Method of making sensor

a sensor and electrode technology, applied in the field of electrochemical sensors, can solve the problems of dimensional variation, micro-cracks, shrinkage, and dimensional variations, and achieve the effect of enhancing the performance and relieving pressur

Inactive Publication Date: 2005-03-31
RAPPIN CRAIG +2
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0012] As noted, the electrodes are molded into the plastic. In one embodiment, the electrodes are conductive wires. In another embodiment, the electrodes are constructed from a metal plate. The electrodes may be coated with a different conductive material to enhance their performance.

Problems solved by technology

Variations in the morphology of the electrode can result in very significant changes in the electrochemical signal readout.
While many advances have been made in the field of screen printing and conductive ink production, the technology still suffers from poor reproducibility of the electrode surface area, dimensional variations, thickness variations, micro-cracks, and shrinkage due to the repetitive and high temperature curing processes involved in using film printing technology.
Loss of solvent during printing is another factor that leads to variations in the thickness of electrodes.
Slight variations in positioning the screens can lead to substantial errors in IR drop and the applied potentials.
Wear and tear of these screens is another source of error.
Also, sensor strip production by screen printing suffers from a high level of raw material waste.
Generally, for every gram of ink used, there is a gram of ink wasted.
Manufacture of such sensors also involves several lamination processes that add to the production complexity and cost of the final product.

Method used

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Examples

Experimental program
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first embodiment

[0038] The First Embodiment

[0039] Referring to FIGS. 1-6, an electrochemical sensor in accordance with the present invention, first embodiment, is depicted. FIG. 1 shows the sensor 10 as though it were made out of clear plastic, permitting one to look inside it. As discussed herein, the internal components and hidden external components would not normally be visible looking down on the sensor 10. This rendition would be similar to a view taken along plane x-x in FIG. 2.

[0040] The sensor or test strip of the first embodiment 10 includes an injection molded plastic body 12, opaque or preferably translucent, having a meter attachment end or plug end 14 and a fluid sample receiving end 16. The body has a bottom surface 13, a top surface 15 and a tapered portion 20 connecting a first top surface 15a to a second top surface 15b, the first top surface being lower than the second top surface, and a third top surface 15c, also lower than the second top surface. The body 12 contains three sp...

second embodiment

[0042] While the cap 27 is shown as a separate piece, it can also be constructed as part of the body 12 and hingeably connected to the body such that it can be pivoted onto the third top surface 15c and attached [e.g., see The Second Embodiment]. In this manner, the entire sensor can be made at one time and as one molded, unitary piece.

[0043] A capillary opening 28 is formed in the terminal end 16 of the sensor 10 when the cap 27 is welded (or folded) to the body 12. This capillary opening leads to the reaction zone 24. Preferably, the sensor 10 is a capillary fill device, that is, the reaction zone 24 is small enough to draw a fluid sample into the zone when the capillary opening or inlet 28 is placed in contact with the fluid being tested, such as a drop of blood. Accordingly, if one wants to test his / her blood, s / he touches the terminal end 16 to the blood and the blood is drawn into the sensor 10 and reaction zone 24 through the capillary opening 28. This is much easier than pla...

third embodiment

[0083] The Third Embodiment

[0084] Shown in FIGS. 13-20 is a third embodiment of an electrochemical sensor in accordance with the present invention. These figures use the same reference numbers, but in the 300 series, to identify components that are similar to those in the previous embodiments. FIGS. 13 and 17, respectively, depict the sensor 310,310′ in its entirety, including its internal components not normally visible when looking down on the sensor 310,310′.

[0085] In the third embodiment sensor 310, 310′ is used in conjunction with a meter capable of measuring an electrochemical property of the fluid sample after the fluid sample is drawn into the reaction zone 324,324′. The sensor 310,310′ includes a molded plastic body 312,312′ having a meter attachment end or plug end 314,314′ and a fluid sample receiving end 316,316′. The plug end 314,314′ is insertable or connectable to a meter, as with the two prior embodiments. The body also has a bottom surface 313,313′ and a top surfac...

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Abstract

A sensor is provided for the determination of various concentrations of one or more components within a fluid sample. The sensor includes an injection molded body, at least two electrodes, an enzyme, and if desired, an electron transfer mediator. The body includes a reaction zone for receiving a fluid sample. The electrodes are at least partially embedded within the plastic body and extend into the reaction zone. Also contained within the reaction zone is an enzyme capable of catalyzing a reaction involving a compound within the fluid sample. Additionally, the sensor incorporates fill detection which activates a meter, attached to the sensor, for measuring the electrochemical changes occurring in the reaction zone.

Description

CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is a continuation of copending prior U.S. application Ser. No. 10 / 419,581 filed Apr. 21, 2003, which is a Divisional of U.S. application Ser. No. 10 / 017,751 filed Dec. 7, 2001, (now U.S. Pat. No. 6,572,745 issued Jun. 3, 2003) which is a Continuation-In-Part of U.S. application Ser. No. 09 / 820,372, filed Mar. 23, 2001 (now U.S. Pat. No. 6,576,102 issued Jun. 10, 2003).TECHNICAL FIELD [0002] The present invention generally relates to electrochemical sensors and, in particular, to molded electrochemical sensors for detection or measurement of analytes in test samples, such as fluids and dissolved solid materials, and the methods of making and using these sensors. BACKGROUND OF THE INVENTION [0003] Electrochemical sensors are used to determine the concentrations of various analytes in testing samples such as fluids and dissolved solid materials. For instance, electrochemical sensors have been made for measuring glucose in h...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): G01N27/327G01N27/403
CPCY10T29/49002G01N27/3272
Inventor RAPPIN, CRAIGHAJIZADEH, KIAMARSMILLS, KELLY
Owner RAPPIN CRAIG
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