U.S. patent application number 10/950111 was filed with the patent office on 2005-02-17 for sensor connection means.
Invention is credited to Beck, Thomas William, Chambers, Garry, Hodges, Alastair McIndoe, Maxwell, Ian Andrew.
Application Number | 20050034983 10/950111 |
Document ID | / |
Family ID | 3800116 |
Filed Date | 2005-02-17 |
United States Patent
Application |
20050034983 |
Kind Code |
A1 |
Chambers, Garry ; et
al. |
February 17, 2005 |
Sensor connection means
Abstract
The invention relates to a sensor adapted for electrical
connection to a power source having an electrical contact means
(3). The sensor has a first insulating substrate (1) carrying a
first electrode (2) and a second insulating substrate (7) carrying
a second electrode (6). The electrodes are disposed to face each
other in spaced apart relationship, sandwiching a spacer (4)
therebetween. A first cut-out portion extends through the first
insulating substrate (1) and a spacer (4) to expose a first contact
area (23) on the second insulating substrate (7). This permits the
electrical contact means (31) to effect electrical connection with
the first contact (23) which in turn is in electrically conductive
connection with the second electrode (6). A similar contact
arrangement may be disposed on the opposite side of the sensor.
Inventors: |
Chambers, Garry; (San Diego,
CA) ; Hodges, Alastair McIndoe; (Blackburn South,
AU) ; Beck, Thomas William; (North Richmond, AU)
; Maxwell, Ian Andrew; (Five Dock, AU) |
Correspondence
Address: |
NUTTER MCCLENNEN & FISH LLP
WORLD TRADE CENTER WEST
155 SEAPORT BOULEVARD
BOSTON
MA
02210-2604
US
|
Family ID: |
3800116 |
Appl. No.: |
10/950111 |
Filed: |
September 24, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10950111 |
Sep 24, 2004 |
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10012680 |
Nov 13, 2001 |
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10012680 |
Nov 13, 2001 |
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09399512 |
Sep 20, 1999 |
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6379513 |
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09399512 |
Sep 20, 1999 |
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PCT/AU98/00184 |
Mar 20, 1998 |
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Current U.S.
Class: |
204/403.01 ;
204/433 |
Current CPC
Class: |
G01N 27/3272
20130101 |
Class at
Publication: |
204/403.01 ;
204/433 |
International
Class: |
H01L 021/8228; C12M
001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 21, 1997 |
AU |
PO 5813 |
Claims
1. A sensor adapted for electrical connection with a power source
having a contactor, the sensor comprising: a first insulating
substrate carrying a first electrode and a second insulating
substrate carrying a second electrode, said electrodes being
disposed to face each other in spaced apart relationship, a first
cut-out portion extending through said first insulating substrate
and a spacer to expose a first contact area on the second
insulating substrate to permit the contactor to effect electrical
connection with the first contact area disposed on the second
insulating substrate, the first contact area being in electrically
conductive connection with the second electrode.
2-22. Cancelled
Description
RELATED APPLICATIONS
[0001] This application is a continuation application of
International Patent Application No. PCT/AU98/00184,
internationally filed 20 Mar. 1998, and claiming priority from
Australian Provisional Patent Application No. PO 5813, filed 21
Mar. 1997.
TECHNICAL FIELD
[0002] This invention relates to disposable electrochemical sensors
of the type used for quantitative analysis, for example, of glucose
levels in blood, for pH measurement, or the like. More particularly
the invention relates to means for electrical connection of such
sensors to a measuring apparatus.
BACKGROUND ART
[0003] U.S. Pat. No. 5,437,999 discloses an electrochemical sensor
of the kind which in use is electrically connected with a power
source. The sensor is constructed from two spaced apart printed
circuit boards each having a metal layer on one side and disposed
so that the metal layers are facing each other in spaced apart
relationship. The metal layers are photolithographically treated to
define electrode areas which form part of a cell. At one end of the
assembly the electrode substrates are cut to provide laterally
spaced protruding tabs bearing the metal layer. The exposed metal
surfaces of the tabs act as contact pads, each contact pad being
electrically connected with a corresponding electrode. The contact
pads in turn engage contact prongs connected to a power source and
provide electrical connection between the sensor and a power
source.
[0004] The arrangement of U.S. Pat. No. 5,437,999 suffers from the
disadvantages that the substrate is required to be of considerable
rigidity in order to ensure satisfactory and reliable electrical
contact. Moreover the user is often left uncertain as to whether a
sensor has satisfactorily been connected with the power source.
[0005] In co-pending applications PCT/AU96/00207, PCT/AU96/00365,
PCT/AU96/00723 and PCT/AU96/00724 there are described various very
thin electrochemical cells. Each cell is defined between facing
spaced apart electrodes which are formed as thin metal coatings
(for example sputter coatings) deposited on thin inert plastic film
(for example 100 micron thick PET). The electrodes are separated
one from the other by a spacer of thickness of for example 500
.mu.m or less.
