US20070023287A1 - Method of making an electrochemical sensor - Google Patents
Method of making an electrochemical sensor Download PDFInfo
- Publication number
- US20070023287A1 US20070023287A1 US11/412,301 US41230106A US2007023287A1 US 20070023287 A1 US20070023287 A1 US 20070023287A1 US 41230106 A US41230106 A US 41230106A US 2007023287 A1 US2007023287 A1 US 2007023287A1
- Authority
- US
- United States
- Prior art keywords
- capillary channel
- casting material
- insert
- sensor
- sacrificial
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
- G01N27/28—Electrolytic cell components
- G01N27/30—Electrodes, e.g. test electrodes; Half-cells
- G01N27/327—Biochemical electrodes, e.g. electrical or mechanical details for in vitro measurements
- G01N27/3271—Amperometric enzyme electrodes for analytes in body fluids, e.g. glucose in blood
- G01N27/3272—Test elements therefor, i.e. disposable laminated substrates with electrodes, reagent and channels
Definitions
- the present invention relates generally to electrochemical sensors, and more, particularly, to electrochemical sensors with capillary channels formed by sacrificial inserts, and a method of making these sensors.
- Electrochemical sensors are used for the qualification of components or analytes in a sample of liquid such as blood or urine. Sensors of this type are disclosed in U.S. Pat. Nos. 5,958,199 and 5,798,031. These sensors include an insulating base with carbon electrodes printed on the base. The electrodes are covered with a reagent and are located in a capillary channel. The capillary channel is defined by a spacer positioned between the base and a cover piece.
- Electrochemical sensors have two parts, a base and a lid.
- the lid forms three sides of a capillary space and the base forms the fourth.
- the base and lid are laminated together to form the sensor.
- Sensors of this type are used by dipping an open end of the capillary channel into test liquid.
- the liquid is drawn by capillary action into the capillary channel to cover a reagent and/or enzyme in the capillary channel near one or more electrodes.
- a measurement of an analyte in the test liquid can then be made.
- the usual way to fabricate sensors of this type is to precision screen print active areas within a capillary area formed by a shaped top lid. It is desirable to reduce the cost and assembly required by this construction. Moreover, it is difficult to provide electrodes in a small molded capillary channel of less than 0.005 inches in height and it is desirable to provide a sensor of this size with molded electrodes so that such a sensor could be used for electrochemical analysis.
- the present invention is directed to an electrochemical sensor and to the method for making the sensor.
- the sensor of the present invention includes a capillary channel of approximately 0.005 inch in height that is formed by a sacrificial insert in a casting process. Electrodes may be printed and reagent applied on a sensor base and a sacrificial or protective insert is placed over the printed electrodes and reagent. Casting material is then applied over the insert. Once that casting material is cured, the insert is removed leaving a capillary channel and lid.
- FIG. 1 is a perspective view of a base sheet or base of an electrochemical biosensor
- FIG. 2 is a view similar to FIG. 1 with a sacrificial protective insert in position over printed circuits on the base sheet;
- FIG. 3 in a view similar to FIG. 2 with a casting material dispenser in position to dispense casting material
- FIG. 4 is a perspective view of the biosensor with the casting material on the biosensor.
- FIG. 5 illustrates the insert removed from the casting material
- FIGS. 1-5 there is illustrated the formation of a lid 10 and capillary channel for an electrochemical biosensor 14 .
- Existing biosensor construction requires that a spacer and a lid or a formed lid be bonded to produce a capillary channel necessary for sensor operation.
- the method of the present invention utilizes a casting process whereby the capillary channel 12 and the lid 10 are produced in one operation.
- the formation of the biosensor 14 starts with a standard base sheet 16 having a precision screen printed active area 18 that is standard in current biosensors ( FIG. 1 ).
- a protective or sacrificial insert 20 is placed over the active area 18 where the capillary channel 12 is required ( FIG. 2 ).
- a dispenser 22 for dispensing casting material is positioned over the insert 20 above the printed active area 18 ( FIG. 3 ), and casting material is dispensed over the insert 20 and the printed active area 18 ( FIG. 4 ). After the casting material has cured, it has formed the lid 10 . At this time the insert 20 may be removed from the casting material or lid 10 and the base sheet 16 leaving the very small capillary channel 12 . This process produces very small, precise and reproducable capillary channels at low cost.
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- Life Sciences & Earth Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Physics & Mathematics (AREA)
- Biochemistry (AREA)
- Hematology (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- Biophysics (AREA)
- Analytical Chemistry (AREA)
- Molecular Biology (AREA)
- General Health & Medical Sciences (AREA)
- General Physics & Mathematics (AREA)
- Immunology (AREA)
- Pathology (AREA)
- Investigating Or Analysing Biological Materials (AREA)
- Measurement Of The Respiration, Hearing Ability, Form, And Blood Characteristics Of Living Organisms (AREA)
Abstract
An electrochemical sensor with a capillary channel is formed by placing a sacrificial insert on a sensor base and applying casting material. After a casting material is cured, the sacrificial is removed leaving a capillary channel in the sensor. The insert may be removed by a tool including a clamp for clamping and holding the insert stationary and a sliding block to which the sensor is secured.
