Laser defined features for patterned laminates and electrodes

• US 6,662,439 B1
• Filed: 10/04/1999
• Issued: 12/16/2003
• Est. Priority Date: 10/04/1999
• Status: Expired due to Term

• Current Assignee: Roche Diabetes Care Inc. (Roche Holding AG)
• Original Assignee: Roche Diagnostics Corporation (Roche Holding AG)
• Inventors: Bhullar, Raghbir Singh
• Primary Examiner(s): Arbes, Carl J.
• Application Number:
  US09/411,940
• Time in Patent Office: 1,534 Days
• Field of Search: 298/46, 298/25, 298/47, 298/30, 204/294
• US Class Current: 29/825
• 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: 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 patterned laminate includes ablating through a portion of a metallic layer with a laser, to form a pattern in the metallic layer, where the metallic layer is on and in contact with an insulating substrate. The patterned laminate may be patterned to form electrodes, and can be formed into an electrochemical sensor strip.

Claims

1. A method of making a biosensor electrode set, comprising:

ablating through a portion of a first metallic layer with a laser, to form an interlacing electrode pattern;

wherein said first metallic layer is on a flexible insulating substrate.

2. The method of claim 1, wherein said first metallic layer comprises copper.

3. The method of claim 1, wherein said first metallic layer comprises at least one member selected from the group consisting of gold, platinum, palladium and iridium.

4. The method of claim 1, wherein said insulating substrate is a polymer.

5. The method of claim 4, wherein said pattern has a feature size of less than 100 μ

m.

6. The method of claim 1, wherein said pattern has a feature size of less than 75 μ

m.

7. The method of claim 1, wherein said pattern has a feature size of 1 μ

m to 50 μ

m.

8. The method of claim 4, wherein said first metallic layer is in contact with said insulating substrate.

9. The method of claim 8, wherein said first metallic layer comprises at least one member selected from the group consisting of gold, platinum, palladium and iridium.

10. A method of making a sensor strip, comprising:

forming an electrode set by the method of claim 1; and

cutting said substrate, to form a strip.

11. The method of claim 10, further comprising applying a dielectric on a portion of said metallic layer.

12. The method of claim 11, further comprising applying a reagent on a portion of said electrode set.

13. A method of making a biosensor electrode set, comprising:

ablating through a portion of a first metallic layer with a laser to form an interlacing electrode pattern;

wherein said first metallic layer is on a flexible insulating substrate; and

applying a second metallic layer on said first metallic layer.

14. The method of claim 13 wherein said first metallic layer comprises copper.

15. The method of claim 13 wherein said first metallic layer comprises at least one member selected from the group consisting of gold, platinum, palladium and iridium.

16. The method of claim 13 wherein said insulating substrate is a polymer.

17. The method of claim 13 wherein said pattern has a feature size of less than 100 μ

m.

18. The method of claim 13 wherein said pattern has a feature size of less than 75 μ

m.

19. The method of claim 13 wherein said pattern has a feature size of 1 μ

m to 50 μ

m.

20. The method of claim 16 wherein said first metallic layer is in contact with said insulating substrate.

21. The method of claim 20 wherein said first metallic layer comprises at least one member selected from the group consisting of gold, platinum, palladium and iridium.

22. A method of making a sensor strip, comprising:

forming an electrode set by the method of claim 13; and

cutting said substrate, to form a strip.

23. The method of claim 22 further comprising applying a dielectric on a portion of said metallic layer.

24. The method of claim 23 further comprising applying a reagent on a portion of said electrode set.

25. A method of making a biosensor electrode set ribbon, comprising:

ablating through a portion of a first metallic layer with a laser, to form a plurality of interlacing electrode patterns;

wherein said first metallic layer is on a flexible insulating substrate, and

said electrode set ribbon comprises a plurality of electrode sets.

26. The method of claim 25, wherein said first metallic layer comprises at least one member selected from the group consisting of gold, platinum, palladium and iridium,

said insulating substrate is a polymer, and

said first metallic layer is in contact with said insulating substrate.

27. A method of making a sensor strip, comprising:

forming an electrode set ribbon by the method of claim 25; and

cutting said ribbon into a plurality of strips;

wherein each of said strips comprises at least one of said electrode sets.

28. The method of claim 27, further comprising applying a dielectric on a portion of said metallic layer.

29. The method of claim 28, further comprising applying a reagent on a portion of said electrode set.