Method for encapsulating an electrochemical sensor

A method for encapsulating an electrochemical sensor including the steps of

• (a) fabricating an essentially flexible tool having a three-dimensional cavity and at least one protruding flexible structure;
• (b) inserting a hybrid having at least one electrochemical sensor, and at least one contact area on the sensor, into the three-dimensional cavity within the flexible tool, such that the hybrid is supported within the cavity by the flexible tool, and such that the at least one contact area of the hybrid is in contact with at least one of the protruding flexible structures so as to seal the contact area of the hybrid to the flexible structure;
• (c) filling the three-dimensional cavity with a potting material to encapsulate the electrochemical sensor without encapsulating each sealed contact area of the hybrid to form an encapsulated hybrid having a depression corresponding to each protruding flexible structure;
• (d) disengaging the encapsulated hybrid from the cavity, such that each protruding flexible structure is disengaged from the corresponding depression without appreciable damage to the flexible tool.

A method for encapsulating an electrochemical sensor including the steps of:.

• (a) fabricating an essentially flexible tool by means of an injection molding process, the flexible tool having a cavity and at least one protruding flexible structure;
• (b) inserting a hybrid having at least one electrochemical sensor, and at least one contact area on the sensor, into the cavity within the flexible tool, such that the at least one contact area of the hybrid is in contact with at least one of the protruding flexible structures so as to seal the contact area of the hybrid to the flexible structure;
• and
• (c) filling the cavity with a potting material to encapsulate the electrochemical sensor without encapsulating each sealed contact area.

A method for encapsulating an electrochemical sensor, including the steps of:

• (a) forming a master pattern having a three-dimensional external profile and a plurality of depressions formed at the surface of the master pattern;
• (b) using the master pattern to fabricate an essentially flexible tool having a three-dimensional cavity with a three-dimensional internal profile substantially matching the external profile of the master pattern, the cavity including a plurality of flexible protrusions extending from the surface of the cavity, each flexible protrusion corresponding to one of the plurality of depressions on the master pattern;
• (c) placing a hybrid having a mechanical sensor and a contact area on the sensor into contact with the flexible tool, such that the hybrid is supported within the cavity by at least one of the flexible protrusions, and such that the contact area of the hybrid is in contact with at least one of the flexible protrusions so as to seal the contact area of the hybrid to the flexible structure;
• (d) filling the cavity with a potting material to surround and encapsulate at least three surfaces of the hybrid without encapsulating the sealed contact area;
• and
• (e) disengaging the encapsulated hybrid from the cavity in the flexible tool, such that the plurality of flexible structures are disengaged from the corresponding depressions without appreciable damage to the flexible tool so as to allow the flexible tool to be used for encapsulating multiple hybrids.