ANALYTE SENSOR FABRICATION

• US 20110017594A1
• Filed: 06/25/2010
• Published: 01/27/2011
• Est. Priority Date: 06/30/2009
• Status: Abandoned Application

• Current Assignee: Edwards Lifesciences Corporation
• Original Assignee: Edwards Lifesciences Corporation
• Inventors: Petisce, James R., Huang, Wei
• Application Number:
  US12/824,054
• Publication Number:
  US 20110017594A1
• Time in Patent Office: Days
• US Class Current: 204/403.06
• CPC Class Codes: A61B 2562/02 Details of sensors specially adapted for in-vivo measurements
• CPC Class Codes: A61B 5/1486 using enzyme electrodes, e.g. with immobilised oxidase
• CPC Class Codes: B41F 17/001 Pad printing apparatus or machines
• CPC Class Codes: G01N 27/3272 Test elements therefor, i.e. disposable laminated substrates with electrodes, reagent and channels optical biosensors G01N33/52

Abstract

A biosensor fabrication process comprising transferring one or more layers (e.g., conductive ink and/or membrane layers) from a surface to the biosensor substrate and biosensors produced therefrom. Layers are transferred from the surface to the biosensor substrate using a deposition device, such as a pick and place machine or a printing pad/plate.

Claims

1-56. -56. (canceled)

57. A method of fabricating a biosensor comprising:

depositing one or more layers on a surface, the surface being releasable of the one or more layers; and

transferring the one or more layers from the surface to at least one biosensor substrate.

58. The method of claim 57, wherein the transferring is performed using a pick and place device.

59. The method of claim 57, wherein the one or more layers comprises conductive ink, optionally in combination with an enzyme-containing layer.

60. The method of claim 57, further comprising treating the one or more layers after deposition.

61. The method of claim 57, wherein the biosensor substrate comprises one of a printed circuit board or a MEMs-based substrate.

62. The method of claim 57, further comprising:

forming a sheet of the one or more layers on a surface; and

forming at least one object having a predetemined shape from the sheet.

63. The method of claim 62, wherein the at least one predetermined shaped object is a conductive material capable of forming an electrode.

64. The method of claim 57, wherein the depositing and transferring is performed by pad printing.

65. The method of claim 64, wherein the pad printing process comprises:

providing an etched printing plate and a corresponding printing pad;

introducing the one or more layers to the etched printing plate;

contacting the one or more layers with the printing pad; and

transferring the one or more layers to the at least one biosensor substrate using the printing pad.

66. The method of claim 57, wherein the one or more layers comprise at least one or more of an electrode layer, an interference layer, an enzyme layer, a flux-limiting layer, or any combination thereof.

67. The method of claim 65, wherein the pad printing one or more liquid membrane layers comprises:

applying at least one liquid membrane layer;

contacting a pad onto the at least one liquid membrane layer; and

transferring the at least one liquid membrane layer to the substrate.

68. The method of claim 57, wherein said depositing comprises:

providing a position-controlled platen for receiving at least one substrate, each of the at least one substrate having at least one surface area portion adapted for receiving an electrode-forming material;

positioning the platen in a predetermined position relative to a deposition unit; and

depositing at least one layer on the at least one surface area portion of the at least one substrate.

69. The method of claim 68, wherein the depositing comprises depositing the at least one layer at a plurality of portions on a substrate to form a plurality of electrodes on the biosensor.

70. The method of claim 68, wherein the at least one layer comprises a conductive ink and at least one membrane layer.

71. A method for fabrication of a biosensor comprising:

depositing a first working electrode at a first portion of a substrate, comprising;

depositing a first conductive ink layer on a surface; and

transferring the first conductive ink layer from the surface to the first substrate portion;

depositing a second working electrode at a second portion of the substrate, comprising;

depositing a second conductive ink layer on the surface;

depositing at least one membrane layer over the second conductive ink layer; and

transferring the second conductive ink layer from the surface to the second substrate portion; and

depositing a reference electrode at a third portion of the substrate, comprising.

depositing a third conductive ink layer on the surface; and

transferring the third conductive ink layer from the surface to the third substrate portion,

wherein one or more of the transferring steps is performed using a printing pad process or a pick and place device.

72. The method of claim 71 further comprising:

depositing a counter electrode at a fourth portion of the substrate, comprising;

depositing a fourth conductive ink layer on the surface; and

transferring the fourth conductive ink layer from the surface to the fourth substrate portion.

73. The method of claim 71, further comprising depositing conductive ink on the surface at two additional portions of the substrate to form a thermistor on the substrate.

74. The method of claim 71, further comprising:

applying at least one liquid membrane layer;

contacting a pad onto the at least one liquid membrane layer; and

transferring the at least one liquid membrane layer to the substrate on one of said first or second working electrodes.

75. A biosensor formed by a process comprising:

depositing one or more layers on a surface, the surface being releasable of the one or more layers; and

transferring the one or more layers from the surface to at least one biosensor substrate.

76. A biosensor formed by a process comprising:

depositing a first working electrode at a first portion of a substrate, comprising;

depositing a first conductive ink layer on a surface; and

transferring the first conductive ink layer from the surface to the first substrate portion;

depositing a second working electrode at a second portion of the substrate, comprising;

depositing a second conductive ink layer on the surface;

depositing at least one membrane layer over the second conductive ink layer; and

transferring the second conductive ink layer from the surface to the second substrate portion; and

depositing a reference electrode at a third portion of the substrate, comprising.

depositing a third conductive ink layer on the surface; and

transferring the third conductive ink layer from the surface to the third substrate portion,

wherein one or more of the transferring steps is performed using a printing pad process or a pick and place device.

77. A system for fabricating a biosensor, the system comprising:

a deposition device for depositing one or more layers on a surface; and

a pick and place device for transferring the one or more layers from the surface to a biosensor substrate.

78. The system of claim 77, wherein the one or more layers comprises at least one or more of an electrode layer, an interference layer, an enzyme layer, a flux-limiting layer, or any combination thereof.

79. The system of claim 77, wherein the pick and place device and the deposition device are cooperatively configured.

80. The system of claim 77, further comprising treating the one or more layers after deposition.

81. The system of claim 77, further comprising a device to cut the one or more layers into one or more predetermined shapes on the surface.

82. The system of claim 77, wherein the deposition unit is configured to deposit a plurality of predetermined shaped objects from the surface to a plurality of biosensor substrates.

83. The system of claim 77, further comprising a pad printing system to pad print one or more layers, wherein the pad printing system comprises:

an etched printing plate to receive the one or more layers; and

a printing pad adapted to contact and releasably transfer the one or more layers to the substrate.