[0006] The connection arrangement of U.S. Pat. No. 5,437,999 is not
suitable for use with the extremely thin sensor devices of the kind
discussed in our co-pending applications in view of the flexibility
of the insulating electrode carriers. In general, it is desirable
that the disposable sensor be capable of simple, quick, reliable
and effective connection with the power source in the measuring
device by unskilled users. It is an object of the present invention
to overcome or ameliorate at least one of the disadvantages of the
prior art, or to provide a useful alternative.
DESCRIPTION OF THE INVENTION
[0007] According to a first aspect, the invention provides a sensor
adapted for electrical connection with a power source having first
contact means, the sensor comprising:
[0008] a first insulating substrate carrying a first electrode and
a second insulating substrate carrying a second electrode, said
electrodes being disposed to face each other in spaced apart
relationship,
[0009] a first cut-out portion extending through said first
insulating substrate and a spacer to expose a first contact area on
the second insulating substrate to permit a first contact means to
effect electrical connection with the first contact area disposed
on the second insulating substrate, the first contact area being in
electrically conductive connection with the second electrode.
[0010] The first contact area may be maintained at a predetermined
depth from the first insulating substrate.
[0011] According to a second aspect, the invention provides a
sensor according to the first aspect further comprising a second
cut-out portion extending through said second insulating substrate
and the, or another, spacer to expose a second contact area on the
first insulating substrate to permit a second contact means to
effect electrical connection with a second contact area disposed on
the first insulating substrate, the second contact area being in
electrically conductive connection with the first electrode.
[0012] The second contact area may be maintained at a predetermined
depth from the second insulating substrate.
[0013] According to a third aspect, the invention also provides a
sensing system comprising a sensor according to the first or second
aspects and a sensing apparatus including a first contact means
and/or second contact means adapted to effect electrical contact
with the first and second contact areas respectively.
[0014] "Comprising" as herein used is used in an inclusive sense,
that is to say in the sense of "including" or "containing." The
term is not intended in an exclusive sense ("consisting of" or
"composed of").
[0015] In preferred embodiments the insulating substrate is made of
a flexible insulating material. The second electrode and the first
contact area are formed from a unified layer of metal deposited on
the first substrate, and more preferably deposited by being sputter
coated thereon. Suitable metals include, but are not limited to
palladium, gold, platinum, iridium, and silver. Carbon may also be
used. Desirably the contactor is a metal contactor which is
resiliently biased to extend through the first cut-out portion to
make contact with the metal first contact area on the second
substrate. In highly preferred embodiments the contactor is adapted
for click engagement with the cut-out portion which extends through
the first insulating substrate and the spacer.
[0016] With a connector according to the current invention the
spacer layer provides extra strength. A rigid connector can
therefore be formed using flexible materials. This allows a wider
range of materials to be utilized. An audible confirmation of
connection can also be simply provided by the current invention
unlike the connector described in U.S. Pat. No. 5,437,999.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will now be described by way of example only
with reference to the accompanying drawings in which:
[0018] FIG. 1 shows a first embodiment of a sensor according to the
invention in plan view.
[0019] FIG. 2 shows a scrap side elevation of the sensor of FIG. 1
in cross-section on line 10-10.
[0020] FIG. 3 is a diagrammatic enlargement showing a part of the
sensor of FIG. 2 in engagement with contacts.
[0021] FIG. 4 shows an end elevation of the sensor of FIG. 3 in
section on line A-A.
[0022] FIG. 5 shows a second embodiment of the invention in plan
view.
[0023] FIG. 6 shows a cross-section of the embodiment of FIG. 5 in
end elevation when viewed on line C-C.
[0024] FIG. 7 shows a cross-section of the embodiment of FIG. 5 in
side elevation on line D-D.
[0025] FIG. 8 shows a third embodiment of the invention in plan
view.
BEST MODES FOR CARRYING OUT THE INVENTION
[0026] With reference to FIGS. 1 to 3 there is shown a first
embodiment of an electrochemical sensor. The sensor comprises a
polyester spacer 4 approximately 25 mm.times.5 mm and 100 microns
thick and having a circular aperture 8 of 3.4 mm diameter. Aperture
8 defines a cylindrical cell wall 10. Adhered to one side of spacer
4 is a first insulating substrate polyester sheet 1 having a first
coating of palladium 2. The palladium was sputter coated on sheet 1
at between 4 and 5 millibar pressure in an atmosphere of argon gas
to give a uniform coating thickness of about 100-1000 angstroms.
Sheet 1 is adhered by means of adhesive 3 to spacer 4 with
palladium coating 2 adjacent spacer 4 and covering one side of
aperture 8.