Description
- This application is a divisional of U.S. application Ser. No. 10/156,572, entitled Electrochemical Sensor And Method Of Making”, filed on May 29, 2002, which is incorporated by reference in its entirety; U.S. application Ser. No. 10/156,572 claims benefit of U.S. Provisional Application No. 60/297,023, filed on Jun. 11, 2001, which is incorporated by reference in its entirety.
- The present invention relates generally to electrochemical sensors, and more, particularly, to electrochemical sensors with capillary channels formed by sacrificial inserts, and a method of making these sensors.
- Electrochemical sensors are used for the qualification of components or analytes in a sample of liquid such as blood or urine. Sensors of this type are disclosed in U.S. Pat. Nos. 5,958,199 and 5,798,031. These sensors include an insulating base with carbon electrodes printed on the base. The electrodes are covered with a reagent and are located in a capillary channel. The capillary channel is defined by a spacer positioned between the base and a cover piece.
- Other electrochemical sensors have two parts, a base and a lid. The lid forms three sides of a capillary space and the base forms the fourth. The base and lid are laminated together to form the sensor.
- Sensors of this type are used by dipping an open end of the capillary channel into test liquid. The liquid is drawn by capillary action into the capillary channel to cover a reagent and/or enzyme in the capillary channel near one or more electrodes. A measurement of an analyte in the test liquid can then be made. The usual way to fabricate sensors of this type is to precision screen print active areas within a capillary area formed by a shaped top lid. It is desirable to reduce the cost and assembly required by this construction. Moreover, it is difficult to provide electrodes in a small molded capillary channel of less than 0.005 inches in height and it is desirable to provide a sensor of this size with molded electrodes so that such a sensor could be used for electrochemical analysis.
- The present invention is directed to an electrochemical sensor and to the method for making the sensor. The sensor of the present invention includes a capillary channel of approximately 0.005 inch in height that is formed by a sacrificial insert in a casting process. Electrodes may be printed and reagent applied on a sensor base and a sacrificial or protective insert is placed over the printed electrodes and reagent. Casting material is then applied over the insert. Once that casting material is cured, the insert is removed leaving a capillary channel and lid.
- Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
-
FIG. 1 is a perspective view of a base sheet or base of an electrochemical biosensor; -
FIG. 2 is a view similar toFIG. 1 with a sacrificial protective insert in position over printed circuits on the base sheet; -
FIG. 3 in a view similar toFIG. 2 with a casting material dispenser in position to dispense casting material; -
FIG. 4 is a perspective view of the biosensor with the casting material on the biosensor; and -
FIG. 5 illustrates the insert removed from the casting material; - While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of examples in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, by on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
- Referring to
FIGS. 1-5 , there is illustrated the formation of alid 10 and capillary channel for anelectrochemical biosensor 14. Existing biosensor construction requires that a spacer and a lid or a formed lid be bonded to produce a capillary channel necessary for sensor operation. The method of the present invention utilizes a casting process whereby thecapillary channel 12 and thelid 10 are produced in one operation. - The formation of the
biosensor 14 starts with astandard base sheet 16 having a precision screen printedactive area 18 that is standard in current biosensors (FIG. 1 ). A protective orsacrificial insert 20 is placed over theactive area 18 where thecapillary channel 12 is required (FIG. 2 ). Adispenser 22 for dispensing casting material is positioned over theinsert 20 above the printed active area 18 (FIG. 3 ), and casting material is dispensed over theinsert 20 and the printed active area 18 (FIG. 4 ). After the casting material has cured, it has formed thelid 10. At this time theinsert 20 may be removed from the casting material orlid 10 and thebase sheet 16 leaving the very smallcapillary channel 12. This process produces very small, precise and reproducable capillary channels at low cost.
Claims (9)
1. A method of making a capillary channel in an electrochemical biosensor, the method comprising the acts of:
forming a base member including an active area with at least one electrode;
placing a sacrificial insert on said base member;
applying casting material over said sacrificial insert and on said base member; and
mechanically removing said sacrificial insert leaving a capillary channel in said casting material.
2. The method of claim 1 comprising providing a reagent in said active area.
3. The method of claim 1 wherein the at least one electrode is a plurality of electrodes and wherein the plurality of electrodes is in said capillary channel.
