METHOD FOR MANUFACTURING A BIOLOGICAL FLUID SENSOR

• US 20160270239A1
• Filed: 02/09/2016
• Published: 09/15/2016
• Est. Priority Date: 03/09/2015
• Status: Active Grant

• Current Assignee: CoreSyte, Inc.
• Original Assignee: CoreSyte, Inc.
• Inventors: Pizer, Adam, Pont, Dalton
• Granted Patent: US 9,645,133 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B23K 1/0016 Brazing of electronic components
• CPC Class Codes: B23K 1/008 Soldering within a furnace B23K1/012 takes precedence
• CPC Class Codes: B23K 2101/36 Electric or electronic devices
• CPC Class Codes: B23K 2101/42 Printed circuits
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B23K 26/402 involving non-metallic material, e.g. isolators
• CPC Class Codes: G01N 33/48785 Electrical and electronic details of measuring devices for physical analysis of liquid biological material not specific to a particular test method, e.g. user interface or power supply
• CPC Class Codes: H01L 23/488 consisting of soldered or bonded constructions bump connectors H01L24/01
• CPC Class Codes: H05K 3/341 Surface mounted components
• CPC Class Codes: H05K 3/3494 Heating methods for reflowing of solder using integral heating means H05K1/0212

Abstract

The present invention presents a method of fabrication for a physiological sensor with electronic, electrochemical and chemical components. The fabrication method comprises steps for manufacturing an apparatus comprising at least one electrochemical sensor, a microcontroller, and a transceiver. The physiological sensor is operable to analyze biological fluids such as sweat.

Claims

1. A method of fabrication for a physiological sensor with electronic, electrochemical and chemical components, the method comprising:

fabricating a substrate;

fabricating a circuit;

picking and placing the electronic components onto the circuit;

reflow soldering of the circuit;

fabricating at least one electrode;

fabricating a membrane;

sealing and curing the at least one electrode; and

fabricating a dressing.

2. The method of claim 1, wherein the physiological sensor comprises at least one electrochemical sensor, a microcontroller, and a transceiver.

3. The method of claim 2, wherein the at least one electrochemical sensor houses the at least one electrode, wherein the at least one electrode includes a standard electrode and an active electrode.

4. The method of claim 3, wherein the standard electrode and the active electrode include silver, zinc, copper, gold, platinum, rhodium, carbon, and/or a combination thereof.

5. The method of claim 2, wherein the physiological sensor is a biological fluid sensor operable to analyze a biological fluid.

6. The method of claim 5, wherein the biological fluid is sweat.

7. The method of claim 6, wherein the at least one electrochemical sensor is operable to detect and continuously analyze at least one biomarker of the sweat.

8. The method of claim 7, wherein the at least one biomarker of the sweat includes electrolytes, small molecules, proteins, and/or metabolites.

9. A method of fabrication for a biological fluid sensor with electronic, electrochemical and chemical components, the method comprising:

fabricating a substrate;

fabricating a circuit;

picking and placing the electronic components onto the circuit;

reflow soldering of the circuit;

fabricating at least one electrode;

fabricating a membrane;

sealing and curing the at least one electrode; and

fabricating a dressing;

wherein fabricating the at least one electrode further comprises;

fabricating a metallization paste and sequencing a reference probe;

applying the metallization paste to at least one active probe;

sequencing the at least one active probe; and

creating the biological fluid sensor with line and space characteristics,

wherein the biological fluid sensor is operable to analyze a biological fluid.

10. The method of claim 9, wherein the biological fluid sensor comprises at least one electrochemical sensor, a microcontroller, and a transceiver.

11. The method of claim 9, wherein the biological fluid is sweat.

12. The method of claim 11, wherein the biological fluid sensor is configured and designed for sensing and/or analyzing sweat flow rate and small protein probes.

13. The method of claim 9, wherein the metallization paste is made of at least one stable metal selected from the group consisting of silver, gold, platinum, and/or palladium.

14. A method of fabrication for a biological fluid sensor with electronic, electrochemical and chemical components, the method comprising:

fabricating a substrate;

fabricating a circuit;

picking and placing the electronic components onto the circuit;

reflow soldering of the circuit;

fabricating an electrode;

fabricating a membrane;

sealing and curing the electrode; and

fabricating a dressing;

wherein the step of fabricating the membrane further comprises applying an ionophore polymer coating on the electrode and curing the ionophore polymer coating; and

wherein the step of fabricating the dressing further comprises;

laser cutting;

bonding;

and assembling the electronic components and the dressing,

wherein the biological fluid sensor is operable to analyze a biological fluid.

15. The method of claim 14, wherein the biological fluid sensor comprises at least one electrochemical sensor, a microcontroller, and a transceiver.

16. The method of claim 14, wherein applying the ionophore polymer coating on the electrode is performed via an automated dispenser.

17. The method of claim 15, wherein the at least one electrochemical sensor is operable to detect and continuously analyze at least one biomarker of the sweat.

18. The method of claim 17, wherein the at least one biomarker of the sweat includes electrolytes, small molecules, proteins, and/or metabolites.

19. The method of claim 14, wherein about 2 microliters of the ionophore polymer coating is applied to the electrode.

20. The method of claim 14, wherein the ionophore polymer coating does not exceed more than about 0.5 millimeters from the edge of the electrode.