Methods of Manufacture to Optimize Performance of Transdermal Sampling and Analysis Device

A method of making a transdermal sampling and analysis device, comprising:

• forming a base structure with at least one counter electrode and a plurality of channel support structures;
• forming a lid configured to be positioned above the plurality of channel support structures, wherein the lid has at least one sensing electrode and an analyte sensing layer;
• attaching the lid to the base structure using an adhesive material on surfaces of the plurality of channel support structures,
• wherein attaching the lid to the base structure forms a plurality of channels in a reservoir between the plurality of channel support structures.

A method of making a transdermal sampling and analysis device, comprising:

• forming a base structure with at least one counter electrode, a first spacer layer with a plurality of channel support structures, and a second spacer layer formed over the first spacer layer, wherein the second spacer layer is recessed back from an edge of the plurality of channel support structures;
• forming a lid configured to be positioned above the second spacer layer, wherein the lid has at least one sensing electrode and an analyte sensing layer;
• and
• attaching the lid to the base structure,
• wherein attaching the lid to the base structure forms a plurality of channels in a reservoir between the plurality of channel support structures.

A transdermal sampling and analysis device comprising:

• a substrate having a first side;
• at least one disruptor mounted on the first side of the substrate, wherein the at least one disruptor is configured to generate a localized heat capable of altering permeability characteristics of barrier cells of an organism to become permeable when a voltage is applied across the at least one disruptor;
• a reservoir on the first side of the transdermal sampling and analysis device configured to collect and contain in a sensing chamber a biological sample that is obtained through permeable barrier cells;
• a lid structure configured to enclose the reservoir;
• a biological sensing element comprising at least a first electrode mounted on the first side of the substrate and at least a second electrode mounted on an underside of the lid structure, wherein the biological sensing element is configured to determine a level of an analyte in the biological sample;
• a first spacer layer disposed on the first side of the substrate;
• and
• a second spacer layer disposed over the first spacer layer, wherein the second spacer layer is configured to separate the first spacer layer from the at least second electrode on the underside of the lid structure,
• wherein the sensing chamber of the reservoir is configured to contain the biological sample between the at least first electrode and the at least second electrode.