4. The method of claim 1 comprising curing said casting material prior to removing said sacrificial insert.
5. (canceled)
6. (canceled)
7. (canceled)
8. The method of claim 1 wherein said capillary channel has a height of about 0.005 inch.
9. The method of claim 1 further including screen-printing said active area.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/412,301 US20070023287A1 (en) | 2001-06-11 | 2006-04-27 | Method of making an electrochemical sensor |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US29702301P | 2001-06-11 | 2001-06-11 | |
US10/156,572 US7122102B2 (en) | 2001-06-11 | 2002-05-29 | Electrochemical sensor |
US11/412,301 US20070023287A1 (en) | 2001-06-11 | 2006-04-27 | Method of making an electrochemical sensor |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/156,572 Division US7122102B2 (en) | 2001-06-11 | 2002-05-29 | Electrochemical sensor |
Publications (1)
Publication Number | Publication Date |
---|---|
US20070023287A1 true US20070023287A1 (en) | 2007-02-01 |
Family
ID=23144535
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/156,572 Expired - Lifetime US7122102B2 (en) | 2001-06-11 | 2002-05-29 | Electrochemical sensor |
US11/412,301 Abandoned US20070023287A1 (en) | 2001-06-11 | 2006-04-27 | Method of making an electrochemical sensor |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/156,572 Expired - Lifetime US7122102B2 (en) | 2001-06-11 | 2002-05-29 | Electrochemical sensor |
Country Status (6)
Country | Link |
---|---|
US (2) | US7122102B2 (en) |
EP (1) | EP1267159B1 (en) |
JP (1) | JP3691457B2 (en) |
AU (1) | AU784599B2 (en) |
CA (1) | CA2388207A1 (en) |
DE (1) | DE60217226T2 (en) |
Families Citing this family (59)
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US6036924A (en) | 1997-12-04 | 2000-03-14 | Hewlett-Packard Company | Cassette of lancet cartridges for sampling blood |
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US7344507B2 (en) | 2002-04-19 | 2008-03-18 | Pelikan Technologies, Inc. | Method and apparatus for lancet actuation |
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US8221334B2 (en) | 2002-04-19 | 2012-07-17 | Sanofi-Aventis Deutschland Gmbh | Method and apparatus for penetrating tissue |
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US7713214B2 (en) | 2002-04-19 | 2010-05-11 | Pelikan Technologies, Inc. | Method and apparatus for a multi-use body fluid sampling device with optical analyte sensing |
US7674232B2 (en) | 2002-04-19 | 2010-03-09 | Pelikan Technologies, Inc. | Method and apparatus for penetrating tissue |
US8579831B2 (en) | 2002-04-19 | 2013-11-12 | Sanofi-Aventis Deutschland Gmbh | Method and apparatus for penetrating tissue |
US7976476B2 (en) | 2002-04-19 | 2011-07-12 | Pelikan Technologies, Inc. | Device and method for variable speed lancet |
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US8702624B2 (en) | 2006-09-29 | 2014-04-22 | Sanofi-Aventis Deutschland Gmbh | Analyte measurement device with a single shot actuator |
US9248267B2 (en) | 2002-04-19 | 2016-02-02 | Sanofi-Aventis Deustchland Gmbh | Tissue penetration device |
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US9795334B2 (en) | 2002-04-19 | 2017-10-24 | Sanofi-Aventis Deutschland Gmbh | Method and apparatus for penetrating tissue |
US8267870B2 (en) | 2002-04-19 | 2012-09-18 | Sanofi-Aventis Deutschland Gmbh | Method and apparatus for body fluid sampling with hybrid actuation |
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US5591139A (en) | 1994-06-06 | 1997-01-07 | The Regents Of The University Of California | IC-processed microneedles |
-
2002
- 2002-05-29 US US10/156,572 patent/US7122102B2/en not_active Expired - Lifetime
- 2002-05-30 CA CA002388207A patent/CA2388207A1/en not_active Abandoned
- 2002-06-03 AU AU45769/02A patent/AU784599B2/en not_active Ceased
- 2002-06-06 EP EP02012366A patent/EP1267159B1/en not_active Expired - Fee Related
- 2002-06-06 DE DE60217226T patent/DE60217226T2/en not_active Expired - Lifetime
- 2002-06-07 JP JP2002166490A patent/JP3691457B2/en not_active Expired - Lifetime
-
2006
- 2006-04-27 US US11/412,301 patent/US20070023287A1/en not_active Abandoned
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Also Published As
Publication number | Publication date |
---|---|
JP2003028827A (en) | 2003-01-29 |
AU784599B2 (en) | 2006-05-11 |
US20020185375A1 (en) | 2002-12-12 |
US7122102B2 (en) | 2006-10-17 |
EP1267159B1 (en) | 2007-01-03 |
CA2388207A1 (en) | 2002-12-11 |
EP1267159A2 (en) | 2002-12-18 |
AU4576902A (en) | 2002-12-12 |
EP1267159A3 (en) | 2004-06-16 |
DE60217226D1 (en) | 2007-02-15 |
DE60217226T2 (en) | 2007-11-22 |
JP3691457B2 (en) | 2005-09-07 |
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Legal Events
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |