WO2001025775A1 - Patterned laminates and electrodes with laser defined features - Google Patents

Patterned laminates and electrodes with laser defined features Download PDF

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Publication number
WO2001025775A1
WO2001025775A1 PCT/US2000/027197 US0027197W WO0125775A1 WO 2001025775 A1 WO2001025775 A1 WO 2001025775A1 US 0027197 W US0027197 W US 0027197W WO 0125775 A1 WO0125775 A1 WO 0125775A1
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WO
WIPO (PCT)
Prior art keywords
metallic layer
electrode set
electrode
insulating substrate
electrodes
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2000/027197
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English (en)
French (fr)
Inventor
Raghbir Singh Bhullar
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Roche Diagnostics Corp
Original Assignee
Roche Diagnostics Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Roche Diagnostics Corp filed Critical Roche Diagnostics Corp
Priority to JP2001528688A priority Critical patent/JP3805676B2/ja
Priority to EP00967259.3A priority patent/EP1218732B1/en
Priority to CA002386172A priority patent/CA2386172C/en
Priority to AU77483/00A priority patent/AU7748300A/en
Publication of WO2001025775A1 publication Critical patent/WO2001025775A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
    • G01N27/28—Electrolytic cell components
    • G01N27/30—Electrodes, e.g. test electrodes; Half-cells
    • G01N27/327—Biochemical electrodes, e.g. electrical or mechanical details for in vitro measurements
    • G01N27/3271—Amperometric enzyme electrodes for analytes in body fluids, e.g. glucose in blood
    • G01N27/3272—Test elements therefor, i.e. disposable laminated substrates with electrodes, reagent and channels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/49155—Manufacturing circuit on or in base
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/49155—Manufacturing circuit on or in base
    • Y10T29/49156—Manufacturing circuit on or in base with selective destruction of conductive paths

