US5246576A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Cathode in a layered circuit and electrochemical cell for a measurement of oxygen in fluids
Assignee: SenDx Medical Inc
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Filing: 1990-12-10
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Granted: 1993-09-21
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Expires: 2010-12-10
Abstract
Abstract The electrode of the present invention has metallic surface within a laser produced opening where the metallic surface extends into an electronic metallic conductive pathway and the pathway is covered for electric insulation by an encapsulant layer. The encapsulant layer around the metallic surface has the opening to allow the exposure of the metallic surface from the encapsulant layer. The metallic pathway and encapsulant are resident on a substrate, and are produced from layered circuitry. The electrochemical cell has the aforementioned electrode juxtaposed to another electrode. This electrode is part of the patterned metallic layer that is produced by layered circuitry. The electrode extends into an electronic metallic conductive pathway that is spaced apart and electronically insulated from the other pathway. The insulation can be supplied by a covering of encapsulant material that covers the pathway except does not cover the second electrode. The encapsulant would not cover the second electrode by virtue of its removal by laser and/or masking during production of the layered circuitry. Both of the electrodes are covered with an oxygen permeable fluid electrolyte that provides ionic contact between the two electrodes. The electrodes and electrolyte are covered with one or more oxygen permeable membranes, and these along with the metallic conductive pathways are resident on a substrate. The cell is useful in detecting oxygen in fluids when a negative potential is applied to the laser-produced electrode relative to the other electrode through the pathways that are in contact with leads for external electrical contact from the substrate.
Inventors
- 👤 Matthew J. Leader
- 👤 Jeffery A. Graves
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 20:07
CPC Classifications
G; G01; G01N; G01N27/00; G01N27/26; G01N27/403; G01N27/404
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
208 words
An improved electrochemical cell that is useful in an oxygen sensor that measures the oxygen tension or concentration in a fluid including those that have small quantities of oxygen where the cell is part of a printed wiring board, comprising: a nonconducting substrate, at least one metallic layer overlying the said nonconducting substrate in a pattern to provide distinct cathode and anode and conductive pathways to both electrodes where the pathways are electrically isolated from each other and where they allow for eventual external electrical connection to the cell, an encapsulant layer overlying that portion of said metallic layer other than the anode to electrically isolate the conductive pathway to the anode from the conductive pathway to the cathode in the metallic layer and having at least one laser-produced finite-sided opening with a bottom and tapered walls, where the opening extends through at least said encapsulant layer, where at least a portion of the walls of said opening are formed by the encapsulant layer, where the opening exposes a portion of the metallic layer to act as a cathode, and where the opening is capable of ionic contact, and an electrolyte to provide ionic contact with the cathode and the anode for electrical ionic relationship between the electrodes.
Claim 2
Dependent Claim
208 words
An improved electrochemical cell that is useful in an oxygen sensor that measures the oxygen tension or concentration in a fluid including those that have small quantities of oxygen where the cell is part of a printed wiring board, comprising: a nonconducting substrate, at least one metallic layer overlying the said nonconducting substrate in a pattern to provide distinct cathode and anode and conductive pathways to both electrodes where the pathways are electrically isolated from each other and where they allow for eventual external electrical connection to the cell, an encapsulant layer overlying that portion of said metallic layer other than the anode to electrically isolate the conductive pathway to the anode from the conductive pathway to the cathode in the metallic layer and having at least one laser-produced finite-sided opening with a bottom and tapered walls, where the opening extends through at least said encapsulant layer, where at least a portion of the walls of said opening are formed by the encapsulant layer, where the opening exposes a portion of the metallic layer to act as a cathode, and where the opening is capable of ionic contact, and an electrolyte to provide ionic contact with the cathode and the anode for electrical ionic relationship between the electrodes.
Claim 3
Dependent Claim
16 words
The electrochemical cell of claim 1, which includes a hydrophobic oxygen permeable membrane covering the electrolyte.
Claim 4
Dependent Claim
39 words
A electrochemical cell of claim 2 wherein the ratio of the surface area of the anode to the surface area of the cathode is in the range of at least 50 to 1 and up to 300 to 1.
Claim 5
Dependent Claim
15 words
The electrochemical cell of claim 2 wherein the cathode walls are essentially free of swarf.
Claim 6
Dependent Claim
31 words
The electrochemical cell of claim 1 wherein the electrolyte is selected from the group consisting of a gel and liquid and when a liquid there is a membrane covering the electrolyte.
Claim 7
Dependent Claim
15 words
The electrochemical cell of claim 5 wherein the cathode walls are essentially free of swarf.
Claim 8
Dependent Claim
36 words
The electrochemical cell of claim 1 wherein the electrolyte is a liquid and there is a hydrophobic membrane covering the electrolyte and there is an oxygen porous membrane covering the cathode and anode as a submembrane.
Claim 9
Dependent Claim
26 words
The electrochemical cell of claim 1 wherein the anode has a semi-circular shape that is equidistant from the cathode opening at every point along the semicircle.
