Recloseable biosensor

[0001] The present application is a Continuation-in-Part of U.S. application Ser. No. 09/620,191, filed Jul. 20, 2000, which has issued as U.S. Pat. No. 6,488,828 on Dec. 3, 2002.

[0002] The present invention relates to a biosensor for use in determining the concentration of an analyte in a sample.

[0003] Electrochemical biosensors are known. They have been used to determine the concentration of various analytes from biological samples, particularly from blood. Biosensors are described in U.S. Pat. Nos. 5,288,636; 5,413,690; 5,762,770; 5,798,031; and 5,997,817, the disclosure of each of which are hereby incorporated by reference. Storage containers for test strips are also known. See U.S. Pat. Nos. 5,788,064 and 5,985,675.

[0004] According to the present invention, a recloseable biosensor is provided that comprises a substrate formed to include a sample site, a cover including first and second ends and a middle portion between the ends, the first end of the cover being coupled to the substrate and the middle portion extending over the sample site and being releasable and recloseable over the sample site, and a biocide positioned between the cover and the substrate.

[0005] In addition, according to the invention a biosensor is provided that comprises a substrate formed to include a sample site, a reagent positioned at the sample site, a cover extending across the reagent, a biocide positioned between the cover and the substrate, and a desiccant spaced apart from the reagent. Further, according to the invention a recloseable biosensor is provided that comprises a substrate, a reagent positioned on the substrate, an openable and recloseable cover including a fixed end coupled to the substrate, an opposite free end, and a middle portion extending between the opposite ends across the reagent, said cover being operative to selectively block access to the reagent, and a biocide positioned between the cover and the substrate.

[0006] Additional features of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of the preferred embodiment exemplifying the best mode of carrying out the invention as presently perceived.

[0024] The present invention relates to a recloseable biosensor that can be closed after the initial opening to protect a sample site. Thus, the need to locate a storage container for the biosensor either prior to use or before disposal is avoided. As such, providing biosensors with recloseable covers appreciably enhances the marketability, hygenic storage by containing an applied sample within the biosensor after use, and environmental friendliness of the biosensor. Moreover, biosensors with biocide brings the above benefits plus an added factor of safety following use of the biosensor. Biosensors with desiccants further enables packaging of individual test strips leading to improved portability and an improved level of discretion—transport and use of a singly packaged strip versus transport and use of a vial or larger. Biosensors can take the form of any number of diagnostic biosensors including, for example, electrochemical and photometric biosensors. Various aspects of the invention are presented in FIGS. 1–16, which are not drawn to scale and wherein like components in the several views are numbered alike.

[0025] FIGS. 1–7 illustrate an aspect of the invention in the form of biosensor 10 having a first insulating substrate 12, a second insulating substrate 14, electrically conductive tracks 16, 18 situated between substrates 12, 14, a testing reagent 20, spreading mesh 22, and a cover 24 positioned over reagent 20 and mesh 22. Biosensor 10 is produced from rolls of material. Thus, the selection of materials for the construction of biosensor 10 necessitates the use of materials that are sufficiently flexible for roll processing, but which are still rigid enough to give a useful stiffness to finished biosensor 10.

[0026] First substrate 12 of biosensor 10 includes a first surface 30 that supports conductive tracks 16, 18 and an opposite second surface 32. See FIG. 1. In addition, as shown in FIG. 12, first substrate 12 has opposite ends 31, 33. First substrate 12 may be constructed from a wide variety of insulative materials. Non-limiting examples of insulative materials that provide desirable electrical and structural properties include vinyl polymers, polyimides, polyesters, and styrenics. Preferably, first substrate 12 is 7 mil thick MELINEX 329 plastic, a polyester commercially available from E. I. DuPont de Nemours, Wilmington, Del.

[0027] As shown in FIGS. 1–5, electrically conductive tracks 16, 18 are laid down onto first surface 30 of first substrate 12. Tracks 16, 18 represent the electrodes of biosensor 10. Therefore, track 16 may be a working electrode and track 18 may be an auxiliary electrode or counter electrode. The distance between tracks 16, 18 is about 1.2 millimeters (mm). It is appreciated that the distance between tracks 16, 18 may vary in accordance with this disclosure.

[0028] Tracks 16, 18 are constructed from electrically-conductive materials. Non-limiting examples of electrically-conductive materials include aluminum, carbon (such as graphite), cobalt, copper, gallium, gold, indium, iridium, iron, lead, magnesium, mercury (as an amalgam), nickel, niobium, osmium, palladium, platinum, rhenium, rhodium, selenium, silicon (such as highly doped polycrystalline silicon), silver, tantalum, tin, titanium, tungsten, uranium, vanadium, zinc, zirconium, mixtures thereof, and alloys, oxides, or metallic compounds of these elements. Preferably, tracks 16, 18 include gold, platinum, palladium, iridium, or alloys of these metals, since such noble metals and their alloys are unreactive in biological systems. Most preferably, track 16 is a working electrode made of platinum, and track 18 is an auxiliary or counter electrode that is also made of platinum and is substantially the same size as the working electrode. Tracks 16, 18 are deposited on an insulative backing (not shown), such as polyimide or polyester. An example of such an insulator is the polyimide UPILEX from UBE INDUSTRIES, LTD., Japan, which is available pre-coated with gold, palladium or platinum from TECHNI-MET of Connecticut, USA.