Definitions

  • the present invention relates to laser ablation to pattern a metallic layer, as well as an electrode for an electrochemical biosensor.
  • Electrochemical biosensors are well known. They have been used to determine the concentration of various analytes from biological samples, particularly from blood. Electrochemical biosensors are described in U.S. Patent Nos. 5,413,690; 5,762,770 and 5,798,031 ; as well as in International
  • An electrochemical biosensor typically includes a sensor strip.
  • the sensor strip includes a space that holds the sample to be analyzed, may include reagents to be released into the sample, and includes an electrode set.
  • the electrode set normally includes an insulating substrate, electrodes that contact the sample, which have contact pads for electrically connecting the electrodes to the electronics of electrochemical biosensor.
  • electrochemical biosensors it is desirable for electrochemical biosensors to be able to analyze electrolytes using as small a sample as possible, and therefore it is necessary to miniaturize the sensor strip, as well as its parts, including the electrodes, as much as possible.
  • screen printing techniques have been used to form miniaturized electrodes.
  • Electrodes formed by screen printing techniques can only be formed from composition that are both electrically conductive and which are screen printable. Furthermore, screen printing techniques only allow for the reliable formation of structures and patterns having a feature size of approximately 75 ⁇ m or greater. In addition, screen printing is a wet chemical process. It would be desirable to have a new method of forming electrodes which allows for the use of different composition, and which can form features smaller than
  • Laser ablation is a technique using a laser to cut or mold a material. This technique usually uses a high power excimer laser, such as a krypton- fluoride excimer laser with an illumination wavelength of 248 nm, to blast away surface material. This technique has been used to ablate metals, polymers and even biological material, such as the cornea of the human eye.
  • a high power excimer laser such as a krypton- fluoride excimer laser with an illumination wavelength of 248 nm
  • the invention is a method of making a patterned laminate comprising ablating through a portion of a metallic layer with a laser.
  • the metallic layer comprises at least one member of gold, platinum, palladium and iridium. Furthermore, the metallic layer is on, and in contact with, an insulating substrate, for example, a polymer.
  • the invention is a method of making a electrode set, comprising ablating through a portion of a first metallic layer with a laser, to form an electrode pattern.
  • the first metallic layer is on an insulating substrate.
  • the invention is a method of making an electrode set ribbon, comprising ablating through a portion of a first metallic layer with a laser, to form a plurality of electrode patterns.
  • the first metallic layer is on an insulating substrate, for example, a polymer.
  • the electrode set ribbon comprises a plurality of electrode sets.
  • the present invention is an electrode set, comprising a first metallic layer, on an insulating substrate, comprising a plurality of electrodes.
  • the first metallic layer has a feature size of less than
  • the present invention is a patterned laminate, comprising a patterned metallic layer on, and in contact with, an insulating substrate.
  • the metallic layer comprises at least one of gold, platinum, palladium and iridium.
  • the insulating substrate comprises a polymer, and the patterned metallic layer has a feature size of less than 75 ⁇ m.
  • An advantage of the present invention is that it allows for the possibility of small feature sizes.
  • patterned laminate means a multilayered structure that includes an overlayer through which an underlying layer is exposed, i.e. the overlayer has gaps and does not completely cover the underlying layer.
  • the gaps or areas of exposure form the "pattern" of the patterned laminate.
  • pattern means one or more intentionally formed gaps having a feature size, for example, a single linear gap having a constant width, where the smallest width is the feature size. Not included in the term “pattern” are natural, unintentional defects.
  • feature size is the smallest dimension of a gap found in a pattern.
  • electrode pattern is a pattern which when formed in a metallic layer includes at least two, for example 2 to 60, or 3 to 20, electrodes which are not electrically connected to each other, but each of which includes its own contact pad.
  • metallic layer refers to a layer made of a material that is a metallic conductor of electricity, such as a pure metal or alloys.
  • electrode set is a set of at least two electrodes, for example 2 to 60, or 3 to 20, electrodes. These electrodes may be, for example, a working electrode and a reference electrode.
  • ablating means the removing of material.
  • Figure 1 illustrates an electrochemical sensor strip of the present invention
  • Figure 2 illustrates an exploded view of an electrochemical sensor strip of the present invention, more clearing show each individual part
  • FIG. 3 illustrates an electrode set of the present invention
  • Figure 4 illustrates another electrode set of the present invention
  • FIG. 5 illustrates still another electrode set of the present invention
  • FIG. 6 is a schematic of still another electrode set of the present invention.
  • Figure 7 is a schematic of an electrode set ribbon of the present invention.
  • Figure 8 is a schematic of a device of the present invention for making an electrode set ribbon of the present invention.
  • Figure 9 is a block diagram of a process of the present invention for making a sensor strip of the present invention.
  • Figure 1 illustrates the assembled electrochemical sensor strip 12, which includes a base 1 , the contact pads 9 and 9 that are part of the electrodes.
  • the sensing region 10 of the electrodes is also illustrated.
  • Figure 2 illustrates an exploded view of a sensor strip 12, which includes a base 1 , adhesive foil 2 for holding the base to the electrode substrate 3.
  • the electrode set 16 is on the electrode substrate 3, and is partially covered by a dielectric 5.
  • a cover 8 is attached to one end of the dielectric with adhesive tape 7.
  • a small gap 13 in the dielectric, and a space 14 in the adhesive tape, together with the cover and the electrodes, form a pocket inside of which may be place reagent 6 used to aid in electro- chemically detecting and quantifying an analyte.
  • This pocket can act as a capillary, drawing the fluid to be tested onto the sensing region 10 (not shown) of the electrodes.
  • the cover may be absent, exposing the sensing region of the electrodes, and the sample may be directly applied onto this region.
  • FIG. 3 illustrates an electrode set 16, including two electrodes 4 and 4.
  • the electrodes have contact pads 9 and 9, which are electrically connected to the sensing region 10 of the electrode.
  • dielectric 5 which covers the first and second electrodes, exposing only the sensing region and the contact pads.
  • Figures 4 and 5 illustrate two different electrode sets 16, which each include a substrate 1 , and first and second electrodes 4 and 4.
  • the electrodes are separated by a gap 18 that prevents electrical contact between the two electrodes.
  • the gap 18 corresponds to the feature size of this electrode set, since it is the smallest intentional feature.
  • Figures 4 and 5 illustrate two different electrode patterns, one having a simple straight gap ( Figure 4), and the other more complex and containing a rectilinear gap, forming a region of interlacing fingers of the two electrodes ( Figure 5).
  • Figure 6 is a schematic of an electrode set of the present invention, including two electrodes 4 and 4.
  • the sensing region 10 of the electrodes contains interlacing fingers of the two electrodes, again a rectilinear gap. Also shown opposite the sensing region are the contact pads 9 and 9 of each electrode.
  • the gap between the electrodes corresponds to the feature size, and may be 1 to 100 ⁇ m, preferably less than 75 ⁇ m, more preferably 5 to 50 ⁇ m, most preferably 10 to 30 ⁇ m.
  • the gap passes completely through the metallic layer so that the two electrodes are not electrically connected in the electrode set.
  • the values for the dimensions illustrated in Figure 6 are for a single specific embodiment, and these values may be selected as need for the specific use.
