Biosensor with laser-sealed capillary space and method of making
First Claim
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1. A method, comprising:
- depositing a reagent on a base substrate;
laser welding together the base substrate and a cover layer to form a sample-receiving chamber of a biosensor that contains the reagent, wherein no reagent is deposited where the layers are laser welded together;
providing continuous webs of the base substrate and the cover layer;
wherein said laser welding includes laser welding together the continuous webs of the base substrate and the cover layer to form a laminate, wherein the laminate includes multiple sample-receiving chambers containing the reagent;
rotating a rotary-type mask as the continuous webs of the base substrate and the cover layer move thereby, wherein the rotary-type mask includes a plurality of mask apertures that form laser welding patterns for said laser welding;
wherein said laser welding includes shining a laser beam through at least one of the mask apertures to form a laser weld in the shape of one of the laser welding patterns between the continuous webs;
wherein one of the base substrate and the cover layer is more transparent than the other; and
wherein said laser welding includes laser welding through the one that is more transparent by directing a laser beam through the one that is more transparent.
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Abstract
A test strip or biosensor comprising a base substrate on which an electrode system is formed. One or more laminate layers overlie the base substrate to form a sample-receiving chamber in which a reagent is deposited. An opening is provided from the sample-receiving chamber to the exterior of the biosensor. The layers and the base substrate are laser welded to secure the biosensor. One of the layer and base substrate is light transmissive to allow laser welding at the interface therebetween. The biosensor may be formed from a series of continuous webs that are subsequently sliced to form individual biosensors.
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Citations
29 Claims
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1. A method, comprising:
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depositing a reagent on a base substrate; laser welding together the base substrate and a cover layer to form a sample-receiving chamber of a biosensor that contains the reagent, wherein no reagent is deposited where the layers are laser welded together; providing continuous webs of the base substrate and the cover layer; wherein said laser welding includes laser welding together the continuous webs of the base substrate and the cover layer to form a laminate, wherein the laminate includes multiple sample-receiving chambers containing the reagent; rotating a rotary-type mask as the continuous webs of the base substrate and the cover layer move thereby, wherein the rotary-type mask includes a plurality of mask apertures that form laser welding patterns for said laser welding; wherein said laser welding includes shining a laser beam through at least one of the mask apertures to form a laser weld in the shape of one of the laser welding patterns between the continuous webs; wherein one of the base substrate and the cover layer is more transparent than the other; and wherein said laser welding includes laser welding through the one that is more transparent by directing a laser beam through the one that is more transparent. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20, 21, 22, 23, 24, 25, 26, 28, 29)
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19. A method, comprising:
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depositing a reagent on a base substrate; laser welding together the base substrate and a cover layer to form a sample-receiving chamber of a biosensor that contains the reagent; wherein one of the base substrate and the cover layer is more transparent than the other; wherein said laser welding includes laser welding through the one that is more transparent by directing a laser beam through the one that is more transparent; said depositing the reagent includes depositing the reagent to form discrete reagent pads with uncovered sections in between that lack any reagent, wherein said depositing the reagent to form discrete reagent pads occurs before said laser welding; the uncovered sections providing a clean contact surface between the base substrate and the covered layer; and said laser welding includes laser welding at the uncovered sections, wherein no reagent is deposited where the layers are laser welded together.
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27. A method, comprising:
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depositing a reagent on a base substrate; laser welding together the base substrate, a spacer layer, and a cover layer to form a sample-receiving chamber of a biosensor that contains the reagent, wherein the spacer layer has an opening that along with the base substrate and cover layer form the sample-receiving chamber; wherein the base substrate and the cover layer are more transparent than the spacer layer; said depositing the reagent includes depositing the reagent to form discrete reagent pads with uncovered sections in between that lack any reagent; the uncovered sections providing a clean contact surface between the base substrate and the spacer layer, wherein no reagent is deposited where the layers are laser welded together; and said laser welding includes laser welding the spacer layer and the base substrate together at the uncovered sections of the base substrate after said depositing the reagent by shining a laser beam through the base substrate, wherein one of the discrete reagent pads is located in the opening of the spacer layer, and laser welding the cover layer and the spacer layer together by shining the laser beam through the cover layer.
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Specification