Biosensor

• US 20040206625A1
• Filed: 05/13/2004
• Published: 10/21/2004
• Est. Priority Date: 04/24/2001
• Status: Active Grant

• Current Assignee: Roche Diabetes Care Inc. (Roche Holding AG)
• Original Assignee: Brian S. Hill, Christopher D. Wilsey, John T. Austera, Raghbir S. Bhullar
• Inventors: Hill, Brian S., Bhullar, Raghbir S., Wilsey, Christopher D., Austera, John T.
• Granted Patent: US 7,479,211 B2
• 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 of forming a biosensor is provided in accordance with the present invention. The method includes providing a metallized electrode support substrate and a sensor support, ablating the electrode support substrate to form electrodes, coupling the sensor support substrate to the electrode support substrate, and positioning spaced-apart electrically conductive tracks across the sensor support substrate so that each track is in electrical communication with one electrode.

Claims

1-20. -20 (Cancelled).

21. :

A method of forming a biosensor, the method comprising the steps of;

providing a metallized electrode support substrate and a sensor support,

ablating the electrode support substrate to form electrodes,

coupling the sensor support substrate to the electrode support substrate, and

positioning spaced-apart electrically conductive tracks across the sensor support substrate so that each track is in electrical communication with one electrode.

22. :

The method of claim 21 further comprising the step of punching notches in the sensor support substrate and the coupling step includes aligning the notches with respective electrodes.

23. :

The method of claim 21 further comprising the step of applying a reagent to a portion of the electrodes.

24. :

The method of claim 21 further comprising the step of punching an opening in the substrate spaced-apart from the notches.

25. :

A method of forming a biosensor comprising;

providing an electrode support substrate and a sensor support substrate having a first surface, an opposite second surface facing the electrode support substrate, and notches extending between the first and second surfaces,

ablating the electrode support substrate to form electrodes,

coupling the sensor support substrate to the electrode support substrate to form a capillary channel between the sensor and electrode support substrates and to align each notch with at least a portion of one electrode, wherein at least a portion of the electrodes are positioned in the capillary channel, and

positioning electrically conductive tracks on the first surface of the sensor support substrate, a portion of each track extending from the first surface into at least one notch and being in electrical communication with one of the electrodes.

26. :

The method of claim 25 wherein the electrodes are positioned to define an electrode array and leads extend from the array and each notch is aligned with at least a portion of one lead.

27. :

The method of claim 25 wherein the electrodes are positioned to define spaced-apart electrode arrays.

28. :

The method of claim 27 wherein the sensor support substrate is formed to include an opening and the coupling step includes aligning the opening with one of the electrode arrays.

29. :

The method of claim 25 wherein the tracks are formed to include layers.

30. :

The method of claim 29 wherein one layer is silver ink.

31. :

The method of claim 29 wherein one layer is carbon ink.

32. :

The method of claim 25 wherein the sensor support substrate is formed to include an opening and the coupling step includes aligning the opening with at least a portion of the electrodes.

33. :

The method of claim 32 further comprising the step of coupling a cover substrate to the sensor support substrate.

34. :

The method of claim 33 wherein the cover substrate, sensor support substrate, and electrode support substrate cooperate with one another to define the channel.

31-1. :

The method of claim 25 wherein the electrodes are gold.

35. :

A method of forming a biosensor comprising;

providing a metallized electrode support substrate being formed to define an electrode array and leads extending from the array,

coupling a sensor support substrate to the electrode support substrate, the sensor support substrate being formed to include notches and an opening, at least a portion of each notch being aligned with one lead and the opening being spaced-apart from the leads, and

positioning electrically conductive tracks on the sensor support substrate, each track extending across one of the notches and into engagement with one lead.

36. :

The method of claim 35 wherein the tracks are formed to include layers.

37. :

The method of claim 36 wherein one layer is silver ink.

38. :

The method of claim 36 wherein one layer is carbon ink.

39. :

The method of claim 35 wherein the electrode array and leads are gold.

40. :

The method of claim 35 further comprising the step of coupling a cover substrate to the sensor support substrate so that the cover substrate extends across the electrode array.

41. :

The method of claim 35 wherein the electrode support substrate is ablated to form the electrode array.

42. :

A method of forming a biosensor comprising;

providing an electrode support substrate being formed to define an electrode array and leads extending from the array,

positioning a sensor support substrate on the electrode support substrate, the sensor support substrate being formed to include notches and an opening, at least a portion of each notch being aligned with one lead and the opening being spaced-apart from the leads, and

positioning electrically conductive tracks on the sensor support substrate, each track extending across one of the notches and into engagement with one lead.

43. :

The method of claim 42 wherein the tracks are formed to include layers.

44. :

The method of claim 43 wherein one layer is silver ink.

45. :

The biosensor of claim 43 wherein one layer is carbon ink.

46. :

The biosensor of claim 42 wherein the electrode array and leads are gold.

47. :

The biosensor of claim 42 further comprising the stop of coupling a cover substrate to the sensor support substrate so that the cover substrate extends across the electrode array.

48. :

The method of claim 42 wherein the electrode support substrate is ablated to form the electrode array.