Method of Defining Electrodes Using Laser-Ablation and Dielectric Material

Abstract

A method of forming an electrochemical test sensor includes providing a base. Electrochemically-active material is placed on the base. Dielectric material is applied over the electrochemically-active material. A first selected area of the dielectric material is laser-ablated to expose the electrochemically-active material. A second selected area of the dielectric material and the electrochemically-active material are laser-ablated to expose the base. The first selected area is different from the second selected area. A second layer is applied to assist in forming a channel in the test sensor. The channel assists in allowing a fluid sample to contact a reagent located therein. The dielectric material is located between the base and the second layer.

1 . A method of forming an electrochemical test sensor, the method comprising the acts of:
 providing a base;   placing electrochemically-active material on the base;   laser-ablating the electrochemically-active material to form an electrode pattern;   applying dielectric material over the electrode pattern;   laser-ablating selected areas of the dielectric material to expose a portion of the electrode pattern; and   applying a second layer to assist in forming a channel in the test sensor, the channel assisting in allowing a fluid sample to contact a reagent located therein, wherein the dielectric material is located between the base and the second layer.   
   
   
       2 . The method of  claim 1  wherein the laser-ablating of the selected areas further exposes meter contacts on the test sensor. 
   
   
       3 . The method of  claim 1  wherein the second layer is a lid. 
   
   
       4 . The method of  claim 1  wherein the second layer is a spacer and further includes applying a lid to the spacer so as to define the channel, the spacer being located between the lid and the base. 
   
   
       5 . The method of  claim 1  wherein the second layer is a spacer-lid combination. 
   
   
       6 . The method of  claim 1  wherein the electrochemically-active material is a metallic conductive material. 
   
   
       7 . The method of  claim 1  wherein the reagent includes glucose oxidase or glucose dehydrogenase. 
   
   
       8 . The method of  claim 1  wherein the channel is a capillary channel. 
   
   
       9 . A method of forming an electrochemical test sensor, the method comprising the acts of:
 providing a base;   forming an electrode pattern on the base;   applying dielectric material over the electrode pattern;   laser-ablating selected areas of the dielectric material to expose a portion of the electrode pattern; and   applying a second layer to assist in forming a channel in the test sensor, the channel assisting in allowing a fluid sample to contact a reagent located therein, wherein the dielectric material is located between the base and the second layer.   
   
   
       10 . The method of  claim 9  wherein the electrode pattern is formed by printing, coating, vapor deposition, sputtering or electrochemical deposition. 
   
   
       11 . The method of  claim 10  wherein the electrode pattern is formed by printing. 
   
   
       12 . The method of  claim 9  wherein the second layer is a lid. 
   
   
       13 . The method of  claim 9  wherein the second layer is a spacer and further includes applying a lid to the spacer so as to define the channel, the spacer being located between the lid and the base. 
   
   
       14 . The method of  claim 9  wherein the second layer is a spacer-lid combination. 
   
   
       15 . A method of forming an electrochemical test sensor, the method comprising the acts of:
 providing a base;   placing electrochemically-active material on the base;   applying dielectric material over the electrochemically-active material;   laser-ablating a first selected area of the dielectric material to expose the electrochemically-active material;   laser-ablating a second selected area of the dielectric material and the electrochemically-active material to expose the base, the first selected area being different from the second selected area; and   applying a second layer to assist in forming a channel in the test sensor, the channel assisting in allowing a fluid sample to contact a reagent located therein, wherein the dielectric material is located between the base and the second layer.   
   
   
       16 . The method of  claim 15  wherein the laser-ablating of the selected areas further exposes meter contacts on the test sensor. 
   
   
       17 . The method of  claim 15  wherein the second layer is a lid. 
   
   
       18 . The method of  claim 15  wherein the second layer is a spacer and further includes applying a lid to the spacer so as to define the channel, the spacer being located between the lid and the base. 
   
   
       19 . (canceled) 
   
   
       20 . The method of  claim 15  wherein the electrochemically-active material is a metallic conductive material. 
   
   
       21 . The method of  claim 15  wherein the reagent includes glucose oxidase or glucose dehydrogenase. 
   
   
       22 . (canceled)