Biosensor Auxiliary Electrode Region for Batch-Stable Testing
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Solution Overview
Problem
Existing electrochemical sensors suffer from batch-to-batch variations due to deviations in the position of the interlayer or reagent layer, leading to inconsistent electrode areas and inaccurate test results.
Innovation Solution
Incorporating an auxiliary region on the conductive layer, enclosed by engraved lines, to ensure consistent effective electrode areas by maintaining the position of the reagent layer relative to the electrodes, thereby stabilizing sensor performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen printing technology is used to form electrodes on insulating substrate, then manufacturing process is simple and easy to implement, but batch-to-batch variations occur leading to inconsistent electrode areas and inaccurate test results
Solution Approach 1:
The patent applies preliminary action by pre-defining the electrode area boundary through engraved lines on the conductive layer before the actual electrode formation process. This boundary is established in advance using laser etching to create precise geometric constraints that will limit and standardize the electrode area across all batches, preventing variations that would otherwise occur during screen printing.
Solution Approach 2:
The patent changes the parameter of electrode area control from process-dependent (screen printing alignment) to geometry-dependent (engraved line boundary). By transforming the control mechanism from relying on process precision to relying on pre-defined geometric parameters, the electrode area consistency is improved while maintaining the simplicity of screen printing for electrode material deposition.
2Manufacturing precision
If laser etching method is used to form thin film electrodes, then manufacturing precision is high and batch-to-batch variations are eliminated, but the electrode area may change due to position deviations of interlayer or reagent layer
Solution Approach 1:
The patent applies local quality by creating a specific functional region (auxiliary region) with distinct geometric boundaries defined by engraved lines. This auxiliary region is locally differentiated from other areas and serves the specific function of accommodating position deviations of the interlayer or reagent layer, thereby protecting the main electrode area from variation while maintaining overall sensor reliability.
Solution Approach 2:
The patent implements beforehand cushioning by designing the auxiliary region in advance to compensate for potential position deviations. This auxiliary region acts as a buffer zone that absorbs the impact of alignment variations between layers, preventing these deviations from affecting the effective electrode area and thus ensuring test result stability before problems occur.
3Measurement precision
If calibration chip is inserted to correct batch-to-batch variations, then test result accuracy is improved, but operation steps increase and operator errors may occur
Solution Approach 1:
The patent applies self-service by designing the sensor to automatically ensure consistent electrode areas through pre-defined engraved line boundaries. The sensor structure itself provides the correction mechanism rather than requiring external calibration chips or operator intervention. The geometric constraints built into the electrode design enable the system to self-regulate and eliminate batch-to-batch variations without additional operational steps.
Solution Approach 2:
The patent extracts the calibration function from the operational phase and integrates it into the manufacturing phase. Instead of requiring calibration chips to be inserted during testing, the calibration parameters (electrode area boundaries) are extracted and fixed during sensor fabrication through laser etching of engraved lines, thereby eliminating the need for post-manufacturing calibration operations.
Data Source
AI summary
The present invention provides a biosensor and a method for preparing the biosensor. The biosensor includes an insulating substrate, a sample injection port, a sample injection channel for entrance of a test sample, and a conductive layer disposed on the insulating substrate, engraved lines and electrodes formed through division by the engraved lines being distributed on the conductive layer, a reagent layer being disposed on part or all of the electrodes located in the region of the sample injection channel, and an auxiliary region being also disposed on the conductive layer under the other end of the sample injection channel opposite to the sample injection port. According to the present invention, by providing the auxiliary region on the conductive layer, the testing accuracy and stability of the biosensor are effectively ensured.