sustain sensor
function for 3 months, 6 months, 12 months, or 24 months or
more.
[0239] When a sensor is first implanted into host tissue, the
sensor and receiver are initialized. This is referred to as
start-up mode, and involves optionally resetting the sensor data
and calibrating the sensor 32. In selected embodiments, mating the
electronics unit 16 to the mounting unit triggers a start-up mode.
In other embodiments, the start-up mode is triggered by the
receiver, which is described in more detail with reference to FIG.
19, below.
[0240] Preferably, the electronics unit 16 indicates to the
receiver (FIGS. 14 and 15) that calibration is to be initialized
(or re-initialized). The electronics unit 16 transmits a series of
bits within a transmitted data packet wherein a sensor code can be
included in the periodic transmission of the device. The status
code is used to communicate sensor status to the receiving device.
The status code can be inserted into any location in the
transmitted data packet, with or without other sensor information.
In one embodiment, the status code is designed to be unique or near
unique to an individual sensor, which can be accomplished using a
value that increments, decrements, or changes in some way after the
transmitter detects that a sensor has been removed and/or attached
to the transmitter. In an alternative embodiment, the status code
can be configured to follow a specific progression, such as a BCD
interpretation of a Gray code.
[0241] In some embodiments, the sensor electronics 132 are
configured to detect a current drop to zero in the working
electrode 44 associated with removal of a sensor 32 from the host
(or the electronics unit 16 from the mounting unit 14), which can
be configured to trigger an increment of the status code. If the
incremented value reaches a maximum, it can be designed to roll
over to 0. In some embodiments, the sensor electronics are
configured to detect a voltage change cycle associated with removal
and/or re-insertion of the sensor, which can be sensed in the
counter electrode (e.g., of a three-electrode sensor), which can be
configured to trigger an increment of the status code.
[0242] In some embodiments, the sensor electronics 132 can be
configured to send a special value (for example, 0) that indicates
that the electronics unit is not attached when removal of the
sensor (or electronics unit) is detected. This special value can be
used to trigger a variety of events, for example, to halt display
of analyte values. Incrementing or decrementing routines can be
used to skip this special value.
[0243] In some embodiments, the electronics unit 16 is configured
to include additional contacts, which are designed to sense a
specific resistance, or passive value, in the sensor system while
the electronics unit is attached to the mounting unit. Preferably,
these additional contacts are configured to detect information
about a sensor, for example, whether the sensor is operatively
connected to the mounting unit, the sensor's ID, a calibration
code, or the like. For example, subsequent to sensing the passive
value, the sensor electronics can be configured to change the
sensor ID code by either mapping the value to a specific code, or
internally detecting that the code is different and adjusting the
sensor ID code in a predictable manner. As another example, the
passive value can include information on parameters specific to a
sensor (such as in vitro sensitivity information as described
elsewhere herein).
[0244] In some embodiments, the electronics unit 16 includes
additional contacts configured to communicate with a chip disposed
in the mounting unit 14. In this embodiment, the chip is designed
with a unique or near-unique signature that can be detected by the
electronics unit 16 and noted as different, and/or transmitted to
the receiver 158 as the sensor ID code.
[0245] In some embodiments, the electronics unit 16 is inductively
coupled to an RFID or similar chip in the mounting unit 14. In this
embodiment, the RFID tag uniquely identifies the sensor 32 and
allows the transmitter to adjust the sensor ID code accordingly
and/or to transmit the unique identifier to the receiver 158.
[0246] In some situations, it can be desirable to wait an amount of
time after insertion of the sensor to allow the sensor to
equilibrate in vivo, also referred to as "break-in". Accordingly,
the sensor electronics can be configured to aid in decreasing the
break-in time of the sensor by applying different voltage settings
(for example, starting with a higher voltage setting and then
reducing the voltage setting) to speed the equilibration
process.
[0247] In some situations, the sensor may not properly deploy,
connect to, or otherwise operate as intended. Accordingly, the
sensor electronics can be configured such that if the current
obtained from the working electrode, or the subsequent conversion
of the current into digital counts, for example, is outside of an
acceptable threshold, then the sensor is marked with an error flag,
or the like. The error flag can be transmitted to the receiver to
instruct the user to reinsert a new sensor, or to implement some
other error correction.