[0029] Three electrode arrangements are also possible, wherein biosensor 10 includes an additional electrically conductive track (not shown). In a three-electrode arrangement, track 16 is a working electrode, track 18 is a counter electrode, and the third electrode is a reference electrode. It is also appreciated that a three-electrode arrangement is possible where tracks 16 and 18 are working electrodes and a third electrode is provided as an auxiliary or reference electrode in accordance with this disclosure. Moreover, it is appreciated that the size, shape, relative position, and number of electrodes may vary depending upon the specifications of the specific biosensor and that the electrodes may be formed by any number of commercially available processes in accordance with this disclosure.

[0030] Second substrate 14 of biosensor 10 overlaps tracks 16, 18. Second substrate 14 has a first surface 34 and a second surface 36 facing conductive tracks 16, 18. As shown in FIG. 1, second substrate 14 is formed to include first and second openings 38, 40. First opening 38 exposes portions of tracks 16, 18 for electrical connection with a meter (not shown), which measures some electrical property of a liquid sample 133 (FIG. 5) after sample 133 is applied to reagent 20 of biosensor 10. Second opening 40 includes an edge 41 that defines a perimeter of a sample site 66. Sample site 66 can take on a variety of shapes and sizes to aid a user in identifying where to deposit the liquid sample 133 in accordance with this disclosure. Second substrate 14 is coupled to first substrate 12 and tracks 16, 18 by an adhesive such as a hot melt glue. A non-limiting example of such glue is DYNAPOL S-1358 glue, available from Hüls America, Inc., 220 Davidson Street, P.O. Box 6821, Somerset, N.J. 08873. It is appreciated that first and second substrates 12, 14 may be coupled together using a wide variety of commercially available adhesives or with welding (heat or ultrasonic) in accordance with this disclosure.

[0031] Second opening 40 of second substrate 14 is positioned to expose a portion of tracks 16, 18 for application of reagent 20 to those exposed surfaces of tracks 16, 18. See FIGS. 1–2. The length and width of opening 40 define the length and width of sample site 66 and the thickness of second substrate 14 defines the height of a test chamber. Sample site 66 is formed as a rectangle of about 4.0 mm on one side and about 4.2 mm on the other side. The degree to which tracks 16, 18 are exposed determines the surface area for each electrode. The working electrode 16 and auxiliary or counter electrodes 18 each have substantially equivalent surface areas of about 6 mm². It is appreciated, however, that the degree of exposure of tracks 16, 18 may vary in accordance with this disclosure.

[0032] Reagent 20 provides electrochemical probes for specific analytes and is positioned in test chamber 66 such that reagent 20 covers working electrode 16. Reagent 20 is placed as a film of generally uniform thickness over first surface 30 in test chamber 66 and across electrodes 16, 18. Reagent 20 will then present a hydrophilic surface to the interior of test chamber 66.

[0033] After drying, reagent mesh 22, which has been impregnated with a surfactant, is placed over opening 40. Mesh 22 is preferably a polyester monofilament mesh from Sefar America, Inc. 333 S. Highland Avenue, Briarcliff Manor, N.Y. Mesh 22 is preferably dipped in a solution of 0.8% (wt:vol) dioctylsodium sulfosuccinate (DONS) in a solution of 50:50 (vol.:vol.) methanol:water and then dried. It is appreciated that biosensor 10 may be constructed using a variety of commercially available meshes or may even be constructed without mesh in accordance with this disclosure.

[0034] The choice of specific reagent 20 depends on the specific analyte or analytes to be measured, and are well known to those of ordinary skill in the art. An example of a reagent that may be used in biosensor 10 of the present invention is a reagent for measuring glucose from a whole blood sample. A non-limiting example of a reagent for measurement of glucose in a human blood sample contains 62.2 mg polyethylene oxide (mean molecular weight of 100–900 kilodaltons), 3.3 mg NATROSOL 250M, 41.5 mg AVICEL RC-591 F, 89.4 mg monobasic potassium phosphate, 157.9 mg dibasic potassium phosphate, 437.3 mg potassium ferricyanide, 46.0 mg sodium succinate, 148.0 mg trehalose, 2.6 mg TRITON X-100 surfactant, and 2,000 to 9,000 units of enzyme activity per gram of reagent. The enzyme is prepared as an enzyme solution from 12.5 mg coenzyme PQQ and 1.21 million units of the apoenzyme of quinoprotein glucose dehydrogenase. This reagent is further described in U.S. Pat. No. 5,997,817, the disclosure of which is incorporated herein by reference.

