Method of forming an electrochemical sensor
View Patent ↗An electrochemical sensor with a capillary channel is formed by placing a sacrificial insert and electrodes on a sensor base and applying plastic material. After the plastic material is cured, the sacrificial is removed leaving a capillary channel in the sensor. The inserts may be removed by a tool including a clamp for clamping and holding each insert stationary and a sliding block to which the sensor is secured.
1. A method of molding an electrochemical sensor, the method comprising the acts of:
providing a first mold;
inserting a first electrical contact in the first mold;
inserting a second electrical contact in the first mold;
placing a sacrificial insert in the first mold;
closing the first mold with a second mold;
injecting material for forming the electrochemical sensor into the closed first and second molds;
curing the material;
opening the first and second molds with respect to each other; and
extracting the sacrificial insert from the cured material so as to leave a channel in the cured material and form the electrochemical sensor, the channel extending from a first end of the electrochemical sensor and terminating before a second end of the electrochemical sensor.
2. The method of claim 1 wherein the sacrificial insert comprises metal.
3. The method of claim 2 wherein the metal comprises stainless steel.
4. The method of claim 1 wherein the sacrificial insert comprises a material having a melt temperature higher than the melt temperature of the injected material.
5. The method of claim 1 further including disposing a reagent within the channel.
6. The method of claim 1 wherein the electrochemical sensor is adapted to analyze a liquid sample.
7. The method of claim 1 wherein the first mold includes a plurality of locator pins to assist in locating the first and second electrical contacts.
8. A method of forming an electrochemical sensor, the method comprising the acts of:
providing a sensor base;
placing a sacrificial insert on the sensor base;
placing a first electrical contact and a second electrical contact on the sensor base, the sacrificial insert being positioned between the first electrical contact and the second electrical contact;
placing plastic material on the sensor base and over the sacrificial insert; and
removing the sacrificial insert from the plastic material and the sensor base leaving a capillary channel in the plastic material so as to form the electrochemical sensor, the capillary channel extending from a first end of the electrochemical sensor and terminating before a second end of the electrochemical sensor.
9. The method of claim 8 wherein the sacrificial insert comprises metal.
10. The method of claim 9 wherein the metal comprises stainless steel.
11. The method of claim 8 wherein the sacrificial insert comprises a material having a melt temperature higher than the melt temperature of the plastic material.
12. The method of claim 8 further including disposing a reagent within the capillary channel.
13. The method of claim 8 wherein the electrochemical sensor is adapted to analyze a liquid sample.
14. A method of forming an electrochemical sensor, the method comprising the acts of:
providing a sensor base;
placing a sacrificial insert on the sensor base;
placing a first electrical contact and a second electrical contact in the sensor base, the sacrificial insert being positioned between the first electrical contact and the second electrical contact;
placing plastic material on the sensor base and over the sacrificial insert; and
removing the sacrificial insert from the plastic material and the sensor base leaving a capillary channel in the plastic material so as to form the electrochemical sensor, the capillary channel extending from a first end of the electrochemical sensor and terminating before a second end of the electrochemical sensor.
15. The method of claim 1 , wherein the first end of the electrochemical sensor has a curved surface.
16. The method of claim 8 , wherein the first end of the electrochemical sensor has a curved surface.
17. The method of claim 14 , wherein the first end of the electrochemical sensor has a curved surface.