Biosensor and method of making
First Claim
1. A biosensor, comprising:
- a base substrate having first and second electrode elements formed thereon;
the first and second electrode elements having first and second respective edges defining a gap therebetween, the gap having a width and a length;
the first edge being spaced from a first theoretical line by a first distance that varies along the length of the gap, the first theoretical line defining a desired shape and placement of the first edge, wherein the standard deviation of the first distance is less than about 6 μ
m over the entire length of the gap;
a reagent at least partially covering the base substrate; and
one or more layers overlying and adhered to the base substrate, the one or more layers cooperating to form a sample-receiving chamber and a cover for the biosensor, at least a portion of the reagent and an electrode being positioned in the chamber.
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Abstract
An electrochemical biosensor with electrode elements that possess smooth, high-quality edges. These smooth edges define gaps between electrodes, electrode traces and contact pads. Due to the remarkable edge smoothness achieved with the present invention, the gaps can be quite small, which provides marked advantages in terms of test accuracy, speed and the number of different functionalities that can be packed into a single biosensor. Further, the present invention provides a novel biosensor production method in which entire electrode patterns for the inventive biosensors can be formed all at one, in nanoseconds—without regard to the complexity of the electrode patterns or the amount of conductive material that must be ablated to form them.
304 Citations
102 Claims
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1. A biosensor, comprising:
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a base substrate having first and second electrode elements formed thereon;
the first and second electrode elements having first and second respective edges defining a gap therebetween, the gap having a width and a length;
the first edge being spaced from a first theoretical line by a first distance that varies along the length of the gap, the first theoretical line defining a desired shape and placement of the first edge, wherein the standard deviation of the first distance is less than about 6 μ
m over the entire length of the gap;
a reagent at least partially covering the base substrate; and
one or more layers overlying and adhered to the base substrate, the one or more layers cooperating to form a sample-receiving chamber and a cover for the biosensor, at least a portion of the reagent and an electrode being positioned in the chamber. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A biosensor, comprising:
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a base substrate having first and second electrode elements formed thereon;
the first and second electrode elements having first and second respective edges defining a gap therebetween, the gap having a width and a length;
the first edge being spaced from a first theoretical line by a first distance that varies along the length of the gap, the first theoretical line defining a desired shape and placement of the first edge, wherein the first distance is less than about 6 μ
m over the entire length of the gap;
a reagent at least partially covering the base substrate; and
one or more layers overlying and adhered to the base substrate, the one or more layers cooperating to form a sample-receiving chamber and a cover for the biosensor, at least a portion of the reagent layer and an electrode being positioned in the chamber. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32, 33, 34, 35)
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36. A method of making a biosensor comprising the following steps:
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providing a base substrate having a layer of electrically conductive material thereon;
removing a portion of the conductive material to form first and second electrode elements on the base substrate having first and second respective edges defining a gap therebetween, the gap having a width and a length;
the first edge being spaced from a first theoretical line by a first distance that varies along the length of the gap, the first theoretical line defining a desired shape and placement of the first edge, wherein the standard deviation of the first distance is less than about 6 μ
m over the entire length of the gap;
providing a reagent at least partially covering the base; and
adhering one or more layers to the base, the one or more layers cooperating to form a sample-receiving chamber and a cover for the biosensor, at least a portion of the reagent and an electrode being positioned within the chamber. - View Dependent Claims (37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49)
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50. A method of forming a biosensor used to measure presence or concentration of an analyte in a fluid sample, comprising:
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(a) providing an electrically conductive material on a base;
(b) removing a portion of the electrically conductive material by broad field laser ablation to form an electrode set on the base;
(c) providing a reagent at least partially covering the base; and
(d) adhering one or more layers to the base, the one or more layers cooperating to form a sample-receiving chamber and a cover for the biosensor, at least a portion of both the reagent layer and the electrode set being positioned in the chamber. - View Dependent Claims (51, 52, 53, 54, 55, 56, 57, 58, 59)
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60. A method of forming a biosensor used to measure concentration of an analyte in a fluid sample, comprising:
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(a) providing an electrically conductive material on a base;
(b) removing at least 10% of the electrically conductive material to form at least two electrode sets on the base, the electrode sets having different feature sizes;
(c) providing a reagent at least partially covering the base; and
(d) adhering one or more layers to the base, the one or more layers cooperating to form a sample-receiving chamber, at least a portion of one of the electrode sets being positioned in the chamber. - View Dependent Claims (61, 62, 63, 64, 65, 66, 67)
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68. A method of manufacturing a plurality of biosensors, comprising:
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(a) providing a web of base substrate material having a metal conductive layer formed thereon;
(b) projecting an image of an electrode pattern onto the metal conductive layer with a laser apparatus, wherein an electrode pattern that corresponds to the image is formed by laser ablation on the web of base substrate material;
(c) moving one of the laser apparatus and the web of base substrate material and repeating step (b) a plurality of times to produce a plurality of the electrode patterns at spaced intervals along the web of base substrate material;
(d) depositing a reagent on the web of base substrate material and at least partially covering each electrode pattern of the plurality of electrode patterns with the reagent;
(e) laminating at least one web of a covering layer or a spacing layer over the web of base substrate material, thereby forming a cover and a sample-receiving chamber for each biosensor; and
(f) cutting through the at least one web of a covering layer or a spacing layer and the web of base substrate material to form the plurality of biosensors. - View Dependent Claims (69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102)
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Specification