Method for manufacturing electrochemical sensor and structure thereof

• US 20040149578A1
• Filed: 01/30/2003
• Published: 08/05/2004
• Est. Priority Date: 01/30/2003
• Status: Abandoned Application

• Current Assignee: Chun-Mu Huang
• Original Assignee: Chun-Mu Huang
• Inventors: Huang, Chun-Mu
• Application Number:
  US10/354,684
• Publication Number:
  US 20040149578A1
• Time in Patent Office: Days
• US Class Current: 204/403.01
• CPC Class Codes: G01N 27/3272 Test elements therefor, i.e. disposable laminated substrates with electrodes, reagent and channels optical biosensors G01N33/52
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A method for manufacturing an electrochemical sensor and a structure thereof are provided. The method includes steps of (a) providing an injection-molding device, (b) providing an isolating substrate having a first recess and a first through hole, (c) positing the isolating substrate in the injection-molding device, (d) injecting a conductive plastic material into the injection-molding device for forming a conductive strip disposed in the first recess and including an output terminal and a testing electrode disposed in the first through hole, (e) providing a chemical reagent, and (f) positing the chemical reagent on the testing electrode for testing a sample solution.

Claims

1. A method for manufacturing an electrochemical sensor, comprising steps of:

(a) providing an injection-molding device;

(b) providing an isolating substrate having at least a first recess and at least a first through hole;

(c) positing said isolating substrate in said injection-molding device;

(d) injecting a conductive plastic material into said injection-molding device for forming an electrode set having a conductive strip disposed in said first recess and including an output terminal and a testing electrode disposed in said first through hole;

(e) providing a chemical reagent; and

(f) positing said chemical reagent on said testing electrode for testing an analyte in a sample.

2. The method according to claim 1, wherein said sample is a fluid solution and said chemical reagent tests said analyte and produces an electric measuring signal to be outputted via said testing electrode, wherein said electric measuring signal has a proportion with a concentration of said analyte.

3. The method according to claim 2, wherein said testing electrode is further electrically connected to an electronic meter.

4. The method according to claim 1, wherein said conductive plastic material is a resin mixed with at least one of a conductive carbon and a metal powder.

5. The method according to claim 4, wherein said resin is at least one of a thermosetting resin and a thermoplastic resin.

6. The method according to claim 4, wherein said resin is an epoxy resin.

7. The method according to claim 4, wherein said conductive carbon is at least one selected from a group consisting of a carbon black, a graphite power, a carbon fiber and a carbon nanotube.

8. The method according to claim 4, wherein said metal powder is one selected from a group consisting of a gold powder, a platinum powder, a palladium powder, and a rhodium powder.

9. The method according to claim 4, wherein said conductive carbon is of a weight density ranged from 3% to 80% in said conductive plastic material.

10. The method according to claim 4, wherein said metal powder is of a weight density ranged from 0.1% to 5% in said conductive plastic material.

11. The method according to claim 4, wherein said step (d) further comprises an antecedent step of:

mixing said resin with at least one of said conductive carbon and said metal powder for forming said conductive plastic material.

12. An electrochemical sensor, comprising:

an isolating substrate having at least a first recess and at least a first through hole;

an electrode set having a first conductive strip disposed in said first recess and having an output terminal and a first testing electrode disposed in said first through hole; and

a chemical reagent disposed on said first testing electrode for testing an analyte in a sample solution and producing a electric measuring signal to be outputted via said first testing electrode.

13. The electrochemical sensor according to claim 12 further comprising an isolating layer on said first conductive strip for isolating said first conductive strip.

14. The electrochemical sensor according to claim 12 wherein said first testing electrode serves as a working electrode, said isolating substrate further comprises a second recess and a second through hole, said electrode set further comprises a second conductive strip disposed in said second recess and having a second output terminal and a second testing electrode disposed in said second through hole, and said second testing electrode serves as a counter electrode.

15. The electrochemical sensor according to claim 14 wherein said isolating substrate further comprises a third recess and a third through hole, and said electrode set further comprises a third conductive strip disposed in said third recess and having a third output terminal and a third testing electrode disposed in said third through hole, wherein said third electrode has an Ag/AgCl film disposed on a surface thereof to serves as a reference electrode.