[0027] A second insulating substrate 7 consists of a polyester
sheet having a second sputter coating 6 of palladium adhered by
means of contact adhesive 5 to the other side of spacer 4 and
covering the opposite side of aperture 8. There is thereby defined
a cell having cylindrical side wall 10 and closed at one cylinder
end by a first electrode of palladium metal 2. The other cylinder
end wall is a second electrode formed from palladium 6. The
assembly is notched at 9 to provide a means for admission of a
solution to the cell, and to allow air to escape.
[0028] Adjacent one end 20 a cut-out aperture 21 pierces first
insulating layer 1 and first metal layer 2. In the present example
cut-out 21 is oval-shaped. A corresponding cut-out portion 22 in
spacer 4 is in registration with cut-out 21. FIG. 3 shows a side
elevation cross-section of sensor 1 inserted into a receiving slot
formed in part 30 of measuring apparatus and to which is mounted a
first resilient contactor 31 and a second resilient contactor 32.
Upon insertion of sensor end 20 into the slot, contactor 31 rides
over the outer surface of insulating layer 1 and clicks into the
well formed by apertures 21 and 22 to engage a first contact area
portion 23 of metal layer 6. First contact area 23 is a portion of
the same metal layer 6 deposited on insulating layer 7 from which
the second electrode is formed and is therefore in electrically
conductive communication with the second electrode area of cell 8.
Contact area 23 is in effect defined by the diameter of cut-out 20
of spacer 4 in the present example.
[0029] In the embodiment shown in FIG. 1 a second circular cut-out
portion 25 spaced further from edge 20 than aperture 21 extends
through second insulating layer 7 and second metal layer 6. A
cut-out portion 26 (see FIG. 2) of spacer 4 corresponds with an
registers with cut-out portion 25 of insulating layer 7. Referring
again to FIG. 3, in use the sensor is configured to permit a second
resiliently biased contactor 32 to extend through the well defined
by cut-out portions 25 and 26 whereby resilient contactor 32
engages and makes electrical contact with metal layer 2 at 27 and
thereby with the first electrode 2 of cell 8.
[0030] Resilient connectors 31 and 32 are arranged in a slot 30 of
the measuring device and are electrically connected in a measuring
circuit. In use, the sensor is inserted into slot 30 with edge 20
leading. The first resilient contactor 31 rides over the end margin
of the sensor 1 until it encounters first aperture 21, 22 whereupon
it click engages with the opening and makes electrical contact with
the first contact area 23 of metal layer 6. Slight additional
insertion of sensor 1 in slot 30 causes the second contactor 32 to
click engage with the second aperture 25, 26 and make contact with
second contact area 27 of metal layer 2.
[0031] Spacer 4 surrounds both apertures and ensures that, despite
the intrinsic flexibility of the insulating layers and the thinness
of the sensor, electrical contact can be made with reliable
precision.
[0032] A second embodiment of the invention is shown in FIGS. 5, 6
and 7 wherein parts corresponding in function to corresponding
parts of the embodiment of FIGS. 1 and 2 are identified by
corresponding numerals. The major difference between the second
embodiment and the first is that in the second embodiment cut-out
portions 21, 22 are cut from one side edge of sensor 1 while
cut-out portions 25, 26 are cut out from the opposite side edge of
the sensor 1. In this case contactors 31 and 32 are spaced
laterally and click substantially simultaneously into their
respective cut-out opening. The cut-out openings are surrounded on
three sides by spacer 4, the fourth side being exposed at
respective edges of the sensor.
[0033] Although in the embodiment shown in FIGS. 5, 6 and 7 the
openings are at a corresponding distance from end 20 in other
embodiments they could be spaced in the longitudinal direction as
is the case in the first described embodiment. This ensures that
contact is only made when the sensor is inserted in a correct
orientation and ensures correct polarity.
[0034] A third embodiment is shown schematically in FIG. 8. In this
case the openings take the form of slots 21, 25 extending
longitudinally from edge 20. For preference spacer 4 extends around
all edges of openings 21 and 25 of FIG. 8 but in a less preferred
embodiment spacer 4 only extends on three sides of slots 21 and 25
in which case click engagement is not obtained or is obtained only
if the contacts extend from the opposite direction. However, the
advantage that the contact pad area of the sensor is at a
predetermined dimension from the opposite face is maintained. If
desired the slots can differ in length and co-operation with
contacts spaced longitudinally so that contact with both contacts
requires correctly orientated insertion of the sensor.
[0035] It will be understood that both construction materials and
dimensions are given merely by way of example and that sensors of a
differing design or construction may utilize the invention. One,
two or more than two contacts may be provided by the means shown.
The invention extends to include a power source or measuring device
when connected to a sensor by the means described. Any suitable
form of contactor may be used with sensors according to the
invention.
* * * * *