AU693678B2 - Defining an electrode area - Google Patents

Description

DEFINING AN ELECTRODE AREA TECHNICAL FIELD:

The present invention relates to a method for defining an area of a coating or

layer attached to or in contact with a porous substrate. More particularly, the present

invention relates to a method wherein the coating or layer is an electrode. Although

the invention will be described with reference to its application in the electrochemical

area it is not intended that the invention be limited to that use. It may extend to any

application where a defined area of a porous substrate is required.

BACKGROUND ART:

In the past it has been found that whenever quantitative electrochemical

measurements are performed it is necessary to have both a reproducible and accurately

defined electrode area which is in contact with the sample being analysed. When

performing a measurement in a bulk solution the usual practice has been either to have

the electrode immersed to a certain level in the liquid or alternatively to have an

insulation layer applied to the electrode to leave only a precisely defined area in contact with the solution. These practices have proved to be relatively expensive and

unreliable. It has also been found that when these methods are used it is difficult to

prevent leakage and contact with the electrode outside the defined area, especially

when the substrate upon which the electrode is placed is porous.

The present invention seeks to overcome or at least ameliorate the problems of

the prior art by providing a method which is inexpensive, simple to apply and reliable.

SUMMARY OF THE INVENTION:

According to one aspect the present invention consists in a method for defining

an area of a layer on a porous substrate comprising compressing a volume of the

substrate to produce a compressed region which defines, or which in combination with

an edge of the substrate or of the layer defines, a boundary of the area and which

substantially prevents the transport of material through or across its surface.

According to a second aspect the invention consists in an electrochemical

sensing device comprising:

a porous substrate; and

an electrode on one side of the substrate; wherein a region of the

substrate is compressed to an extent which forms a barrier to migration of electrolyte

within the substrate, the compressed region defining, or in combination with an edge

of the substrate or the electrode defining, a zone on the electrode of predetermined

area.

According to a third aspect the porous substrate of the second aspect is a

membrane that is permeable to a fluid containing a first species to be analysed but

substantially impermeable to a second species contained in the fluid, the second species being of a kind which would interfere with electrochemical sensing of the first

species.

Preferably, the layer, which may be attached to or in contact with the porous

substrate or may be a coating applied to the substrate, is an electrode and the area

being defined is an electrode area. When the layer is an electrode it is usually sputter

deposited on the surface of the substrate so as to form a continuous film on the

surface. However, other methods such as electroless plating, electroplating,

evaporation, anodization or the like can be used to form the electrode. Usually the

film thickness on the substrate is 10-200nm, more preferably 60-120nm.

Materials which would be suitable as an electrode include gold, silver,

platinum, palladium, iridium, lead, and alloys of those metals, carbon, carbon mixed

with a binding material, and silver partially covered with a porous layer of an

insoluble silver salt such as silver chloride, silver bromide, silver iodide, silver

ferricyanide and silver ferrocyanide. In electrochemical sensing devices according to

the invention there will typically be two or more electrodes and these may be disposed

on one side of the substrate or on opposite sides of the substrate.

In a preferred form the resulting substrate produced from the method of the

invention will have at least two discrete regions - one region being compressed and the

other region being uncompressed. This resulting substrate has been found to be

particularly useful when used as an electrochemical sensing device. When a sample is

placed on the uncompressed region of the resulting substrate, migration of the sample

to another region of that substrate, being divided from the first region by the

compressed region, is substantially prevented. It has been found that the sample is confined to a predetermined area of the resulting substrate and therefore to a

predetermined area of the electrode attached to or otherwise in contact with the

resulting substrate.

The method of the present invention works by substantially eliminating or

sufficiently constricting the porous structure of the substrate in the compressed region

to render that region effectively impermeable.

The method of the present invention can be used alone or preferably, in

conjunction with a blocker. A blocker, in the present invention, is a substance which

is placed in the substrate such that it does not prevent the transport of material in the

uncompressed regions of the substrate but assists in preventing transport of material in

the compressed areas. Examples of material suitable as a blocker may include

glucose, agar, gelatine, starch or the like.

In a preferred form the blocker is conveniently loaded into the precompressed

porous substrate using the steps of:

(a) dissolving the blocker in a suitable solvent;

(b) wetting the substrate with the solution of the blocker; and then

(c) removing the solvent by evaporation.

