Method of forming an electrochemical sensor

• US 20070116603A1
• Filed: 01/18/2007
• Published: 05/24/2007
• Est. Priority Date: 12/12/2000
• Status: Active Grant

• Current Assignee: Ascensia Diabetes Care Holdings AG (PHC Holdings Corporation)
• Original Assignee: Bayer Healthcare LLC (Bayer AG)
• Inventors: Brenneman, Allen, Wogoman, Frank
• Granted Patent: US 8,298,487 B2
• Time in Patent Office: Days
• US Class Current: 422/82.10
• CPC Class Codes: B01L 2200/12 Specific details about manufacturing devices
• CPC Class Codes: B01L 2300/0645 Electrodes
• CPC Class Codes: B01L 2300/0809 rectangular shaped
• CPC Class Codes: B01L 2300/0825 Test strips
• CPC Class Codes: B01L 2400/0406 capillary forces
• CPC Class Codes: B01L 3/5027 by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip B01L3/5023 takes precedence; micromixers B01F33/30; microreactors for synthesis B01J19/0093; microcapillary devices in general B81B1/00
• CPC Class Codes: B01L 3/502707 characterised by the manufacture of the container or its components by shaping or joining plastic parts B29C59/00, B29C65/00; by laminating B32B37/00; manufacture of microstructural devices in general B81C
• CPC Class Codes: B29C 2045/1477 Removable inserts, e.g. the insert being peeled off after moulding
• CPC Class Codes: B29C 45/14 incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles B29C45/1671 takes precedence
• CPC Class Codes: B29C 45/14065 Positioning or centering articles in the mould
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: B29C 45/14754 being in movable or releasable engagement with the coating, e.g. bearing assemblies
• CPC Class Codes: G01N 2021/0346 Capillary cells; Microcells
• CPC Class Codes: G01N 21/03 Cuvette constructions
• CPC Class Codes: G01N 27/4473 by electric means

Abstract

An optical reagent format with a precise capillary channel is made by molding a format on a carrier of a precise predetermined thickness. The carrier includes an insert at least a portion of which is molded in the format. Once the format is made, the insert is detached from the carrier and removed from the format leaving a precisely dimensioned capillary channel with an inlet and vent. A reagent may be applied in the capillary channel and the format used to measure the analyte in a fluid such as blood. An electrochemical sensor with a capillary channel is formed by placing a sacrificial insert and electrodes on a sensor base and applying plastic material. After the plastic material is cured, the sacrificial is removed leaving a capillary channel in the sensor. The inserts may be removed by a tool including a clamp for clamping and holding each insert stationary and a sliding block to which the sensor is secured.

Claims

1. (canceled)

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. (canceled)

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12. (canceled)

13. (canceled)

14. A method of molding an electrochemical sensor, the method comprising the acts of:

providing a first mold;

inserting a first electrical contact in the first mold;

inserting a second electrical contact in the first mold;

placing a sacrificial insert in the first mold;

closing the first mold with a second mold;

injecting material for forming the electrochemical sensor into the closed first and second molds;

curing the material;

opening the first and second molds with respect to each other; and

extracting the sacrificial insert from the cured material so as to leave a channel in the cured material and form the electrochemical sensor.

15. The method of claim 14 wherein extracting the sacrificial insert includes clamping the insert and moving the electrochemical sensor relative to the insert.

19. The method of claim 14 wherein the sacrificial insert comprises metal.

20. The method of claim 19 wherein the metal comprises stainless steel.

21. The method of claim 14 wherein the sacrificial insert comprises a material having a melt temperature higher than the melt temperature of the injected material.

22. The method of claim 14 further including disposing a reagent within the channel.

23. The method of claim 14 wherein the electrochemical sensor is adapted to analyze a liquid sample.

24. The method of claim 15 wherein the first mold includes a plurality of locator pins to assist in locating the first and second electrical contacts.

16. (canceled)

17. (canceled)

18. (canceled)

25. A method of forming an electrochemical sensor, the method comprising the acts of:

providing a sensor base;

placing a sacrificial insert on the sensor base;

placing a first electrical contact and a second electrical contact in the sensor base, the sacrificial insert being positioned between the first electrical contact and the second electrical contact;

placing plastic material on the sensor base and over the sacrificial insert; and

removing the sacrificial insert from the plastic material and the sensor base leaving a capillary channel in the plastic material so as to form the electrochemical sensor.

26. The method of claim 25 wherein the sacrificial insert comprises metal.

27. The method of claim 26 wherein the metal comprises stainless steel.

28. The method of claim 25 wherein the sacrificial insert comprises a material having a melt temperature higher than the melt temperature of the plastic material.

29. The method of claim 25 further including disposing a reagent within the capillary channel.

30. The method of claim 25 wherein the electrochemical sensor is adapted to analyze a liquid sample.