Electrochemical sensor

• US 6,911,130 B2
• Filed: 12/07/2001
• Issued: 06/28/2005
• Est. Priority Date: 12/12/2000
• Status: Expired due to Fees

• Current Assignee: Ascensia Diabetes Care Holdings AG (PHC Holdings Corporation)
• Original Assignee: Bayer Healthcare LLC (Bayer AG)
• Inventors: Brenneman, Allen J., Wogoman, Frank W.
• Primary Examiner(s): Olsen, Kaj K.
• Application Number:
  US10/010,233
• Publication Number:
  US 20020079218A1
• Time in Patent Office: 1,299 Days
• Field of Search: 204/400, 204/403.01, 204/403.02, 204/409
• US Class Current: 204/400
• 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. An electrochemical sensor, comprising:

a sensor base;

a sacrificial insert on said sensor base;

a first electrical contact and a second electrical contact in said sensor, said sacrificial insert positioned between said first electrical contact and said second electrical contact; and

plastic material on said sensor base and over said sacrificial inserts said plastic material of a formulation which allows removal of said sacrificial insert from said plastic material and said sensor base leaving a capillary channel in said casting plastic material.

2. The sensor of claim 1 wherein the sacrificial insert is constructed of metal.

3. The sensor of claim 1 wherein the sacrificial insert is constructed of stainless steel.

4. The sensor of claim 1 wherein the insert comprises a material having a melt temperature higher than the melt temperature of the plastic material.

5. The sensor of claim 1 comprising a reagent disposed within the capillary channel.

6. The sensor of claim 1 wherein the sensor is adapted to analyze a liquid sample.