In another preferred form the porous substrate is of a kind having pores which

increase in diameter from a smooth or shiny side to a rough side. The porous substrate

is desirably of the kind disclosed in U.S. Patent Nos 4,629,563 and 4,774,039 both of

which are incorporated herein in their entirety by reference. However according to

end use the substrate may be an asymmetric or symmetric membrane. The substrate may be any suitable porous material that is compressible and

which will maintain its mechanical integrity during compression. Examples of such materials include polymers or mixtures of polymers such as polysulfones,

polyvinylidene halides such as polyvinylidene difluorides, tetrafluoroethene,

polyamides, polyimides, polyethylenes, polypropylenes, polyacrylonitrites,

polycarbonates or the like. The materials may be in the form of a sheet, tube or

hollow fibre which have microscopic or macroscopic pores.

The thickness of the substrate is selected with the end use in mind. Usually it

is desirable for the substrate to be thin to minimise sample volume. However,

sufficient thickness is required to provide mechanical strength for handling and to

maintain sufficient separation between electrodes on opposite faces of the substrate to

prevent electrical short circuits.

In some applications for example anodic stripping, larger sample volumes and greater thickness will be preferred. Preferred embodiments and illustrative examples

of the present invention will now be described, by way of example only, with

reference to the accompanying figures, in which :-

BRIEF DESCRIPTION OF THE FIGURES:

Figure 1 shows a cross-sectional view of a microporous substrate in

uncompressed form, with a portion shown as an enlarged image;

Figure 2 shows the substrate of Figure 1 with compressed regions in

combination with the edge of the microporous substrate to define a perimeter of the

area with a portion of the compressed region shown as an enlarged image;

Figure 3 shows a top view of the substrate of Figure 2; Figure 4 shows an end view of the substrate of Figures 1 or 2;

Figures 5 is similar view to Figure 1 where a blocker has been added to the

substrate;

Figure 6 is a similar view to Figure 2 where a blocker has been added to the

substrate;

Figures 7 is a top view of one embodiment differing in respect of defined

target areas;

Figure 8 is a top view of a second embodiment differing in respect of target

areas;

Figure 9 is a top view of a third embodiment differing in respect of target

areas;

Figure 10 is a top view of a fourth embodiment differing in respect of target

areas; and

Figure 11 shows a top view of a preferred embodiment of the invention.

Figure 1 illustrates a microporous substrate 10 in an uncompressed form

having an electrode 1 being attached to or in contact with substrate 10. The thickness

of the precompressed substrate is preferably about 180μm, more preferably from 30-

150μm. The pore size ranges from 10 kilodaltons cut-off (lower limit) to 5 microns

and preferably from 0.1 μm to 0.8μm, more preferably from 0.2μm to 0.5μm. Also

shown in Figure 1 is the magnified image which shows the uncompressed pores 2 of

the substrate. When pressure is applied to an area 5 of the microporous substrate 10,

one or more discrete compressed regions 8 are produced. As shown in Figure 2 and 3

the compressed regions 8 in combination with the edges 7 of the uncompressed region define a boundary of the area 4. This compressed region 8 substantially prevents the

transport of material (not shown) through or across its volume.

The magnified image of Figure 2 shows the pores 6 of region 8 which have

been compressed so as to substantially prevent transportation of material across or

through region 8.

Figures 5 and 6 illustrate the effect of the addition of a blocker 3. As shown in

the magnified image of Figure 6 the addition of blocker 3 makes the blockage of the

pores 6 in region 8 more complete so as to prevent the transportation of material

across or through it.

Figures 7 and 8 illustrates the compressed area 5 being in the shape of a ring or

square on one side of substrate 10 and overlying an electrode 1 on the opposite side.

The compressed region 8 defines a boundary of an area 4 of the electrode and which

substantially prevents the transport of material (not shown) through or across region 8

to adjoining regions 9.

Although not illustrated in the drawings the area 4 of electrode 1 may be

defined partly by compressed region 8 or region 5 and partly by an electrode edge.

Figure 9 shows a rectangular area 4 being defined on one edge by compressed

substrate 5 and on the other edges by the edge 11 of uncompressed substrate 9.