[0248] The above-described detection and transmission methods can
be advantageously employed to minimize or eliminate human
interaction with the sensor, thereby minimizing human error and/or
inconvenience. Additionally, the sensors of preferred embodiments
do not require that the receiver be in proximity to the transmitter
during sensor insertion. Any one or more of the above described
methods of detecting and transmitting insertion of a sensor and/or
electronics unit can be combined or modified, as is appreciated by
one skilled in the art.
Receiver
[0249] FIG. 14 is a perspective view of a sensor system, including
wireless communication between a sensor and a receiver. Preferably
the electronics unit 16 is wirelessly connected to a receiver 158
via one- or two-way RF transmissions or the like. However, a wired
connection is also contemplated. The receiver 158 provides much of
the processing and display of the sensor data, and can be
selectively worn and/or removed at the host's convenience. Thus,
the sensor system 10 can be discreetly worn, and the receiver 158,
which provides much of the processing and display of the sensor
data, can be selectively worn and/or removed at the host's
convenience. Particularly, the receiver 158 includes programming
for retrospectively and/or prospectively initiating a calibration,
converting sensor data, updating the calibration, evaluating
received reference and sensor data, and evaluating the calibration
for the analyte sensor, such as described in more detail with
reference to co-pending U.S. patent application Ser. No.
10/633,367, filed Aug. 1, 2003 and entitled, "SYSTEM AND METHODS
FOR PROCESSING ANALYTE SENSOR DATA."
Receiver Electronics
[0250] FIG. 15A is a block diagram that illustrates the
configuration of the medical device in one embodiment, including a
continuous analyte sensor, a receiver, and an external device. In
general, the analyte sensor system is any sensor configuration that
provides an output signal indicative of a concentration of an
analyte (e.g., invasive, minimally-invasive, and/or non-invasive
sensors as described above). The output signal is sent to a
receiver 158 and received by an input module 174, which is
described in more detail below. The output signal is typically a
raw data stream that is used to provide a useful value of the
measured analyte concentration to a patient or a doctor, for
example. In some embodiments, the raw data stream can be
continuously or periodically algorithmically smoothed or otherwise
modified to diminish outlying points that do not accurately
represent the analyte concentration, for example due to signal
noise or other signal artifacts, such as described in co-pending
U.S. patent application Ser. No. 10/632,537 entitled, "SYSTEMS AND
METHODS FOR REPLACING SIGNAL ARTIFACTS IN A GLUCOSE SENSOR DATA
STREAM," filed Aug. 22, 2003, which is incorporated herein by
reference in its entirety.
[0251] Referring again to FIG. 15A, the receiver 158, which is
operatively linked to the sensor system 10, receives a data stream
from the sensor system 10 via the input module 174. In one
embodiment, the input module includes a quartz crystal operably
connected to an RF transceiver (not shown) that together function
to receive and synchronize data streams from the sensor system 10.
However, the input module 174 can be configured in any manner that
is capable of receiving data from the sensor. Once received, the
input module 174 sends the data stream to a processor 176 that
processes the data stream, such as is described in more detail
below.
[0252] The processor 176 is the central control unit that performs
the processing, such as storing data, analyzing data streams,
calibrating analyte sensor data, estimating analyte values,
comparing estimated analyte values with time corresponding measured
analyte values, analyzing a variation of estimated analyte values,
downloading data, and controlling the user interface by providing
analyte values, prompts, messages, warnings, alarms, or the like.
The processor includes hardware and software that performs the
processing described herein, for example flash memory provides
permanent or semi-permanent storage of data, storing data such as
sensor ID, receiver ID, and programming to process data streams
(for example, programming for performing estimation and other
algorithms described elsewhere herein) and random access memory
(RAM) stores the system's cache memory and is helpful in data
processing.
[0253] Preferably, the input module 174 or processor module 176
performs a Cyclic Redundancy Check (CRC) to verify data integrity,
with or without a method of recovering the data if there is an
error. In some embodiments, error correction techniques such as
those that use Hamming codes or Reed-Solomon encoding/decoding
methods are employed to correct for errors in the data stream. In
one alternative embodiment, an iterative decoding technique is
employed, wherein the decoding is processed iteratively (e.g., in a
closed loop) to determine the most likely decoded signal. This type
of decoding can allow for recovery of a signal that is as low as
0.5 dB above the noise floor, which is in contrast to conventional
non-iterative decoding techniques (such as Reed-Solomon), which
requires approximately 3 dB or about twice the signal power to
recover the same signal (e.g., a turbo code).