[0035] When hematocrit is to be determined, the reagent includes oxidized and reduced forms of a reversible electroactive compound (potassium hexacyanoferrate (III) (“ferricyanide”) and potassium hexacyanoferrate (II) (“ferrocyanide”), respectively), an electrolyte (potassium phosphate buffer), and a microcrystalline material (Avicel RC-591F—a blend of 88% microcrystalline cellulose and 12% sodium carboxymethyl-cellulose, available from FMC Corp.). Concentrations of the components within the reagent before drying are as follows: 400 millimolar (mM) ferricyanide, 55 mM ferrocyanide, 400 mM potassium phosphate, and 2.0% (weight:volume) Avicel. A further description of the reagent for a hematocrit assay is found in U.S. Pat. No. 5,385,846, the disclosure of which is incorporated herein by reference.

[0036] Non-limiting examples of enzymes and mediators that may be used in measuring particular analytes in sensor 10 of the present invention are listed below in Table 1.

[0037]

TABLE 1
		Mediator
		(Oxidized	Additional
Analyte	Enzymes	Form)	Mediator
Glucose	Glucose	Ferricyanide
	Dehydrogenase
	and Diaphorase
Glucose	Glucose-	Ferricyanide
	Dehydrogenase
	(Quinoprotein)
Cholesterol	Cholesterol	Ferricyanide	2,6-Dimethyl-1,4-
	Esterase and		Benzoquinone
	Cholesterol Oxidase		2,5-Dichloro-1,4-
			Benzoquinone or
			Phenazine
			Ethosulfate
HDL	Cholesterol Esterase	Ferricyanide	2,6-Dimethyl-1,4-
Cholesterol	and Cholesterol		Benzoquinone
	Oxidase		2,5-Dichloro-1,4-
			Benzoquinone or
			Phenazine
			Ethosulfate
Triglycerides	Lipoprotein Lipase,	Ferricyanide	Phenazine
	Glycerol Kinase, and	or Phenazine	Methosulfate
	Glycerol-3-Phosphate	Ethosulfate
	Oxidase
Lactate	Lactate Oxidase	Ferricyanide	2,6-Dichloro-1,4-
			Benzoquinone
Lactate	Lactate	Ferricyanide
	Dehydrogenase	Phenazine
	and Diaphorase	Ethosulfate,
		or Phenazine
		Methosulfate
Lactate	Diaphorase	Ferricyanide	Phenazine
Dehydro-			Ethosulfate, or
genase			Phenazine
			Methosulfate
Pyruvate	Pyruvate Oxidase	Ferricyanide
Alcohol	Alcohol Oxidase	Phenyl-
		enediamine
Bilirubin	Bilirubin Oxidase	1-Methoxy-
		Phenazine
		Methosulfate
Uric Acid	Uricase	Ferricyanide

[0038] In some of the examples shown in Table 1, at least one additional enzyme is used as a reaction catalyst. Also, some of the examples shown in Table 1 may utilize an additional mediator, which facilitates electron transfer to the oxidized form of the mediator. The additional mediator may be provided to the reagent in lesser amount than the oxidized form of the mediator. While the above assays are described, it is contemplated that current, charge, impedance, conductance, potential, or other electrochemically indicated property of sample 133 may be accurately correlated to the concentration of the analyte in sample 133 with biosensor 10 in accordance with this disclosure.

[0039] As shown in FIGS. 1–7, cover 24 overlays a portion of second substrate 14 and sample site 66 to protect reagent 20 from the surrounding environment prior to use. Following use, cover 24 overlays sample site 66 to block exposure of the reagent/sample mixture to the surrounding environment. Referring specifically to FIGS. 4–5, cover 24 includes a top side 26 and a bottom side 28 that engages first surface 34 of second substrate 14. Cover 24 further includes a fixed end 42 coupled to first surface 34 of second substrate 14, an opposite free end 44, and a middle portion 46 that extends between opposite ends 42, 44 across sample site 66 and reagent 20.

[0040] Cover 24 is constructed of a material with a relatively high tear resistance, such as a metallized polyester foil that has a thickness of about 2 mil (0.05 mm) to 6 mil (0.15 mm) thickness. It is appreciated, however, that cover 24 may be constructed from a variety of commercially available flexible polymers that are suitable for reducing the transmission of light and are relatively impermeable to moisture and gas in accordance with this disclosure. Non-limiting examples of suitable materials for use as cover 24 include polyimide, polyolefins, poly (vinyl chloride), poly (ethylene terephthalate), and polypropylene. Additionally, while not illustrated, it is appreciated that top side 26 of cover 24 may be printed with, for example, product labeling or instructions for use in accordance with this disclosure.

