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Portable water quality sensor fabrication method

  • US 8,057,724 B2
  • Filed: 01/06/2010
  • Issued: 11/15/2011
  • Est. Priority Date: 02/06/2004
  • Status: Expired due to Fees
First Claim
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1. A method for fabricating a multilayer disposable microsensor comprising the steps of:

  • (a) forming a one-piece microfluidic package with a first side and a second side in steps consisting of;

    a-i selecting a mold cavity with an inlet for injecting a chemically inert molten polymer;

    a-ii defining a micro pattern of microfluidic channels having at least one set of interconnecting ports, the set having an inlet port and an outlet port, the set including one male port and one female port on a first side of the mold cavity;

    a-iii defining a plurality of inlet/outlet ports on a second side of the mold cavity that is opposite to the first side, the second side having one of a microfluidic channel and a combination of a microfluidic channel and a fluid reservoir, the first side and the second side of the one-piece microfluidic mold cavity together solely providing a one-piece, integrally formed one-piece microfluidic package;

    a-iv injecting a molten polymer into the mold cavity;

    a-v allowing the mold to cool;

    a vi allowing the molten polymer to become a rigid substrate;

    (a-vii) removing the rigid substrate with a plurality of inlet/outlet ports on the first side and a microfluidic channel and a combination of a microfluidic channel and a fluid reservoir on the second side thereby providing a one-piece, integrally formed, microfluidic package capable of permitting flow-through of a sample fluid;

    (b) preparing an electrode layer on a chemically inert, rigid polymer substrate that comprises a first set of electrodes, a second set of electrodes and one set of temperature sensors;

    I covering the electrode layer with a dissolved oxygen selective membrane;

    (d) preparing a microbial layer that is immobilized on one set of sensor electrodes;

    (e) sandwiching the microbial layer between the electrode layer and the microfluidic layer;

    (f) using an adhesive material to hold the electrode layer, the microbial layer and the microfluidic layer in a secure, stacked unitary arrangement; and

    (g) forming a multilayer, disposable microsensor wherein the top layer is the electrode layer with a first set of electrodes, a second set of electrodes and one set of temperature sensors, the middle layer is a microbial layer immobilized on one set of sensor electrodes and the bottom layer is the one-piece, integrally formed, microfluidic package capable of permitting flow-through of the sample fluid.

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