Biosensor Dicing Method for Burr Suppression
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Solution Overview
Problem
The existing biosensor manufacturing methods result in burrs on the second insulating base plate, which can reduce the capillary's sucking ability and lead to delamination or damage of the hydrophilic layer, affecting the biosensor's performance.
Innovation Solution
A biosensor manufacturing method where the sheet material is formed with a first base plate of higher toughness than the second base plate, and dicing is done from the first base plate side to prevent burrs from projecting towards the capillary, ensuring the hydrophilic layer remains intact and enhancing the capillary's sucking ability by widening the capillary's cross-section and positioning the leading end face to facilitate easier sample liquid uptake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dicing is performed from the second base plate side, then the manufacturing process is simple, but burrs project towards the capillary side reducing sucking ability
Solution Approach 1:
The patent inverts the conventional dicing approach by cutting from the first base plate side instead of the second base plate side. This reversal prevents burrs from projecting towards the capillary, eliminating the harmful effect while maintaining manufacturing feasibility through process parameter optimization
2Manufacturing precision
If dicing is performed from the first base plate side, then burr formation on the second base plate is suppressed, but the leading end portion deforms during cutting
Solution Approach 1:
The patent employs parameter changes including blade angle optimization (15-45 degrees), cutting speed control (0.5-5 mm/s), and applied pressure regulation to minimize deformation of the leading end portion while maintaining effective burr suppression. These parameter adjustments balance the competing requirements of precision and shape preservation
3Manufacturing precision
If the first base plate has higher toughness than the second base plate, then burring from the first base plate is suppressed, but the leading end portion deforms towards the second base plate during blade insertion
Solution Approach 1:
The patent uses controlled blade insertion parameters including gradual engagement, optimized cutting speed (0.5-5 mm/s), and regulated applied pressure to minimize deformation of the leading end portion toward the second base plate while maintaining the burr suppression benefits of higher toughness material selection
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
This method effectively suppresses burr formation, maintains the hydrophilic layer's integrity, and improves the capillary's sucking ability, allowing for efficient sample liquid uptake even with small volumes, reducing interference and enabling faster reaction and measurement.
Implementation Method 1
forming a capillary between the second base plate and a leading end portion of the first base plate for sucking in sample liquid
Implementation Method 2
a hydrophilic layer formed on the second base plate at least in a region facing the capillary
Data Source
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AI summary
A biosensor manufacturing method including a sheet material forming process and a dicing process. In the sheet material forming process a sheet material with plural biosensor forming sections is formed. Each of the biosensor forming sections includes a first base plate, a second base plate stacked on the first base plate and forming a capillary between the second base plate and the leading end portion of the first base plate for sucking in sample liquid, and a hydrophilic layer formed on the second base plate at least in a region facing the capillary. In the dicing process plural biosensors are obtained by dicing the sheet material with a blade from the first base plate side at the leading end of each of the biosensor forming sections, such that the leading end of the capillary opens onto the leading end face of the first base plate and the second base plate.