[0041] As shown in FIGS. 6–7, an adhesive 50 permanently bonds fixed end 42 of cover 24 to second substrate 14 and an adhesive 52 creates an initial seal about sample site 66. Unless indicated otherwise, the term “permanent” is used herein to mean continuing or enduring without fundamental or marked change. Still further, an adhesive 54 releasably secures middle portion 46 of cover 24 to second substrate 14. Adhesive 50, which couples fixed end 42 of cover 24 to second substrate 14 is preferably a hot-melt adhesive. Adhesive 50 is distributed over first surface 34 of second substrate 14 and/or the adjacent bottom side 28 of fixed end 42. Adhesive 50 adheres fixed end 42 to second substrate 14 after cover 24 is applied to first surface 34, so that in normal usage of biosensor 10, fixed end 42 stays adhered to second substrate 14. More specifically, the adhesive bond between fixed end 42 and first surface 34 is intended to never be broken. Non-limiting examples of suitable hot-melt adhesives are HL-7276, an ethyl vinlyacetate adhesive and HL-0705-S, an olefin adhesive, both of which are commercially available from H.B. Fuller Company, St. Paul, Minn. It is appreciated that a wide variety of hot-melt adhesives that are designed for case and carton sealing as well as welding (heat or ultrasonic) may be used to couple fixed end 42 onto second substrate 14.

[0042] Middle portion 46 of cover 24 is coupled to second substrate 14 by first and second adhesives 52, 54. First adhesive 52 is distributed over first surface 34 of second substrate 14 spaced-apart from adhesive 50 and/or the adjacent bottom side 28 of middle portion 46. First adhesive 52 adheres middle portion 46 to second substrate 14 after cover 24 is applied to first surface 34, so that in normal usage of biosensor 10, the adhesive bond between middle portion 46 and first surface 34 is broken once just prior to use. Thus, a seal is established between cover 24 and second substrate 14 around reagent 20 during storage of biosensor 10. As shown in FIG. 5, once seal is broken, a film 55 is generally left on first surface 34 and/or cover 24 such that adhesive 52 will not reseal cover 24 and second substrate 14. Non-limiting examples of suitable hot-melt adhesives are HL-7276, an ethyl vinlyacetate adhesive and HL-0705-S, an olefin adhesive, both of which are available from H.B. Fuller Company, St. Paul, Minn. It is appreciated that a wide variety of hot-melt adhesives that are designed for case and carton sealing as well as welding (heat or ultrasonic) may be used to couple fixed end 42 onto second substrate 14.

[0043] Middle portion 46 of cover 24 is also coupled to second substrate 14 by second adhesive 54. Second adhesive 54 is a pressure-sensitive, releasable, resealable adhesive, which serves to hold middle portion 46 of cover 24 against second substrate 14. Adhesive 54 may be permanently applied to second substrate 14 and/or to cover 24. As illustrated, adhesive 54 is permanently applied to second substrate 14 so that the seal between second adhesive 54 and cover 24 is broken when free end 44 of cover 24 is lifted away from second substrate 14.

[0044] A suitable pressure-sensitive adhesive 54 for use with biosensor 10 can be resealed against cover 24 so that cover 24 extends across sample site 66. Second adhesive 54 is preferably spaced-apart from the end of substrate 14 that is in general alignment with a tab 48 that extends from free end 44 of cover 24. Tab 48 is easily grasped by the user to enable the user to selectively lift middle portion 46 of cover 24 away from second substrate 14, as shown in FIGS. 3–5 and 7. A non-limiting example of a suitable pressure-sensitive adhesive 54 is HL-2268, commercially available from H.B. Fuller Company, St. Paul, Minn. It is appreciated that a wide variety of pressure-sensitive adhesives as well as, hook-and-loop type fasteners, tongue and groove fasteners, and the like may be used to affix middle portion 46 on second substrate 14.

[0045] It is appreciated that a desiccant and/or biocide may be permanently applied to either cover 24 or to second substrate 14 in a manner similar to that shown in FIGS. 14 and 15 as it relates to the below described biosensor 210. It is also appreciated that desiccating polymer films are commercially available to manufacture both the cover and substrates in accordance with this disclosure. See, for example CSP Technologies Inc. (Auburn, Ala.). Further, non-limiting examples of suitable desiccants and biocides are also described below with reference to biosensors 10 and 210.

[0046] Biosensor 10 incorporating reagent 20 of the present invention is preferably manufactured using rolls of materials, which are wider than the biosensor itself. Specifically, first substrate 12, tracks 16, 18, and second substrate 14 are assembled as described in U.S. Pat. No. 5,762,770, the disclosure of which is incorporated herein by reference and situated in a roll 68. Roll 68 is unwound and holt-melt adhesives 50, 52 and pressure-sensitive adhesive 54 are applied to first surface 34 of second substrate 14 using a computer controlled hot melt dispense unit 101. It is appreciated that a number of commercially available dispense units may be used to apply adhesives 50, 52, 54 onto second substrate 14 in accordance with this disclosure. It is also appreciated that one of ordinary skill in the art will appreciate that first substrate 12, tracks 16, 18, and second substrate 14 may be assembled using a variety of known manufacturing techniques.