Figure 10 shows a rectangular area 4 being defined by two compressed regions

5 in combination with two edges 1 1 of uncompressed substrate 9.

In the present invention the porous substrate is preferably pressed by means of

a press or any suitable compressing process which will allow for at least one region of

the porous substrate to be compressed. The amount of pressure to be applied varies between substrates, at both the high and low end of the pressure range. It is preferred

that a sufficient amount of pressure is applied to the substrate which will collapse the

pore structure of the substrate to achieve substantial non-porosity, but not too high so

as to significantly destroy the mechanical integrity of the substrate.

An exemplification of the range of pressures needed to compress the porous

substrate will now be described, with reference to the following examples and

comparative examples.

BEST MODE OF CARRYING OUT THE INVENTION:

EXAMPLE 1

A sheet of polysulfone substrate 150μm thick with pores of between 0.2μm

and 0.5μm was dipped into a solution which was 1 wt% gelatine in water. The excess

liquid was wiped from the outside of the substrate and the substrate dried in an oven to

remove the water. The substrate was then pressed with a pressure of 100 MPa such

that a compressed area in the form of a ring was formed on the substrate. The ring had

an internal diameter of 8 mm and an external diameter of 10 mm.

1 Oμl of a solution of a dye (Rose Bengal) in water was dropped onto the

substrate inside the ring. The dye solution was seen to spread to the inside edge of the

compressed ring and then stop. No dye was visible outside the circular region defined

by the compressed ring after approximately 1 hour, by which time the water in the dye

solution had evaporated.

COMPARATIVE EXAMPLE 1

As in example 1 except the substrate was pressed with a pressure of 30 MPa.

At this pressure there was some leakage of the dye to outside the defined area. EXAMPLE 2

As in example 1 except that the substrate was coated with approximately 60nm

of platinum which was used as an electrode. Also, instead of a dye solution being

dropped onto the substrate a solution containing ferrocyanide and ferricyanide was

used, a potential applied to the platinum electrodes and the current recorded over time.

After an initial higher current the current stayed constant for approximately 10

minutes, after which time the substrate started to dry out and lose electrical

connection. This constant current indicated that no spreading of the solution outside

the defined area had occurred. COMPARATIVE EXAMPLE 2

As in example 1 except the substrate was pressed with a pressure of 55 MPa.

Five defined areas were prepared. One showed some leakage of the dye outside the

defined area, the other four showed no leakage.

EXAMPLE 3

As in example 2 except that a polyvinylidene difluoride substrate with

approximately 0.2μm pores was used. EXAMPLE 4

As in example 1 except the substrate was pressed with a pressure of 80 MPa. At this pressure there was no leakage of the dye outside the defined area.

COMPARATIVE EXAMPLE 4

As in example 1 except the substrate was not dipped into a gelatine solution.

The pressure applied was 70 MPa. Four defined areas were prepared and the dye

leaked to outside the defined area in all cases. COMPARATIVE EXAMPLE 5

As in example 1 except the substrate was not dipped into a gelatine solution

and pressed with a pressure of 80 MPa. Five defined areas were prepared and the dye

leaked to outside the defined area in four cases and no leakage was apparent in one

case.

COMPARATIVE EXAMPLE 6

As in example 1 except the substrate was not dipped into a gelatine solution

and pressed with a pressure of 100 MPa. Three defined areas were prepared and the

dye leaked to outside the defined area in one case and no leakage was apparent in two

cases.

Preferably, the membrane in the present invention is permeable to a fluid

containing a first species to be analysed but substantially impermeable to a second

species. An exemplification of this preferred embodiment of the invention will now

be described with reference to the following example.

EXAMPLE A

A sheet of polysulfone lOOμm thick with pores of 0.2μm was coated on one

side with two 1mm strips of platinum. A defined electrode area was prepared in

accordance with the method of Example 1. A sample of blood to be analysed was

brought into contact with the substrate on the opposite side on which the sensing

electrode was coated and within the defined area. It was found that the membrane was

impermeable to the interfering species erythrocytes (II) in the blood but permeable to

glucose or cholesterol (I). The first species, either glucose or cholesterol, could be

analysed without interference from erythrocytes (II). - l i ¬

lt will be understood that in an electrochemical sensing device it is usual to

employ two or three electrodes and in that case all the electrodes may extend into or

pass through an area defined by a barrier or barriers according to the invention. For

example, the compressed barrier may define a square through which two strip

electrodes pass. An area is thus defined on each electrode by the edges of that

electrode and by the compressed barrier where the strip enters and leaves the square.

