Analyte sensors and methods of manufacturing same

A continuous analyte sensor, the continuous analyte sensor comprising:

• an elongated core comprising a working electrode, wherein the elongated core comprises an inner core and an outer core covering the inner core, wherein the inner core comprises a first material, wherein the outer core comprises a second material selected from the group consisting of:
• platinum, platinum iridium, gold, palladium, iridium, alloys thereof, graphite, carbon, and a conductive polymer, wherein the first material is different from the second material;
• an insulating layer covering at least a portion of the elongated core;
• a conductive layer comprising a reference electrode or a counter electrode, wherein the conductive layer covers at least a portion of the insulating layer;
• and
• a membrane covering at least a portion of the working electrode;
• wherein the sensor has an ultimate tensile strength of from about 120 kPsi to about 500 kPsi.

A continuous analyte sensor, the continuous analyte sensor comprising:

• an elongated core comprising a working electrode, wherein the elongated core comprises an inner core and an outer core covering the inner core, wherein the inner core comprises a first material, wherein the outer core comprises a second material selected from the group consisting of:
• platinum, platinum iridium, gold, palladium, iridium, alloys thereof, graphite, carbon, and a conductive polymer, wherein the first material is different from the second material;
• an insulating layer covering at least a portion of the elongated core;
• a conductive layer comprising a reference electrode or a counter electrode, wherein the conductive layer covers at least a portion of the insulating layer;
• and
• a membrane covering at least a portion of the working electrode;
• wherein the sensor is configured to have a fatigue life of at least 1,000 cycles of flexing of from about 28° to about 110° at a bend radius of about 0.125-inches.

A continuous analyte sensor, the continuous analyte sensor comprising:

• an elongated core comprising a working electrode, wherein the elongated core comprises an inner core and an outer core covering the inner core, wherein the inner core comprises a first material, wherein the outer core comprises a second material selected from the group consisting of:
• platinum, platinum iridium, gold, palladium, iridium, alloys thereof, graphite, carbon, and a conductive polymer, wherein the first material is different from the second material;
• an insulating layer covering at least a portion of the elongated core;
• a conductive layer comprising a reference electrode or a counter electrode, wherein the conductive layer covers at least a portion of the insulating layer;
• and
• a membrane covering at least a portion of the working electrode;
• wherein the sensor is configured to have a fatigue life of at least 20 cycles of flexing of from about 45° to about −45° at a bend radius of about 0.031-inches.