16. The electrochemical sensor according to claim 12, wherein said isolating substrate further comprises a flowing recess and a fluid inlet being of a unity with said first through hole.

17. The electrochemical sensor according to claim 16 further comprising a cover layer disposed on said isolating substrate for forming a capillary channel and a measuring section on said flowing recess and said fluid inlet.

18. The electrochemical sensor according to claim 17, wherein said isolating substrate further comprises a protruding spacer for urging against said cover layer and isolating said fluid sample and an adhesive of said cover layer.

19. The electrochemical sensor according to claim 17, wherein said cover layer is a plastic plate having a first printing conductive metal film that having a second output terminal and a second electrode terminal to serve as a counter electrode.

20. The electrochemical sensor according to claim 19, wherein said cover layer further comprises a second printing conductive metal film that having a third output terminal and a third electrode terminal to serve as a reference electrode.

21. The electrochemical sensor according to claim 20 further comprising a fourth testing electrode to be a detecting electrode to test a flow amount of said sample.

22. The electrochemical sensor according to claim 17, wherein said cover layer is one of a transparent layer and a translucent layer, has an opaque part and is shown a direction facilitating a user to observe how said sample flows.

23. The electrochemical sensor according to claim 17, wherein said cover layer is one of a textile cloth and a plastic mesh and has a mesh count from 20 to 150 per cm.

24. The electrochemical sensor according to claim 17, wherein said measuring section and said cover layer further comprise an inner side produced by means of a hydrophilic coating for facilitating said sample to fill up said measuring section.

25. The electrochemical sensor according to claim 16, wherein said flowing recess further comprises a placing recess for disposing said chemical reagent.

26. The electrochemical sensor according to claim 25, wherein a bottom of said measuring section and a top of said first testing electrode have a height difference, and said placing recess and said testing electrode top form a combination base for being coated with said chemical reagent.

27. The electrochemical sensor according to claim 26, wherein said chemical reagent is injected in a specific amount into said placing recess for forming an equal thickness.

28. The electrochemical sensor according to claim 12 further comprising a placing recess for disposing a meshed window.

29. The electrochemical sensor according to claim 28, wherein said electrode set and said chemical reagent are disposed in said placing recess to form said measuring section for said sample.

30. The electrochemical sensor according to claim 28 further comprising a cover layer disposed on said mashed window and connected with said isolating substrate, wherein said cover layer includes an opening for exposing a part of said meshed window.

31. The electrochemical sensor according to claim 30, wherein said cover layer is one of a textile cloth and a plastic mesh and has a mesh count from 20 to 150 per cm.

32. The electrochemical sensor according to claim 30, wherein said measuring section and said cover layer further comprise an inner side produced by means of a hydrophilic coating for facilitating said sample to fill up said measuring section.

33. The electrochemical sensor according to claim 12, wherein said isolating substrate further comprises an inlet for said sample being a fluid to be flowed therein and an air opening for facilitating a capillarity of said fluid sample.

34. The electrochemical sensor according to claim 12, wherein said first through hole and said first testing electrode respectively comprise a through-hole cross-section and a testing-electrode cross-section of the same area.

35. The electrochemical sensor according to claim 12, wherein said first through hole is disposed on a top of said isolating substrate.

36. The electrochemical sensor according to claim 35, wherein said first conductive strip is disposed on a bottom of said isolating substrate and has said first testing electrode disposed on a top of said isolating substrate via said first through hole, wherein said first testing electrode serves as a working electrode.

37. The electrochemical sensor according to claim 36 further comprising a first printing conductive metal film is printed on a top side of said isolating substrate, and said first printing conductive metal film having a second output terminal and a second electrode terminal for forming a second testing electrode, and said second testing electrode to serve as a counter electrode.

38. The electrochemical sensor according to claim 37 further comprising a second printing conductive metal film for forming a third output terminal and a third testing electrode.

39. The electrochemical sensor according to claim 38, wherein said third testing electrode further comprises an Ag/AgCl film to serve as a reference electrode.