Claim 10
Dependent Claim
38 words
The electrochemical cell of claim 1 wherein the opening in the encapsulant layer has its walls comprised of the encapsulant layer and the bottom of the opening is comprised of the metal layer that acts as the cathode.
Claim 11
Dependent Claim
66 words
The electrochemical cell of claim 1 wherein in addition to the portion of the walls of the opening that is comprised of the encapsulant layer, the remaining portion of the walls is comprised of the metallic layer, and wherein the bottom of the opening is comprised of the metallic layer, so that the metallic portion of the walls and of the bottom act as the cathode.
Claim 12
Dependent Claim
65 words
The electrochemical cell of claim 1 wherein in addition to the portion of the walls comprised of the encapsulant layer, the remaining portion of the walls is comprised of the metallic layer, and wherein the bottom of the opening is at the nonconducting substrate so that the metallic portion of the walls forms an annular metallic portion of the wall that acts as the cathode.
Claim 13
Dependent Claim
17 words
The electrochemical cell of claim 1 wherein the cathode has a diameter between 0.001 and 0.0015±0.0003 inch.
Claim 14
Dependent Claim
17 words
The electrochemical cell of claim 1 wherein the walls of the cathode are essentially free of swarf.
Claim 15
Dependent Claim
68 words
The electrochemical cell of claim 1, which includes an external lead electrically connected to the pattern of the metallic layer that is connected to the cathode and an external lead electrically connected to the pattern of the metallic layer that is connected to the anode to carry an electric current produced from the reduction of oxygen under the presence of an applied potential between the cathode an anode.
Claim 16
Dependent Claim
90 words
The electrochemical cell of claim 1, wherein the nonconducting substrate has a first and second side and where the cell includes an external lead electrically connected to the pattern of the metallic layer that is connected to the cathode and an external lead electrically connected to the pattern of the metallic layer that is connected to the anode, where the electrodes are on the first side of the substrate and the electrodes are connected through the substrate to the external leads that are on the second side of the substrate.
Claim 17
Dependent Claim
36 words
The electrochemical cell of claim 1 wherein the cathode and anode have a voltage potential between them of about 300 m volts to about 1 volt and the cathode is negative with respect to the anode.
Claim 18
Dependent Claim
25 words
The electrochemical cell of claim 1 wherein the opening in the encapsulant has a depth and diameter so as to reduce oxygen consumption during measurement.
Claim 19
Dependent Claim
31 words
The electrochemical cell of claim 1 wherein the distance between the center of the cathode and the edge of the anode is in the range of around 0.13 to 0.15 inch.
Claim 20
Dependent Claim
26 words
The electrochemical cell of claim 1 wherein the electrolyte that provides ionic contact between the anode and the cathode also contacts the encapsulant at the opening.
Claim 21
Dependent Claim
17 words
The electrochemical cell of claim 1 wherein the opening in the encapsulant is a cylindrical conical hole.
Claim 22
Dependent Claim
24 words
The electrochemical cell of claim 1 wherein the opening in the encapsulant stops at a bottom at the top of the cathodic metallic layer.
Claim 23
Dependent Claim
39 words
The electrochemical cell of claim 1 wherein the walls of the opening result from the laser having a sufficient wavelength and beam power to remove at least the encapsulant that is either vaporized, sublimed or melted by the laser.
Claim 24
Dependent Claim
12 words
The electrochemical cell of claim 1 wherein the opening is heat treated.
Claim 25
Dependent Claim
17 words
A plurality of electrochemical cells of claim 1 wherein the cathode is uniform from cathode to cathode.
Claim 26
Dependent Claim
155 words
A cathode in a layered circuit, comprising: a multilayered composite having: nonconducting base, at least one patterned metallic layer associated with the nonconducting base where the layer has two ends and one end is remote from the other end and one end is capable of electric connection from the nonconducting base by an electrical lead, and at least one encapsulant layer, wherein the encapsulant is selected from the group consisting of glass, ceramics and a mixture thereof and the encapsulant layer overlays all of the metallic layer but for at least one laser-produced finite-sided opening with tapered sides in proximity to the end of the metallic layer that is distant from the end for attachment to the electrical lead, where the opening extends from the top of the encapsulant layer overlying the metallic layer to at least the surface of the metallic layer to form a bottom and walls to make the opening finite sided.
Claim 27
Dependent Claim
155 words
A cathode in a layered circuit, comprising: a multilayered composite having: nonconducting base, at least one patterned metallic layer associated with the nonconducting base where the layer has two ends and one end is remote from the other end and one end is capable of electric connection from the nonconducting base by an electrical lead, and at least one encapsulant layer, wherein the encapsulant is selected from the group consisting of glass, ceramics and a mixture thereof and the encapsulant layer overlays all of the metallic layer but for at least one laser-produced finite-sided opening with tapered sides in proximity to the end of the metallic layer that is distant from the end for attachment to the electrical lead, where the opening extends from the top of the encapsulant layer overlying the metallic layer to at least the surface of the metallic layer to form a bottom and walls to make the opening finite sided.
