Laser-Ablated Electrode Pattern for Precision Test Sensors
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Solution Overview
Problem
Existing electrochemical test sensors face challenges in precision due to high tolerances in the placement of the lid or spacer, affecting the accuracy of the working electrode area, which in turn influences the accuracy of analyte concentration measurements.
Innovation Solution
The method involves using laser ablation to define the electrode pattern and conductive leads more precisely, reducing the volume of the fluid sample required and enhancing the accuracy of the test sensor by applying dielectric material and a second layer to form a capillary channel, allowing for precise analyte detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrode pattern is defined by a second layer (lid or spacer) attached to the base, then the manufacturing process is simple, but the placement tolerance is high (±0.005 in.) which reduces accuracy
Solution Approach 1:
The patent replaces the mechanical attachment method (laminating base and lid/spacer) with a laser-ablation process to define the electrode pattern. This substitution of mechanical system with a laser-based system achieves tighter tolerances (±0.0005 in.) while maintaining manufacturing feasibility.
Solution Approach 2:
The patent changes the critical parameter from mechanical placement tolerance to laser-ablation precision. By controlling laser parameters (power, speed, pulse duration), the electrode pattern can be defined with much higher precision than mechanical attachment allows.
2Manufacturing precision
If laser ablation is used to define the electrode pattern, then the manufacturing precision is improved (±0.0005 in.), but the manufacturing process becomes more complex
Solution Approach 1:
The patent segments the manufacturing process into distinct steps: applying electrochemically-active material, defining the pattern via laser ablation, applying dielectric material, and forming the capillary channel. This segmentation allows each step to be optimized independently, making the complex process more controllable and manufacturable.
Solution Approach 2:
The patent performs preliminary actions by first applying the electrochemically-active material and defining the electrode pattern through laser ablation before applying the dielectric material and forming the final structure. This preliminary definition of the electrode pattern ensures high precision is achieved early in the process.
3Ease of manufacture
If the working electrode area is not precisely defined, then the manufacturing process is simpler, but the accuracy of analyte concentration measurements is reduced
Solution Approach 1:
The patent replaces mechanical attachment methods with laser ablation to define the electrode pattern, achieving precise control over the working electrode area. This precision directly improves the accuracy of analyte concentration measurements by ensuring the electrode area is exactly as specified.
Solution Approach 2:
The patent uses capillary action (a hydraulic principle) to form a capillary channel that precisely controls fluid flow to the electrode. This ensures that the sample volume is controlled and that the electrode area is precisely defined, improving measurement accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves the accuracy and reproducibility of the test sensor system, reducing the cost and sample volume needed for analysis while providing precise readings of analyte concentrations such as glucose, cholesterol, and bilirubin.
Implementation Method 1
The electrochemically-active material is laser-ablated to form an electrode pattern including a plurality of electrodes and conductive leads
Implementation Method 2
A capillary channel assists in allowing a fluid sample to contact a reagent located therein
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2B
AI summary
A method of forming an electrochemical test sensor includes providing a base. Electrochemically-active material is placed on the base. Dielectric material is applied over the electrochemically-active material. A first selected area of the dielectric material is laser-ablated to expose the electrochemically-active material. A second selected area of the dielectric material and the electrochemically-active material are laser-ablated to expose the base. The first selected area is different from the second selected area. A second layer is applied to assist in forming a channel in the test sensor. The channel assists in allowing a fluid sample to contact a reagent located therein. The dielectric material is located between the base and the second layer.