Test device for measuring permeability of a barrier material

1. An electrical calcium test device for measuring permeability of a barrier material, comprising:

a test card including a thin-film pattern of sensor metal deposited onto a substrate;

an impermeable spacer having therein a volume of space defined by an interior wall of the impermeable spacer, wherein the volume of space traverses the impermeable spacer from a first aperture to a second aperture and separates the sensor metal from a test barrier material;

a first edge seal which seals the test card to the impermeable spacer, and

a second edge seal configured to seal the impermeable spacer to the test barrier material.

2. The device of claim 1 , wherein the thin-film pattern includes a plurality of calcium (Ca) sensor lines connected on each side to inert electrically conductive lines extending to an edge of the test card.

3. The device of claim 2 , wherein at least one of the plurality of Ca sensors is positioned external to the volume of space and between the first edge seal and the test card.

4. The device of claim 2 , wherein at least one of the plurality of Ca sensors has a different line width than a second of the plurality of Ca sensors.

5. The device of claim 2 , wherein at least one of the plurality of Ca sensors has enlarged contact pads at each end.

6. The device of claim 2 , further comprising inert electrical lines contacting the plurality of Ca sensors so that resistance of the Ca sensors is measured in either a two- or four-point configuration.

7. The device of claim 6 , wherein the inert electrical lines include one or both of platinum (Pt) or gold (Au), or alternatively include fluorine doped tin-oxide (F:SnO 2 ), indium zinc oxide (IZO), or indium tin oxide (ITO).

8. The device of claim 1 , wherein the thin-film pattern of sensor metal is provided on an insulating substrate to form the test card.

9. The device of claim 1 , wherein the thin-film pattern of sensor metal is deposited by sputtering and evaporation using a shadow mask technique.

10. The device of claim 1 , wherein the interior wall of the impermeable spacer is a non-moisture absorbing wall comprising one or both of an out-gassed aluminum or an out-gassed silica.

11. The device of claim 1 , wherein the impermeable spacer is comprised of at least one of metal, glass, or ceramic.

12. The device of claim 1 , wherein the volume of space traverses the impermeable spacer from a first aperture that defines a barrier material measurement area to a second aperture that opens to the sensor metal and that defines a calcium sensor area.

13. The device of claim 12 , wherein the first aperture is smaller than the second aperture.

14. The device of claim 12 , wherein the second aperture is smaller than the first aperture.

15. The device of claim 1 , wherein the impermeable spacer further comprises a trench positioned to receive sealant material.

16. The device of claim 1 , wherein the impermeable spacer exhibits a height of one inch for separating a barrier from about a two inch square test card and a 0.5 inch wide edge seal.

17. The device of claim 12 , wherein the impermeable spacer separates the sensor metal from the test barrier material such that diffusion normalizes moisture from a defect in the test barrier material across the calcium sensor area.

18. The device of claim 1 , wherein one of both of the first edge seal and the second edge seal comprises a poly-isobutylene (PIB)-based material filled with desiccant.

19. The device of claim 18 , wherein the PIB-based edge seal is applied directly to both ends of the impermeable spacer and allowed to outgas in a heated inert environment for 16 hours at 120-140° C. prior to assembly of the test device.

20. The device of claim 1 wherein the impermeable spacer and the second edge seal are sized for the thin-film pattern of sensor metal to contact an electrical connector extending to an edge of the test card.

21. The device of claim 1 , further comprising a temperature sensing device integrated into the test card.