EXAMPLE B

In a highly preferred embodiment of the invention illustrated in Figure 1 1 ,

substrate 10 is in the form of a strip having electrodes 1, IA on opposite sides of the

strip. Both electrodes 1, 1 A extend longitudinally of the strip which has a plurality of

defined square areas 4 spaced apart along the strip length, each area being defined by a

boundary 8 formed by compression in accordance with the invention.

Each area 4 defines a predetermined area of electrodes 1 and 1 A (shown

crosshatched). In use a sample may be placed on an area 4 nearest the strip end.

Measurements may be made by connecting suitable apparatus with the

electrodes at the opposite strip end in a manner that is conventional. Thereafter the

"used" area may be cut from the strip and the next area 4 now closest to the strip end

may be used for the next sample.

If desired, an absorbent strip may be provided on the side remote from the

sensor electrode to increase the sample volume and hence the signal or to reduce

measuring times. Likewise if desired, one or more analytes might be contained within

the volume of substrate bounded by compressed substrate 8. Although the invention has been described with reference to specific examples

and Figures, it will be appreciated by those skilled in the art that the invention may be

embodied in many other forms.

Claims (42)

CLAIMS:

1. A method for defining an area of a layer on a porous substrate comprising

compressing a volume of the substrate to produce a compressed region which defines,

or which in combination with an edge of the substrate or of the layer defines, a

boundary of the area and which substantially prevents the transport of material

through or across its surface.

2. A method according to claim 1 , wherein the layer is either attached to or in

contact with the porous substrate or is a coating applied to the substrate.

3. A method according to claim 1 or claim 2, wherein the layer is an electrode

and the area being defined is an electrode area.

4. A method according to claim 3, wherein the electrode is formed on the

surface of the substrate by a method selected from the group consisting of electroless

plating, electroplating, evaporation, and sputtering.

5. A method according to claim 4, wherein the electrode is sputter deposited on

the surface of the substrate to form a continuous film.

6. A method according to claim 5, wherein the film thickness on the substrate is

10 to 200 nm.

7. A method according to claim 6, wherein the film thickness is 60 to 120 nm.

8. A method according to any one of claims 3 to 7, wherein the electrode is

made of materials selected from the group consisting of gold, silver, platinum,

palladium, iridium, lead and alloys of those metals, carbon, carbon mixed with a

binding material, and silver partially covered with a porous layer of an insoluble silver

salt.

9. A method according to claim 8, wherein the insoluble silver salt is silver

chloride, silver bromide, silver iodide, silver ferrocyanide or silver ferricyanide.

10. A method according to any one of claims 1 to 9, further including a blocker

in the substrate which assists in preventing transport of material in the compressed

region.

1 1. A method according to claim 10, wherein the blocker is glucose, agar,

gelatine or starch.

12. A method according to claim 10 or claim 11, wherein the blocker is loaded

into the precompressed porous substrate using the steps of:

a) dissolving the blocker in a suitable solvent;

b) wetting the substrate with the solution of the blocker; and then

c) removing the solvent by evaporation.

13. A method according to any one of claims 1 to 12, wherein the substrate is

made of a porous material selected from the group consisting of polymers or mixtures

of polymers.

14. A method according to claim 13, wherein the polymers or mixtures of

polymers consist of polysulfones, polyvinylidene halides, tetrafluoroethene,

polyamides, polyimides, polyethylene, polypropylenes, polyacrylonitrides or

polycarbonates.

15. A method according to claim 14, wherein the polyvinylidene halides are

polyvinylidene difluorides.

16. A method according to any one of claims 1 to 15, wherein the thickness of

the precompressed substrate is about 180μm or less.

17. A method according to claim 16, wherein the thickness of the precompressed

substrate is from 30μm to 150μm.