  • the length of the electrode set may be 2.5 to 250 mm
  • the width may be 0.4 to 40 mm
  • the gap between the contact pads may be 1 ⁇ m to 5 mm
  • the width of each contact pad may be 1 to 20 mm.
  • the electrode pattern shown in Figure 6 (and other figures) is symmetric, however this is not required, and irregular or asymmetric patters (or electrode shapes) are possible.
  • Figure 7 is a schematic of an electrode set ribbon 24.
  • the ribbon includes a plurality of panels 20, each of which includes a plurality of electrode sets 16. Also shown is the original metallic laminate ribbon 22 that is subject to laser ablation to form the electrode set ribbon 24.
  • the width of the ribbon is selected to accommodate the laser ablation system, and may be, for example, 40 to 0.4 inches.
  • the ribbon may be any length, and is selected based on the desired number of electrode sets, and/or the ease of handling and transport of the ribbons.
  • the size of each individual panel is selected to fit conveniently on the ribbon, and therefore each panel may contain 1 to 1000 electrode sets, preferably 2 to 20 electrode sets.
  • Figure 8 is a schematic of a device for producing electrode sets, in the form of an electrode set ribbon 24.
  • First a roll of metallic laminate ribbon 22 is fed through guide rolls 28 into a laser ablator 26.
  • the laser ablator the metallic layer of the metallic laminate ribbon is ablated with the laser, in an electrode pattern, to form the electrode set ribbon 24.
  • the electrode set ribbon 24 is then passed through more guide rolls 28, with a tension loop to adjust the tension of the ribbon, and through an optional inspection camera 30, which may be used to check for defects.
  • the electrode set ribbon 24 may be laminated with an adhesive foil ribbon 32, in a laminator 36, to form a laminated electrode set ribbon 34, which is then guided through guide rolls 28, and rolled up.
  • FIG. 9 is a block diagram of a process for making an electrochemical sensor strip of the present invention.
  • the metallic laminate ribbon 22 is ablated by laser ablation to form an electrode set ribbon, and then laminated with adhesive foil ribbon 32 to form a laminated electrode set ribbon 34.
  • the laminated electrode set ribbon 34 is screen printed with a UV curable dielectric 50, which forms the dielectric 5 (not shown) of each sensor strip, forming a dielectric covered ribbon 38.
  • the starting reagents 40 are compounded to form reagent 6, and then in step 140 the reagent is applied onto the dielectric covered ribbon 38, the ribbon is split into reels, each one panel wide, to form reagent covered panel reels 44.
  • step 150 the reagent covered panel reels 44 are covered with clear polyester roll 52 attach through double sided adhesive tape roll 54, which forms the clear cover 8 (not shown) and adhesive tape 7 (not shown) of each sensor strip.
  • the product of step 150, clear covered panel reels 46, are then split into individual sensor reels, each one electrode set wide, and laminated with a base substrate roll 56, in step 160, which forms the base 1 (not shown) of each sensor strip, to form sensor reels 48.
  • step 170 the sensor reels are cut into individual sensor strips 12 (not shown) which are sorted and packed into vials 60, each closed with a stopper 58, to give packaged sensor strips 62.
  • steps 150 and 160 a liner is release in order to attach the base and cover.
  • a laser system capable of ablating the metallic layer, to form the individual electrode sets is well known to those of ordinary skill in the art. Examples include excimer lasers, with the pattern of ablation controlled by lenses, mirrors or masks.
  • An example of such a system is the LPX-400, or LPX-200, both from LPKF LASER ELECTRONIC, GMBH of Garbsen,
  • the metallic laminate is a metallic layer on the electrode substrate.
  • the metallic layer may contain pure metals or alloys, or other materials which are metallic conductors. Examples include aluminum, carbon (such as graphite), cobalt, copper, gallium, gold, indium, iridium, iron, lead, magnesium, mercury (as an amalgam), nickel, niobium, osmium, palladium, platinum, rhenium, rhodium, selenium, silicon (such as highly doped polycrystalline silicon), silver, tantalum, tin, titanium, tungsten, uranium, vanadium, zinc, zirconium, mixtures thereof, and alloys or metallic compounds of these elements.
  • the metallic layer includes gold, platinum, palladium, iridium, or alloys of these metals, since such noble metals and their alloys are unreactive in biological systems.
  • the metallic layer may be any thickness, but preferably is 10 nm to 1 mm, more preferably, 20 nm to 100 ⁇ m, or even 25 nm to 1 ⁇ m.
  • Figure 9 illustrates the process with a 50 nm gold film.
  • the metallic layer may be ablated into an electrode pattern.
  • the patterned metallic layer may be coated or plated with additional metal layers.
  • the metallic layer may be copper, which is then ablated with a laser, into an electrode pattern; subsequently, the copper may be plated with a titanium/tungsten layer, and then a gold layer, to form the desired electrodes.
  • the copper may be plated with a titanium/tungsten layer, and then a gold layer, to form the desired electrodes.
  • only a single layer of gold is used, which is directly in contact with the electrode substrate, since it allows for the entire elimination of wet chemical steps for the formation of the electrode sets.
  • the electrode substrate is formed from an insulating material, so that it will not provide an electrical connection between the electrodes of the electrode set. Examples include glass, ceramics and polymers.
  • the electrode substrate is a flexible polymer, such as a polyester or polyimide.
  • a suitable material would be the polyimide UPLEX from TECHNI-MET of Connecticut, which is available pre-coated with gold, palladium or platinum; or ULTEM 1000 (polyetherimide) from GE, available coated with copper.
  • a UV curable dielectric and which is screen printable may be used to form the dielectric, for example the polymer composition 5018 dielectric composition from DuPont.
  • the clear cover is a clear material that is inert to biological fluids, for example glass, polyethylene, polypropylene, polyvinylchloride, polyimide, or polyester.
  • the clear cover may have markings.
  • the adhesive tape is also a flexible polymer having a surfaces covered with an adhesive; these materials are also well known to those of ordinary skill in the art.
  • the base is a supporting structure, and is preferably made of flexible polymer material, with a thickness sufficient to provide support to the sensor strip, for example polyester with a thickness of 6 mils.
  • the adhesive foil may be made for the same types of compositions as the adhesive tape.
  • the reagent is optional, and may be used to provide electrochemical probes for specific analytes.
  • the starting reagents are the reactants or components of the reagent, and are often compounded together in liquid form before application to the ribbons or reels. The liquid may then evaporate, leaving the reagent in solid form.
  • the choice of specific reagent depends on the specific analyte or analytes to be measure, and are well known to those of ordinary skill in the art. For example, a reagent for measurement of glucose in a human blood sample contains 62.2 mg polyethylene oxide (mean molecular weight of 100-900 kilodaltons), 3.3 mg NATROSOL 250 M, 41.5 mg
  • AVICEL RC-591 F 89.4 mg monobasic potassium phosphate, 157.9 mg dibasic potassium phosphate, 437.3 mg potassium ferricyanide, 46.0 mg sodium succinate, 148.0 mg trehalose, 2.6 mg TRITON X-100 surfactant, and 2,000 to 9,000 units of enzyme activity per gram of reagent.
  • the enzyme is prepared as an enzyme solution from 12.5 mg coenzyme PQQ and 1.21 million units of the apoenzyme of quinoprotein glucose dehydrogenase, forming a solution of quinoprotein glucose dehydrogenase. This reagent is described in WO 99/30152, pages 7-10.
  • any patterned laminate preferably a patterned laminate of a noble metal (gold, platinum, palladium, iridium, alloys thereof) in direct contact with an insulating substrate, such as a polymer.
  • a noble metal gold, platinum, palladium, iridium, alloys thereof
  • Such laminates can have a variety of electrical function, including use as electrodes, electrical wires or connectors, microwave reflectors, etc.
  • these patterned laminates have a feature size of 100 ⁇ m or less, more preferably 1 to 100 ⁇ m, even more preferably 75 ⁇ m or less, including 5 to 50 ⁇ m, or even 5 to 20 ⁇ m.