[0047] Cover 24 is also situated in a roll 70, as shown in FIG. 8, which is wider than the cover itself. Roll 70 is unwound and fed into a slitting station 102a of a cutting unit 102. In slitting station 102a, cover material of roll 70 is slit into the appropriate width for each biosensor 10. Additionally, cover material of roll 70 is fed into cut/punch & placement unit 102b of cutting unit 102. In unit 102b, contours of tab 48 and cover 24 are punched from cover material of roll 70 and the resulting covers are placed upon adhesives 50, 52, 54 to form a series of attached biosensors. These attached biosensors are then fed into a sensor punch unit 103, where the attached biosensors are cut to form individual biosensors 10. It is appreciated that any number of commercially available dispense units, cutting units, and sensor punch units may be used to form biosensor 10 in accordance with this disclosure.

[0048] A plurality of biosensors are typically packaged in a vial, usually with a stopper formed to seal the vial. It is appreciated, however, that biosensors may be packaged individually, or biosensors can be folded upon one another, rolled in a coil, stacked in cassette magazine, or packed in a blister packaging.

[0049] Biosensor 10 is used in conjunction with the following:

[0050] 1. a power source in electrical connection with the working and auxiliary or counter electrodes and capable of supplying an electrical potential difference between the working and auxiliary or counter electrodes sufficient to cause diffusion limited electro-oxidation of the reduced form of the mediator at the surface of the working electrode; and

[0051] 2. a meter in electrical connection with the working and auxiliary or counter electrodes and capable of measuring the diffusion limited current produced by oxidation of the reduced form of the mediator with the above-stated electrical potential difference is applied.

[0052] The meter will normally be adapted to apply an algorithm to the current measurement, whereby an analyte concentration is provided and visually displayed. Improvements in such power source, meter, and biosensor system are the subject of commonly assigned U.S. Pat. No. 4,963,814, issued Oct. 16, 1990; U.S. Pat. No. 4,999,632, issued Mar. 12, 1991; U.S. Pat. No. 4,999,582, issued Mar. 12, 1991; U.S. Pat. No. 5,243,516, issued Sep. 7, 1993; U.S. Pat. No. 5,352,351, issued Oct. 4, 1994; U.S. Pat. No. 5,366,609, issued Nov. 22, 1994; White et al., U.S. Pat. No. 5,405,511, issued Apr. 11, 1995; and White et al., U.S. Pat. No. 5,438,271, issued Aug. 1, 1995, the disclosures of which are hereby incorporated by reference. Moreover, it is appreciated that the meter may be in electrical connection with conductive tracks, said tracks in communication with potentiometeric or conductometric circuit elements residing on the biosensor.

[0053] Many fluid samples may be analyzed. For example, human body fluids such as whole blood, plasma, sera, lymph, bile, urine, semen, cerebrospinal fluid, spinal fluid, lacrimal fluid and stool specimens as well as other biological fluids readily apparent to one skilled in the art may be measured. Fluid preparations of tissues can also be assayed, along with foods, fermentation products and environmental substances, which potentially contain environmental contaminants. Preferably, whole blood is assayed with this invention.

[0054] In use, the user lifts tab 48 to separate middle portion 46 of cover 24 from second substrate 14 and open sample site 66 to view. See FIGS. 3–5. A liquid sample 133 is then deposited on sample site 66. When reagent 20 is the reagent for measuring glucose as described above, sample 133 containing the analyte dissolves reagent 20 in opening 40 to oxidize the analyte and reduce the oxidized form of the mediator. The reaction between the analyte and reagent 20 is permitted to go to completion. (Completion is defined as sufficient reaction involving analyte, enzyme, and mediator (oxidized form) to correlate analyte concentration to diffusion limited current generated by oxidation of the reduced form of the mediator at the surface of the working electrode.)

[0055] After reaction is complete, a power source (e.g., a battery) applies a potential difference between electrodes. When the potential difference is applied, the amount of oxidized form of the mediator at the auxiliary or counter electrode and the potential difference must be sufficient to cause diffusion-limited electro-oxidation of the reduced form of the mediator at the surface of the working electrode. A current measuring meter (not shown) measures the diffusion-limited current generated by the oxidation of the reduced form of the mediator at the surface of the working electrode. The measured current may be accurately correlated to the concentration of the analyte in sample 133 when the following requirements are satisfied:

[0056] 1. The rate of oxidation of the reduced form of the mediator is governed by the rate of diffusion of the reduced form of the mediator to the surface of the working electrode.

[0057] 2. The current produced is limited by the oxidation of reduced form of the mediator at the surface of the working electrode.

[0058] Once the concentration of the analyte is determined, the user presses the middle portion 46 of cover 24 over sample site 66 to reclose cover 24 onto second substrate 14. Thus, recloseable cover 24 provides a protective covering for sample site 66 during storage before use and prior to disposal following completion of the assay to seal sample 133 in biosensor 10.