18. A method according to any one of claims 1 to 17, wherein the pore size of the

substrate ranges from 10 kilodaltons cut-off (lower limit) to 5 microns.

19. A method according to claim 18, wherein the pore size of the substrate ranges

from 0.1 μm to 0.8 μm.

20. A method according to claim 19, wherein the pore size of the substrate ranges

21. A method for defining an area of a layer on a porous substrate which method

is substantially as herein described with reference to any one of the examples and/or

accompanying figures but excluding the comparative examples.

22. An electrochemical sensing device comprising:

a porous substrate; and

an electrode on one side of the substrate; wherein a region of the substrate is

compressed to an extent which forms a barrier to migration of electrolyte within the

substrate, the compressed region defining, or in combination with an edge of the

substrate or the electrode defining, a zone on the electrode of predetermined area.

23. An electrochemical sensing device according to claim 22, wherein the

electrode is formed on one side of the substrate by a method selected from the group

consisting of electroless plating, electroplating, evaporation, and sputtering.

24. An electrochemical sensing device according to claim 23, wherein the

electrode is sputter deposited on the surface of the substrate to form a continuous film.

25. An electrochemical sensing device according to claim 24, wherein the film

thickness on the substrate is 10 to 200 nm.

26. An electrochemical sensing device according to claim 25, wherein the film

thickness is 60 to 120 nm.

27. An electrochemical sensing device according to any one of claims 22 to 26,

wherein the electrode is made of materials selected from the group consisting of gold,

silver, platinum, palladium, iridium, lead and alloys of those materials, carbon, carbon

mixed with a binding material, and silver partially covered with a porous layer of an

insoluble silver salt.

28. An electrochemical sensing device according to claim 27, wherein the

insoluble silver salt is silver chloride, silver bromide, silver iodide, silver ferricyanide

or silver ferrocyanide.

29. An electrochemical sensing device according to any one of claims 22 to 28,

wherein there are two or more electrodes and they are disposed on one side of the

substrate or on opposite sides of the substrate.

30. An electrochemical sensing device according to any one of claims 22 to 29,

further including a blocker in the substrate which assists in preventing transport of

material in the compressed region.

31. An electrochemical sensing device according to claim 30, wherein the

blocker is glucose, agar, gelatine or starch.

32. An electrochemical sensing device according to claim 30 or claim 31.

wherein the blocker is loaded into the precompressed porous substrate using the steps

of: a) dissolving the blocker in a suitable solvent;

b) wetting the substrate with the solution of the blocker; and then

c) removing the solvent by evaporation.

33. An electrochemical sensing device according to any one of claims 22 to 32,

wherein the substrate is made of a porous material selected from the group consisting

of polymers or mixtures of polymers.

34. An electrochemical sensing device according to claim 33. wherein the

polymers or mixtures of polymers consist of polysulfones, polyvinylidene halides,

tetrafluoroethene, polyamides, polyimides, polyethylene, polypropylene,

polyacrylonitrates or polycarbonates.

35. An electrochemical sensing device according to claim 34, wherein the

polyvinylidene halides are polyvinylidene difluorides.

36. An electrochemical sensing device according to any one of claims 22 to 35,

wherein the thickness of the precompressed substrate is about 180 μm or less.

37. An electrochemical sensing device according to claim 36. wherein the

thickness of the precompressed substrate is from 30 μm to 150 μm.

38. An electrochemical sensing device according to any one of claims 22 to 37,

wherein the pore size of the substrate ranges from 10 kilodaltons cut-off (lower limit)

to 5 microns.

39. An electrochemical sensing device according to claim 38, wherein the pore

size of the substrate ranges from 0.1 μm to 0.8 μm.

40. An electrochemical sensing device according to claim 39, wherein the pore

size of the substrate ranges from 0.2 μm to 0.5 μm.

41. An electrochemical sensing device according to any one of claims 22 to 40,

wherein the porous substrate is a membrane that is permeable to a fluid containing a

first species to be analysed but substantially impermeable to a second species

contained in the fluid, the second species being of a kind which would interfere with

the electrochemical sensing of the first species.

42. An electrochemical sensing device substantially as herein described with reference to any one of the examples and/or accompanying figures but excluding the

comparative examples.