40. The electrochemical sensor according to claim 12, wherein said isolating substrate is one selected from a group consisting of a polyvinyl chloride, a polypropylene, a polycarbonate, a polybutylene terephthalate, a polyethylene terephthalate, a modified polyphenylene oxide and an acrylonitrile butadiene styrene.

41. The electrochemical sensor according to claim 12, wherein said first conductive strip is made by means of molding via a conductive-strip molding device including said isolating substrate.

42. The electrochemical sensor according to claim 12, wherein said isolating substrate is made by means of molding via an isolating-substrate molding device including said first conductive strip.

43. The electrochemical sensor according to claim 12, wherein said first conductive strip and said isolating substrate are made in a double-injection-molding process.

44. The electrochemical sensor according to claim 12, wherein said first conductive strip is adhered to said isolating substrate via an adhesive.

45. The electrochemical sensor according to claim 12, wherein said first conductive strip further comprises a lead for electrically connecting said output terminal and said first testing electrode.

46. The electrochemical sensor according to claim 45, wherein said first testing electrode has a thickness ranged from 0.3 mm to 3 mm.

47. The electrochemical sensor according to claim 45, wherein said lead has a thickness ranged from 0.28 mm to 2.8 mm.

48. An electrochemical sensor, comprising:

an isolating substrate having a recess;

a first conductive device disposed in said recess and having an output terminal and a first testing electrode; and

a chemical reagent disposed on said first testing electrode for testing an analyte in a sample solution and producing an electric measuring signal to be outputted via said first testing electrode.

49. The electrochemical sensor according claim 48, wherein said first conductive device is a first conductive strip, and said recess further comprises a first recess for disposing said first conductive strip therein and a first through hole for disposing said first testing electrode therein.

50. The electrochemical sensor according to claim 48 further comprising a printing metal film having a printing output terminal and a connecting terminal, wherein said first conductive device is a first conductive pad, said recess further includes a first through hole, and said printing metal film is printed on said isolating substrate and said connecting terminal electrically connects to said output terminal of said conductive pad for receiving said measuring signal from said first testing electrode

51. The electrochemical sensor according to claim 50, wherein said first through hole connects with an extended recess for disposing therein an extended base of said first conductive pad.

52. An electrochemical sensor, comprising:

a conductive set having a first conductive device having a first testing electrode;

an isolating substrate having at least a first recess for disposing said first testing electrode;

a first printing metal film printed on said isolating substrate and having an output terminal and a connecting terminal connected with said first conductive device; and

a chemical reagent disposed on said first testing electrode for testing an analyte in a sample and producing an electric measuring signal to be outputted via said first testing electrode.

53. The electrochemical sensor according to claim 52, wherein said isolating substrate further comprises a second recess for disposing a second conductive device of said conductive set.

54. The electrochemical sensor according to claim 53 further comprising a second printing metal film that having an second output terminal and a second connecting terminal connected with said second conductive device.

55. The electrochemical sensor according to claim 54, wherein said first testing electrode serves as a working electrode and said second conductive device further serves as a counter electrode.

56. The electrochemical sensor according to claim 55, wherein said isolating substrate further comprises a third recess for disposing a third conductive device of said conductive set.

57. The electrochemical sensor according to claim 56 further comprising a third printing metal film that having a third output terminal and a third connecting terminal for connecting said third conductive device.

58. The electrochemical sensor according to claim 56, wherein said third conductive device further comprises an Ag/AgCl film to serve as a reference electrode.

59. The electrochemical sensor according to claim 56, wherein said first printing metal film, said second printing metal film and third printing metal film are printed on said isolating substrate and a back side of said working area.

60. The electrochemical sensor according to claim 52, wherein said first testing electrode is a working electrode having a working area on a top side of said isolating substrate.

61. The electrochemical sensor according to claim 52, wherein said first recess is a U-shaped recess, and said first conductive device is a U-shaped conductive device and has an end serving as said first testing electrode and another end serving as a connecting terminal connected with said first conductive metal film for outputting said electric measuring signal of said first testing electrode.

62. The electrochemical sensor according to claim 61, wherein said first printing metal film and a working area of said first testing electrode are disposed on the same side.

63. The electrochemical sensor according to claim 62 further comprising a second printing metal film having a output terminal and a electrode terminal that printed on said isolating substrate to serve as a second testing electrode and second output terminal.