[0059] A biosensor 110 is provided in accordance with another aspect of this invention and is illustrated in FIGS. 9–11. Biosensor 110 includes a second insulating substrate 114 situated on first substrate 12, tracks 16, 18 situated between substrates 12, 114, a testing reagent 120, a third substrate 122 situated over reagent 120 on a portion of second substrate 114, and a cover 124 that extends over third substrate 122. Biosensor 110 is produced from rolls of material in a manner similar to biosensor 10.

[0060] Referring now to FIG. 11, second substrate 114 is formed to include a channel 140 that is sized to receive reagent 120 and defines a sample site 166. Reagent 120 is formed similarly to reagent 20, except for its shape. Reagent 120 and sample site 166 can take on a variety of shapes and in accordance with this disclosure. Second substrate 114 is coupled to first substrate 12, tracks 16, 18, and third substrate 122 by an adhesive such as a hot melt glue. A non-limiting example of such glue is DYNAPOL S-1358 glue, available from Hüls America, Inc., 220 Davidson Street, P.O. Box 6821, Somerset, N.J. 08873. It is appreciated that first and second substrates 12, 114 may be coupled together using a wide variety of commercially available adhesives or with welding (heat or ultrasonic) in accordance with this disclosure.

[0061] Channel 140 is sized to promote capillary flow of liquid sample 133 across tracks 16, 18. The length and width of channel 140 define the length and width of sample site 166 and the thickness of substrate 114 defines the height of the test chamber. Sample site 166 is formed to have a length of about 4 to about 8 mm and a width of about 4 to about 5 mm. Although it is understood that the length and width of the channel may vary widely depending upon the specifications of the specific biosensor. The degree to which tracks 16, 18 are exposed determines the surface area of each electrode. The degree of exposure may vary as discussed above with reference to biosensor 10.

[0062] Third substrate 122 of biosensor 110 overlaps a portion of second substrate 114. Third substrate 122 has a first surface 172 and a second surface 174 facing second substrate 114. As shown in FIGS. 10–11, third substrate 122 is formed to include a sample port 168 and an air vent 170 positioned in alignment with channel 140. Sample port 168 is generally circular in shape, although it is appreciated that sample port 168 can take on a variety of shapes and sizes in accordance with this disclosure. Third substrate 122 is constructed of a material identical to second substrate 114. It is appreciated that third substrate 122, may also be constructed of a variety of materials as discussed above with reference to substrates 12, 14.

[0063] As shown in FIGS. 9–11, cover 124 is formed similarly to cover 24 except that cover 124 includes raised portion 156 that is sized to receive a sink pad 160 therein. As shown in FIG. 10, sink pad 160 is in general alignment with port 168. Sink pad 160 is formed to absorb fluid when cover 124 extends across sample port 168. Sink pad 160 is formed to absorb any liquid sample that remains over port 168 following testing. Sink pad 160 is a cellulose absorbent paper manufactured by PALL Specialty Materials, Port Washington, N.Y. As an alternative, conjugate pads can also be used as “sink pad”, which are commercially available from PALL Specialty Materials, Port Washington, N.Y. Adhesive 54 is used to hold the sink pad in place on cover 124.

[0064] Alternatively, a desiccant and/or biocide may be permanently applied to either cover 124 or to third substrate 122 as shown in FIGS. 14 and 15 as it relates to biosensor 210. A suitable desiccant removes moisture from reagent 120 when cover 124 is in a closed position, sealed against third substrate 122. Non-limiting examples of desiccants include alumina gel, silica gel, a molecular sieve type 3A or 4A, or calcium sulfate. Preferably, desiccant is DesiMax™ SLF Desiccant in tape form, which is commercially available from Multisorb Technologies, Inc., Buffalo, N.Y. It is also appreciated that desiccating polymer films are commercially available to manufacture both the cover and substrates in accordance with this disclosure. See, for example CSP Technologies Inc. (Auburn, Ala.). Non-limiting examples of suitable biocides will be discussed below with reference to biosensor 210.

[0065] Cover 124 is releasably and recloseably coupled to third substrate 122. As shown in FIG. 10, fixed end 42 of cover 124 is affixed to third substrate 122 and adhesive 152 releasably secures middle portion 46 of cover 124 to third substrate 122. Adhesive 152 also creates an initial seal between cover 124 and third substrate 122 about sample site 166. Adhesive 152 is formed similarly to adhesive 52, except that adhesive 152 is applied about raised portion 156 and air vent 170.

[0066] Adhesive 152 is distributed over first surface 34 of second substrate 14 and/or the adjacent bottom side 28 of middle portion 46 spaced-apart from adhesive 50. The adhesive bond between middle portion 46 and third substrate 122 is broken once just prior to use. Thus, a seal is established between cover 124 and third substrate 122 around reagent 120 during storage of biosensor 10. As shown in FIG. 11, once seal is broken, a film 157 is generally left on third substrate 122 and/or cover 124 such that adhesive 152 will not reseal cover 124 and third substrate 122.

[0067] Biosensor 110 is manufactured in a manner similar to biosensor 10 except sink pads are situated in a roll. The roll of sink pads is punched, coated with an adhesive, and placed at the location of raised portion of cover 124 so that sink pad 160 will face third substrate 122.