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  • Life Sciences & Earth Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Biochemistry (AREA)
  • Hematology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Biophysics (AREA)
  • Analytical Chemistry (AREA)
  • Molecular Biology (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Measurement Of The Respiration, Hearing Ability, Form, And Blood Characteristics Of Living Organisms (AREA)
  • Manufacturing Of Printed Circuit Boards (AREA)
  • Parts Printed On Printed Circuit Boards (AREA)
  • Pressure Sensors (AREA)
PCT/US2000/027197 1999-10-04 2000-10-03 Patterned laminates and electrodes with laser defined features Ceased WO2001025775A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
JP2001528688A JP3805676B2 (ja) 1999-10-04 2000-10-03 パターニングされた積層体、およびレーザで形成された特徴部分を有する電極
EP00967259.3A EP1218732B1 (en) 1999-10-04 2000-10-03 Patterned laminates and electrodes with laser defined features
CA002386172A CA2386172C (en) 1999-10-04 2000-10-03 Patterned laminates and electrodes with laser defined features
AU77483/00A AU7748300A (en) 1999-10-04 2000-10-03 Patterned laminates and electrodes with laser defined features

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/411,940 US6662439B1 (en) 1999-10-04 1999-10-04 Laser defined features for patterned laminates and electrodes
US09/411,940 1999-10-04

Publications (1)

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WO2001025775A1 true WO2001025775A1 (en) 2001-04-12

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PCT/US2000/027197 Ceased WO2001025775A1 (en) 1999-10-04 2000-10-03 Patterned laminates and electrodes with laser defined features

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US (1) US6662439B1 (https=)
EP (1) EP1218732B1 (https=)
JP (1) JP3805676B2 (https=)
AU (1) AU7748300A (https=)
CA (1) CA2386172C (https=)
WO (1) WO2001025775A1 (https=)

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