64. The electrochemical sensor according to claim 63 further comprising an isolating layer for covering said first printing metal film and said second printing metal film.

65. The electrochemical sensor according to claim 64, wherein said isolating layer further comprises an inlet for flowing therethrough said sample being a fluid and a C-shaped opening for forming a measuring section.

66. The electrochemical sensor according to claim 65 further comprising a covering layer and an air hole for forming a capillarity channel in said measuring section.

67. The electrochemical sensor according to claim 66 further comprising a third printing metal film having a output terminal and a electrode terminal that is printed on said isolating substrate to serve as a third testing electrode and third output terminal, wherein said third testing electrode further comprises a Ag/AgCl film to serve as a reference electrode.

68. An electrochemical sensor, comprising:

a conductive piece having an outputting terminal and a first testing electrode;

an isolating substrate connected to said conductive piece and having a through hole for disposed said first testing electrode; and

a chemical reagent disposing on said first testing electrode for testing a sample solution and producing an electric measuring signal to be outputted via said first testing electrode.

69. The electrochemical sensor according to claim 68, wherein said first testing electrode is a protruding part of said conductive piece for being disposed in said through hole of said isolating substrate.

70. The electrochemical sensor according to claim 68, wherein said isolating substrate further comprises a first printing metal film to be a second testing electrode and a second output terminal.

71. The electrochemical sensor according to claim 70, wherein said isolating substrate further comprises a second printing metal film to be a third testing electrode and a third output terminal.

72. The electrochemical sensor according to claim 71, wherein said third testing electrode further comprises an Ag/AgCl surface to be a reference electrode.

73. The electrochemical sensor according to claim 71, wherein said first testing electrode, said second testing electrode and said third testing electrode are a working electrode, a counter electrode and a reference electrode respectively.

74. An electrochemical sensor, comprising:

a conductive sheet made by plastic-injection process and having an outputting terminal and a first testing electrode;

an isolating layer connected to said conductive sheet and having a through hole for exposing a surface area of said first testing electrode meanwhile making a placing recess on a top of said first testing electrode; and

a chemical reagent disposing on said placing recess for testing an analyte in a sample solution and producing an electric measuring signal to be outputted via said first testing electrode.

75. The electrochemical sensor according to claim 74, wherein a top of said isolating layer and a top of said first testing electrode have a height difference to form said placing recess, meanwhile said chemical reagent is injected in a specific amount into said placing recess for forming an equal thickness.

76. The electrochemical sensor according to claim 75, wherein said first testing electrode serves as a working electrode, and wherein said isolating layer further comprises a first printing metal film to be a second testing electrode and a second output terminal.

77. The electrochemical sensor according to claim 76, wherein said second testing electrode serves as a counter electrode, and said isolating layer further comprises a second printing metal film to be a third testing electrode and a third output terminal, meanwhile said third testing electrode further comprises an Ag/AgCl surface to be a reference electrode.

78. An electrochemical electrode, comprising:

a conductive strip having an outputting terminal and a first testing electrode; and

an isolating substrate connected to said conductive strip and having a through hole for disposed said first testing electrode.

79. The electrochemical electrode according to claim 78 further comprising a reagent matrix layer on a surface of said first testing electrode to modify said first testing electrode to be said working electrode.

80. The electrochemical electrode according to claim 79, wherein said reagent matrix layer includes at least one of an enzyme, a PH buffer, a surfactant, an redox mediator, a hydrophilic polymer compound.

81. The electrochemical electrode according to claim 80, wherein said enzyme is a glucose oxidase for testing a concentration of a blood glucose in a blood.

82. The electrochemical electrode according to claim 80, wherein said enzyme is an uricase for testing a concentration of a uric acid in a blood.

83. The electrochemical electrode according to claim 80, wherein said enzyme is a cholesterol esterase and a cholesterol oxidase for testing a concentration of cholesterol in a blood.

84. The electrochemical electrode according to claim 78 wherein said first testing electrode serves as a counter electrode.

85. The electrochemical electrode according to claim 78 further comprising a Ag/AgCl layer on a surface of said first testing electrode to modify said first testing electrode to be a Ag/AgCl modified reference electrode.