Claim 28
Dependent Claim
20 words
Cathode of claim 25 wherein the bottom of the opening is the metallic layer that forms a planar cathodic surface.
Claim 29
Dependent Claim
44 words
Cathode of claim 25 wherein the sides of the opening have the uppermost portion composed of the encapsulant material and the lowermost portion comprised of at least a part of the metallic layer so that an annular cathodic surface is formed in the opening.
Claim 30
Dependent Claim
45 words
Cathode of claim 27 wherein the bottom of the opening is comprised of the nonconducting base and the lower most portion of the sides of the opening distant from the top surface of the encapsulant layer form an annular surface to act as the cathode.
Claim 31
Dependent Claim
12 words
Cathode of claim 27 wherein the nonconducting base is a ceramic base.
Claim 32
Dependent Claim
174 words
A cathode in a layered circuit, comprising: a multilayered composite having: nonconducting base, at least one patterned metallic layer associated with the nonconducting base where the layer has two ends and one end is remote from the other end and one end is capable of electric connection from the nonconducting base by an electrical lead, and at least one encapsulant layer overlying all of the metallic layer but for at least one finite sided opening with tapered sides in proximity to the end of the metallic layer that is distant from the end for attachment of the electrical connection from the nonconducting base, where the opening extends from the top of the encapsulant layer overlying the metallic layer to at least the surface of the metallic layer so that the sides of the opening have at least an upper most portion above the metallic layer composed of the encapsulant material selected from the group consisting of glass, ceramics and a mixture thereof and where the opening has a diameter between 0.001 and 0.0015±0.0003 inch.
Claim 33
Dependent Claim
174 words
A cathode in a layered circuit, comprising: a multilayered composite having: nonconducting base, at least one patterned metallic layer associated with the nonconducting base where the layer has two ends and one end is remote from the other end and one end is capable of electric connection from the nonconducting base by an electrical lead, and at least one encapsulant layer overlying all of the metallic layer but for at least one finite sided opening with tapered sides in proximity to the end of the metallic layer that is distant from the end for attachment of the electrical connection from the nonconducting base, where the opening extends from the top of the encapsulant layer overlying the metallic layer to at least the surface of the metallic layer so that the sides of the opening have at least an upper most portion above the metallic layer composed of the encapsulant material selected from the group consisting of glass, ceramics and a mixture thereof and where the opening has a diameter between 0.001 and 0.0015±0.0003 inch.
Claim 34
Dependent Claim
261 words
An improved electrochemical sensor that is useful in measuring the oxygen tension in a blood where the sensor can be located on a planar printed wiring board, comprising: a nonconducting substrate, at least one metallic layer overlying the said nonconducting substrate in a pattern to provide distinct cathode and anode and conductive pathways to both electrodes where the pathways are electrically isolated from each other and where they allow for eventual external electrical connection, an encapsulant layer overlying that portion of said metallic layer other than the cathode and anode to electrically isolate the anode from the cathode and their pathways of the metallic layer and having at least one laser-produced finite-sided opening with tapered walls and a bottom, where the opening extends through at least said encapsulant layer, where at least a portion of the walls of said openings is formed by the encapsulant layer, where the opening exposes a portion of the metallic layer to act as a cathode, and where the opening is capable of ionic contact, and an electrolyte to provide ionic contact with the cathode and the anode for electrical ionic relationship between the electrodes, and an external lead electrically connected to the pattern of the metallic layer that is connected to the cathode and an external lead electrically connected to the pattern of the metallic layer that is connected to the anode to carry an electrical current produced from the reduction of oxygen under the presence of an applied potential between the cathode and anode where the cathode is negative with respect to the anode.
Claim 35
Dependent Claim
261 words
An improved electrochemical sensor that is useful in measuring the oxygen tension in a blood where the sensor can be located on a planar printed wiring board, comprising: a nonconducting substrate, at least one metallic layer overlying the said nonconducting substrate in a pattern to provide distinct cathode and anode and conductive pathways to both electrodes where the pathways are electrically isolated from each other and where they allow for eventual external electrical connection, an encapsulant layer overlying that portion of said metallic layer other than the cathode and anode to electrically isolate the anode from the cathode and their pathways of the metallic layer and having at least one laser-produced finite-sided opening with tapered walls and a bottom, where the opening extends through at least said encapsulant layer, where at least a portion of the walls of said openings is formed by the encapsulant layer, where the opening exposes a portion of the metallic layer to act as a cathode, and where the opening is capable of ionic contact, and an electrolyte to provide ionic contact with the cathode and the anode for electrical ionic relationship between the electrodes, and an external lead electrically connected to the pattern of the metallic layer that is connected to the cathode and an external lead electrically connected to the pattern of the metallic layer that is connected to the anode to carry an electrical current produced from the reduction of oxygen under the presence of an applied potential between the cathode and anode where the cathode is negative with respect to the anode.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-09-20 | 1997-03-22 | 1997-09-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-09-20 | 2001-03-22 | 2001-09-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-09-20 | 2005-03-22 | 2005-09-21 | $7700.00 | Window Closed / Lapsed |