[0068] In use, the user lifts pull tab 48 of cover 124 to separate middle portion 46 of cover 124 from second and third substrates 114, 122 and open sample port 168 to view. Liquid sample 133 is then deposited into sample port 168. Sample 133 travels and spreads through channel 140 across reagent 120 and tracks 16, 18. The reaction between the analyte and reagent 20 is the same as that described above. Once the concentration of the analyte is determined, the user presses adhesive 54 onto third substrate 122 so that cover 124 extends across sample port 168. Thus, recloseable cover 124 provides a protective covering for sample port 168 during storage before use and prior to disposal following completion of the assay to seal the liquid sample 133 in biosensor 110 to maintain a hygienic condition after use. Sink pad takes up or absorbs liquid sample 133 that remains in contact with cover 124 following use of biosensor 110.

[0069] A biosensor 210 is provided in accordance with another aspect of this invention and is illustrated in FIGS. 12–16. Biosensor 210 includes a second insulating substrate 214 situated on first substrate 12, a testing reagent 220, a third substrate 222 situated over the reagent 220 on a portion of the second substrate 214, and a cover 224 coupled to the first substrate 12 and formed to extend over at least a portion of the third substrate 222 and reagent 220. Biosensor 210 is produced from rolls of material and is manufactured in a manner similar to biosensors 10 and 110.

[0070] Referring now to FIGS. 12 and 13, second substrate 214 is formed to include a channel 240 that is sized to receive reagent 220 and defines a sample site 266. Reagent 220 is formed similarly to reagent 20 and may include an enzyme, mediator, buffer, and film formers. Reagent 220 and sample site 266 can take on a variety of shapes and sizes in accordance with this disclosure. Second substrate 214 is coupled to first substrate 12 and to third substrate 222 by an adhesive such as a hot melt glue. A non-limiting example of such glue is DYNAPOL S-1358 glue, available from Hüls America, Inc., 220 Davidson Street, P.O. Box 6821, Somerset, N.J. 08873. It is appreciated that first and second substrates 12, 214 may be coupled together using a wide variety of commercially available adhesives or with welding (heat or ultrasonic) in accordance with this disclosure.

[0071] Channel 240 is sized to promote capillary flow of a liquid sample across tracks 216, 218. Tracks 216, 218 are formed in a manner similar to tracks 16, 18 except that the tracks 216, 218 are interlacing. The length and width of channel 240 define the length and width of sample site 266 and the thickness of substrate 214 defines the height of the test chamber. As shown in FIG. 12, channel 240 has generally parallel side walls 246 extending from a sample port 244. It is appreciated that the sample port 244 can take on a variety of shapes and sizes in accordance with this disclosure. Sample site 266 is formed to have a length of about 3 to about 8 mm and a width of about 2 to about 5 mm. Preferably, sample site is formed to have a length of about 6 mm and a width of about 2.5 mm. The degree to which tracks 216, 218 are exposed determines the surface area of each electrode. The degree of exposure may vary as discussed above with reference to biosensors 10 and 110.

[0072] Third substrate 222 of biosensor 210 overlaps a portion of second substrate 214. As best shown in FIGS. 14 and 15, the third substrate 222 has a first surface 272 and a second surface 274 facing second substrate 214 as well first and second ends 275, 277 (FIG. 12). Third substrate 222 is also formed to include an air vent 270 positioned in alignment with channel 240. Third substrate 222 is constructed of a material identical to second substrate 214. It is appreciated that third substrate 222, may also be constructed of a variety of materials as discussed above with reference to substrates 12, 14.

[0073] As shown in FIG. 14, cover 224 is formed similarly to cover 24 except that the cover 224 is coupled to second surface 32 of substrate 12, is sized to extend about the first end 31 of the substrate 12, and includes a biocide 260 and a desiccant 262 patterned thereon. Cover 224 includes a body portion 225 and a tab 227 extending from the body portion 225. Referring to FIG. 12, the cover 224 has first and second opposite ends 229, 231. Further, as shown in FIG. 15, the cover 224 has a first side 233 facing the substrate 12 and an opposite second side 235. The adhesive 50 is positioned on the first side 233 adjacent to the first end 229, the adhesive 54 is positioned on the middle portion 245 of the first side 233 between biocide 260 and the second end 231, and the adhesive 152 is positioned on the first side 233 and extends about the periphery of the body portion 225.

[0074] As shown in FIG. 16d, when the cover 224 is in a closed position, the biocide 260 and desiccant 262 are in general alignment with channel 240 and afford biocidal and stabilization benefits to the biosensor 210. Specifically, biosensor 210 may be resealed to keep body fluids contained after use. Further, with biocide 260 and desiccant 262, the biosensor 210 may be removed from a bulk package format and transported from home to work in an inconspicuous and highly portable fashion, rendered safe soon after resealing.