[0254] An output module 178, which is integral with and/or
operatively connected with the processor 176, includes programming
for generating output based on the data stream received from the
sensor system 10 and its processing incurred in the processor 176.
In some embodiments, output is generated via a user interface
160.
[0255] The user interface 160 comprises a keyboard 162, speaker
164, vibrator 166, backlight 168, liquid crystal display (LCD)
screen 170, and one or more buttons 172. The components that
comprise the user interface 160 include controls to allow
interaction of the user with the receiver. The keyboard 162 can
allow, for example, input of user information about
himself/herself, such as mealtime, exercise, insulin
administration, customized therapy recommendations, and reference
analyte values. The speaker 164 can produce, for example, audible
signals or alerts for conditions such as present and/or estimated
hyperglycemic or hypoglycemic conditions in a person with diabetes.
The vibrator 166 can provide, for example, tactile signals or
alerts for reasons such as described with reference to the speaker,
above. The backlight 168 can be provided, for example, to aid the
user in reading the LCD 170 in low light conditions. The LCD 170
can be provided, for example, to provide the user with visual data
output, such as is described in co-pending U.S. patent application
Ser. No. 11/007,920 filed Dec. 8, 2004 and entitled "SIGNAL
PROCESSING FOR CONTINUOUS ANALYTE SENSORS." FIGS. 15B to 15D
illustrate some additional visual displays that can be provided on
the screen 170. In some embodiments, the LCD is a touch-activated
screen, enabling each selection by a user, for example, from a menu
on the screen. The buttons 172 can provide for toggle, menu
selection, option selection, mode selection, and reset, for
example. In some alternative embodiments, a microphone can be
provided to allow for voice-activated control.
[0256] In some embodiments, prompts or messages can be displayed on
the user interface to convey information to the user, such as
reference outlier values, requests for reference analyte values,
therapy recommendations, deviation of the measured analyte values
from the estimated analyte values, or the like. Additionally,
prompts can be displayed to guide the user through calibration or
trouble-shooting of the calibration.
[0257] Additionally, data output from the output module 178 can
provide wired or wireless, one- or two-way communication between
the receiver 158 and an external device 180. The external device
180 can be any device that wherein interfaces or communicates with
the receiver 158. In some embodiments, the external device 180 is a
computer, and the receiver 158 is able to download historical data
for retrospective analysis by the patient or physician, for
example. In some embodiments, the external device 180 is a modem or
other telecommunications station, and the receiver 158 is able to
send alerts, warnings, emergency messages, or the like, via
telecommunication lines to another party, such as a doctor or
family member. In some embodiments, the external device 180 is an
insulin pen, and the receiver 158 is able to communicate therapy
recommendations, such as insulin amount and time to the insulin
pen. In some embodiments, the external device 180 is an insulin
pump, and the receiver 158 is able to communicate therapy
recommendations, such as insulin amount and time to the insulin
pump. The external device 180 can include other technology or
medical devices, for example pacemakers, implanted analyte sensor
patches, other infusion devices, telemetry devices, or the
like.
[0258] The user interface 160, including keyboard 162, buttons 172,
a microphone (not shown), and the external device 180, can be
configured to allow input of data. Data input can be helpful in
obtaining information about the patient (for example, meal time,
exercise, or the like), receiving instructions from a physician
(for example, customized therapy recommendations, targets, or the
like), and downloading software updates, for example. Keyboard,
buttons, touch-screen, and microphone are all examples of
mechanisms by which a user can input data directly into the
receiver. A server, personal computer, personal digital assistant,
insulin pump, and insulin pen are examples of external devices that
can provide useful information to the receiver. Other devices
internal or external to the sensor that measure other aspects of a
patient's body (for example, temperature sensor, accelerometer,
heart rate monitor, oxygen monitor, or the like) can be used to
provide input helpful in data processing. In one embodiment, the
user interface can prompt the patient to select an activity most
closely related to their present activity, which can be helpful in
linking to an individual's physiological patterns, or other data
processing. In another embodiment, a temperature sensor and/or
heart rate monitor can provide information helpful in linking
activity, metabolism, and glucose excursions of an individual.
While a few examples of data input have been provided here, a
variety of information can be input, which can be helpful in data
processing.
[0259] FIG. 15B