Biosensor Engraved Lines for Cutting Deviation Detection
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Solution Overview
Problem
Existing electrochemical biosensors face batch-to-batch variations due to unstable assembly processes, leading to deviations in electrode areas and inaccurate test results, which are compounded by the complexity of calibration processes.
Innovation Solution
Incorporating an engraved line for identifying cutting deviation on the biosensor's conductive layer to detect and correct deviations during the assembly process, ensuring precise electrode sizing and uniform performance across batches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If screen printing method is used to manufacture electrochemical sensors, then manufacturing efficiency is improved, but batch-to-batch variations occur leading to inaccurate test results
Solution Approach 1:
The patent replaces the mechanical screen printing process with a laser-based writing system. The laser writing device precisely deposits conductive material to form electrodes according to digital patterns, eliminating the mechanical variability inherent in screen printing while maintaining high manufacturing efficiency. This substitution of mechanical processes with optical/energetic processes resolves the contradiction between productivity and manufacturing precision.
2Measurement precision
If calibration chip is inserted to correct batch-to-batch variations, then test result accuracy is improved, but operation complexity increases
Solution Approach 1:
The patent performs preliminary action by precisely controlling the electrode fabrication process through laser writing to eliminate batch-to-batch variations before testing occurs. The electrode areas are consistently manufactured to specification from the outset, removing the need for subsequent calibration operations. This preliminary precision manufacturing approach resolves the contradiction by achieving measurement precision without adding operational complexity.
3Manufacturing precision
If laser ablation method is used to form thin film electrodes, then manufacturing precision is improved, but assembly process stability becomes critical
Solution Approach 1:
The patent replaces mechanical assembly processes with laser-based direct writing technology. The laser writing system directly forms electrodes on the substrate without requiring separate assembly steps, eliminating the instability associated with mechanical assembly processes. This integration of manufacturing and electrode formation resolves the contradiction by maintaining high precision while improving assembly reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The engraved line allows for easy identification of assembly errors, ensuring accurate and stable test results by maintaining consistent electrode sizes, thereby improving the quality and efficiency of biosensor production.
Implementation Method 1
the conductive layer is divided by engraved lines to form electrodes
Data Source
AI summary
The present invention provides a biosensor and a preparation method thereof. The biosensor includes an insulating substrate and a conductive layer disposed on the insulating substrate, the conductive layer is divided by engraved lines to form electrodes, and an engraved line for identifying cutting deviation is disposed at least at a sample contacting end of the biosensor. According to the present invention, by providing the engraved line for identifying cutting deviation on the conductive layer, the cutting deviation during the cutting assembly process of the sensor can be found in time, ensuring the testing accuracy and stability of the prepared biosensor.