Method of making a biosensor

• US 7,073,246 B2
• Filed: 06/20/2003
• Issued: 07/11/2006
• Est. Priority Date: 10/04/1999
• Status: Expired due to Term

• Current Assignee: Roche Diabetes Care Inc. (Roche Holding AG)
• Original Assignee: Roche Diagnostics Operations Incorporated (Roche Holding AG)
• Inventors: Diebold, Eric R., Hill, Brian S., Bhullar, Raghbir S., Surridge, Nigel A., Walling, Douglas P.
• Primary Examiner(s): Arbes, Carl J.
• Application Number:
  US10/601,144
• Publication Number:
  US 20040194302A1
• Time in Patent Office: 1,117 Days
• Field of Search: 298/25, 298/46, 298/47, 295/95, 219/121.69
• US Class Current: 29/595
• CPC Class Codes: C12Q 1/001 Enzyme electrodes
• 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: G01N 33/5438 Electrodes
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 3/027 the conductive material being removed by irradiation, e.g. by photons, alpha or beta particles
• CPC Class Codes: Y10T 29/49007 Indicating transducer
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49156 with selective destruction of conductive paths

Abstract

A method of making a biosensor is provided. The biosensor includes an electrically conductive material on a base and electrode patterns formed on the base, the patterns having different feature sizes. The conductive material is partially removed from the base using broad field laser ablation so that less than 90% of the conductive material remains on the base and that the electrode pattern has an edge extending between two points. A standard deviation of the edge from a line extending between two points is less than about 6 μm.

Claims

1. A method of making a biosensor, the method comprising the steps of:

providing an electrically conductive material on a base; and

forming electrode patterns on the base using broad field laser ablation, wherein at least two electrode patterns have different feature sizes, wherein at least one electrode pattern has at least one edge extending between two points, a standard deviation of the edge from a line extending between two points is less than about 6 μ

m.

2. The method of claim 1 wherein the conductive material is selected from the group consisting of gold, platinum, palladium, iridium, and indium tin oxide.

3. The method of claim 1 wherein the base is a polymer.

4. The method of claim 1 wherein the forming step includes removing at least 2% of the conductive material from the base.

5. The method of claim 4 wherein at least 50% of the conductive material is removed from the base.

6. The method of claim 4 wherein at least 90% of the conductive material is removed from the base.

7. The method of claim 1 wherein the laser ablation is performed by a laser apparatus and at least one electrode pattern is formed with pulses of a laser beam from the laser apparatus.

8. The method of claim 1 wherein at least one electrode pattern is an interlacing pattern.

9. The method of claim 1 wherein the standard deviation is less than about 2 μ

m.

10. The method of claim 1 wherein the standard deviation is less than about 1.0 μ

m.

11. The method of claim 1 further comprising the step of placing a reagent on at least one of the electrode patterns.

12. The method of claim 1 wherein the laser ablation is perfonned by a laser apparatus and at least one electrode pattern is formed with a single pulse of a laser beam from the laser apparatus.

13. The method of claim 1 wherein the laser ablation is performed by a laser apparatus that produces a laser beam having a dimension that is greater than a feature size of at least one electrode pattern.

14. The method of claim 1 wherein at least one electrode pattern is formed by the forming step in less than about 0.25 seconds.

15. The method of claim 1 wherein at least one electrode pattern is formed by the forming step in less than about 50 nanoseconds.

16. The method of claim 1 wherein at least one electrode pattern is formed by the forming step in about 25 nanoseconds.

17. A method of making a biosensor, the method comprising the steps of:

providing an electrically conductive material on a base; and

forming electrode patterns on the base using broad field laser ablation, wherein at least two electrode patterns have different feature sizes, wherein the at least one electrode pattern has electrode fingers that cooperate with one another to define an electrode gap having a pre-determined width value, a standard deviation of the gap from the width value is less than about 4 μ

m.

18. The method of claim 17 wherein the gap standard deviation is less than about 3 μ

m.

19. The method of claim 17 wherein the gap standard devialion is less than about 1.0 μ

m.

20. A method of making a biosensor, the method comprising the steps of:

providing an electrically conductive material on a base; and

partially removing the conductive material using laser ablation from the base so that less than 90% of the conductive material remains on the base and at least one electrode pattern is formed from the conductive material, the at least one electrode pattern having an edge extending between two points, a standard deviation of the edge from a line extending between two points being less than about 6 μ

m.

21. The method of claim 20 wherein the standard deviation is less than about 2 μ

m.

22. The method of claim 20 wherein the standard deviation is less than about 1 μ

m.

23. The method of claim 20 wherein at least one electrode pattern is formed in less than about 0.25 seconds.

24. The method of claim 20 wherein at least one electrode pattern is formed in less than about 50 nanoseconds.

25. The method of claim 20 wherein said electrode pattern is formed in about 25 nanoseconds.

26. The method of claim 20 wherein the at least one electrode pattern has electrode fingers that cooperate with one another to define an electrode gap having a pre-determined width value, a standard deviation of the gap from the width value is less than about 4 μ

m.

27. The method of claim 26 wherein the gap standard deviation is less than about 3 μ

m.

28. The method ef claim 26 wherein the gap standard deviation is less than about 1.0 μ

m.

29. The method of claim 20 wherein less than 50% of the conductive material remains on the base.

30. The method of claim 20 wherein less than 10% of the conductive material remains on the base.

31. The method oF claim 20 wherein the conductive material is removed using laser ablation.

32. A method of making a biosensor, the method comprising the steps of:

providing an electrically conductive material on a base,

forming electrode patterns on the base using broad field laser ablation, wherein at least two electrode patterns have different feature sizes, and

extending a cover over the base, the cover and base cooperating to define a sample-receiving chamber and at least a portion of the electrode patterns are positioned in the sample-receiving chamber.

33. The niethod of claim 32 wherein the conductive material is selected from the group consisting of gold, platinum, palladium, iridium, and indium tin oxide.

34. The method of claim 32 wherein the base is a polymer.

35. The method of claim 32 wherein the forming step includes removing at least 2% of the conductive material from the base.

36. The method of claim 35 wherein at least 90% of the conductive material is removed from the base.

37. The method of claim 32 wherein the laser ablation is performed by a laser apparatus and at least one electrode pattern is formed with pulses of a laser beam from the laser apparatus.

38. The method of claim 32 wherein at least one electrode pattern is an interlacing pattern.

39. The method of claim 32 wherein at least one electrode pattern has at least one edge extending between two points and a standard deviation of the edge from a line extending between two points is less than about 2 μ

m.

40. The method of claim 39 wherein the standard deviation is less than about 1.5 μ

m.

41. The method of claim 32 wherein the at least one electrode pattern has electrode fingers that cooperate with one another to define an electrode gap having a pre-determined width value, a standard deviation of the gap from the width value is less than about 2 μ

m.

42. The method of claim 41 wherein the standard deviation is less than about 1.75 μ

m.

43. The method of claim 32 further comprising the step of placing a reagent on at least one of the electrode patterns.

44. The method of claim 32 wherein the laser ablation is performed by a laser apparatus that produces a laser beam having a dimension that is greater than a feature size of at least one electrode pattern.

45. The method of claim 32 wherein at least one electrode pattern is formed in less than about 50 nanoseconds.

46. The method of claim 32 wherein said electrode pattern is formed in about 25 nanoseconds.