Methods for microdispensing patterened layers
First Claim
1. A method of forming a patterned layer on a substantially planar surface, comprising(a) microdispensing, at a predetermined location, an amount of a photoformable matrix onto said planar surface sufficient to cover a predetermined area having a defined perimeter and to extend beyond said area and perimeter, forming a microdispensed matrix, wherein the area covered by the microdispensed matrix is less than the entire area of the planar surface;
- (b) drying said microdispensed matrix;
(c) aligning said microdispensed matrix with a mask of the predetermined area and defined perimeter at the predetermined location to form an aligned matrix;
(d) exposing said aligned matrix to radiation to form an exposed matrix; and
(e) developing said exposed matrix to remove excess microdispensed photoformable matrix, such that a patterned layer is formed at the predetermined location, said patterned layer having the predetermined area and defined perimeter.
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Abstract
An efficient method for the microfabrication of electronic devices which have been adapted for the analyses of biologically significant analyte species is described. The techniques of the present invention allow for close control over the dimensional features of the various components and layers established on a suitable substrate. Such control extends to those parts of the devices which incorporate the biological components which enable these devices to function as biological sensors. The materials and methods disclosed herein thus provide an effective means for the mass production of uniform wholly microfabricated biosensors. Various embodiments of the devices themselves are described herein which are especially suited for real time analyses of biological samples in a clinical setting. In particular, the present invention describes assays which can be performed using certain ligand/ligand receptor-based biosensor embodiments. The present invention also discloses a novel method for the electrochemical detection of particular analyte species of biological and physiological significance using an substrate/label signal generating pair which produces a change in the concentration of electroactive species selected from the group consisting of dioxygen and hydrogen peroxide.
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Citations
41 Claims
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1. A method of forming a patterned layer on a substantially planar surface, comprising
(a) microdispensing, at a predetermined location, an amount of a photoformable matrix onto said planar surface sufficient to cover a predetermined area having a defined perimeter and to extend beyond said area and perimeter, forming a microdispensed matrix, wherein the area covered by the microdispensed matrix is less than the entire area of the planar surface; -
(b) drying said microdispensed matrix;
(c) aligning said microdispensed matrix with a mask of the predetermined area and defined perimeter at the predetermined location to form an aligned matrix;
(d) exposing said aligned matrix to radiation to form an exposed matrix; and
(e) developing said exposed matrix to remove excess microdispensed photoformable matrix, such that a patterned layer is formed at the predetermined location, said patterned layer having the predetermined area and defined perimeter. - View Dependent Claims (2, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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3. A method of forming a plurality of different patterned layers on a substantially planar surface, comprising
(a) microdispensing, at a plurality of predetermined locations, a plurality of amounts of different photoformable matrices onto said planar surface, each amount sufficient to cover a predetermined area having a defined perimeter and to extend beyond said area and perimeter, forming a plurality of microdispensed matrices, wherein the area covered by the microdispensed matrices is less than the entire area of the planar surface; -
(b) drying said plurality of microdispensed matrices;
(c) aligning said plurality of microdispensed matrices with a mask, said mask having a plurality of features, each feature corresponding to the predetermined area and defined perimeter;
(d) exposing said plurality of matrices aligned with the mask to radiation to form a plurality of exposed matrices; and
(e) developing said plurality of exposed matrices to remove excess amounts of microdispensed photoformable matrix, such that a plurality of different patterned layers is formed at the plurality of predetermined locations, each layer having the predetermined area and defined perimeter.
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23. A method of forming a patterned layer incorporating a bioactive molecule on a substantially planar surface, comprising
(a) microdispensing, at a predetermined location, an amount of a mixture of a photoformable matrix and a bioactive molecule onto said planar surface sufficient to cover a predetermined area and having a defined perimeter and to extend beyond said area and perimeter, forming a microdispensed mixture, wherein the area covered by the microdispensed matrix is less than the entire area of the planar surface; -
(b) drying said microdispensed mixture to form a layer;
(c) aligning said layer with a mask of the predetermined area and defined perimeter at the predetermined location to form an aligned layer;
(d) exposing said aligned layer to radiation to form an exposed layer; and
(e) developing said exposed layer to remove excess microdispensed mixture of photoformable matrix and bioactive molecule, such that a patterned layer incorporating said bioactive molecule is formed at the predetermined location, said patterned layer having the predetermined area and defined perimeter. - View Dependent Claims (24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41)
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Specification