[0075] Non-limiting examples of suitable biocides 260 include Saponified Phenols eg; “STAPHENE®”, commercially available from STERIS Corporation, Mentor, Ohio (surfactant properties), sodium dichloro-s-triazinetrione=“dichlor”, calcium hypochlorite, and perchloroethylene. Further, when the selected biocide 260 is a chlornated biocide, agents such as cyanuric acid may be present on the cover 224 with the biocide to protect the light sensitive compounds from rapid photodecay. It is appreciated that a wide variety of agents and pharmaceuticals affording biocidal benefits either broad spectrum or for targeted pathogens may be used in accordance with this disclosure.

[0076] Moreover, it is appreciated that the admixture of biocide 260 and desiccant 262 may include commercially available film formers such as water soluble polymers, latex polymers, etc., stabilizer, etc. and film openers such as TiO₂, mica, etc. Once biocide 260 and desiccant 262 are mixed it is appreciated that they can be screen printed, coated or dispensed onto the cover 224. Further, the admixture may be attached to the cover 224 by a custom made adhesive tape, co-extruded, or positioned adjacent to one another on the cover 224. Biocides are well know in the art and are commercially available from The Dow Chemical Company, Midland, Mich.; Great Lakes Chemical Corporation, West Lafayette, Ind.; and Bayer Corporation, Pittsburgh, Pa.

[0077] A non-limiting example of a printable admixture as shown in FIG. 14, comprises a buffer, film Former (water soluble polymers, latex polymers etc.), film Opener (TiO₂, mica, etc.), desiccant (see below), biocide (see above), wetting Agent (Surfactants, eg: DONS, ), and photo-decay Blockers (for chlorine containing agents). A further non-limiting example of a printable biocide composition as shown in FIG. 15, comprises a phosphate Buffer, STAPHENE® biocide, polyethylene oxide, and TiO2. To apply biocide admixture/compositions to the cover 224, aqueous or organic slurries commonly employed in the screen printing industry are pattern printed onto the cover stock material and dried to a prescribed level of water content.

[0078] Desiccant 262 may be permanently applied to biosensor 210. FIG. 14 illustrates that the desiccant 262 may be applied with the biocide 260 to the cover 224. Although, the biocide 260 and desiccant 262 illustratively positioned at the same loci, it is appreciated that they may be positioned in any number of positions and patterns in a spaced-apart relation to one another. It is also appreciated that desiccant 262 may be applied to the third substrate 222 in a manner shown in FIG. 15. Additionally, desiccating polymer films are commercially available to manufacture both the cover and substrates in accordance with this disclosure. See, for example CSP Technologies Inc. (Auburn, Ala.). A suitable desiccant removes moisture from reagent 220 when cover 224 is in a closed position, sealed against third substrate 222. Non-limiting examples of desiccants include clays, silica, alumina gel, silica gel, a molecular sieve type 3A or 4A, or calcium sulfate, and other agents commonly used by those skilled in the art in the diagnostics and food industries. Preferably, desiccant is DesiMax™ SLF Desiccant, which is commercially available from Multisorb Technologies, Inc., Buffalo, N.Y.

[0079] Cover 224 is releasably and recloseably coupled to third substrate 222. As shown in FIG. 15, a fixed end 243 of cover 224 is permanently affixed to second surface 32 of substrate 12 and adhesive 152 releasably secures middle portion 245 of cover 224 to third substrate 222. Further second end 231 may be free of adhesive to easy the user in lifting the cover 224 from the third substrate 222. Adhesive 152 also creates an initial seal between cover 224 and third substrate 222 about sample site 266. See, FIG. 16d. Adhesive 152 is formed similarly to adhesive 52 except that it extends about the perimeter of the body portion 225 of the cover 224.

[0080] Adhesive 152 is distributed over first side 233 of cover 224 and/or the adjacent first surface 272 of the third substrate 222. The adhesive bond between middle portion 245 and third substrate 222 is broken once just prior to use. Thus, a seal is established between cover 224 and third substrate 222 around reagent 220 during storage of biosensor 210. Once seal is broken, a film is generally left on third substrate 222 and/or cover 224 such that adhesive 152 will not reseal cover 224 and third substrate 222.

[0081] The use of biosensor 210 is shown in FIGS. 16a–16d. In use, the user lifts pull tab 227 of cover 224 to separate middle portion 245 of cover 224 from the third substrate 222 and open sample port 244 to view. See, FIG. 13. A liquid sample is then deposited into the sample port 244. The sample travels and spreads through channel 240 across reagent 220 and tracks 216, 218. The reaction between the analyte and reagent 220 is the same as that described above. Once the concentration of the analyte is determined, the user presses adhesive 54 onto third substrate 222 so that cover 224 extends across sample port 268. Thus, recloseable cover 224 provides a protective covering for sample port 268 during storage before use and prior to disposal following completion of the assay to seal the liquid sample in biosensor 210 to maintain a hygienic condition after use.

[0082] Although the invention has been described in detail with reference to a preferred embodiment, variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.