Electrochemical Biosensor Electrode Layout for Short-Circuit Prevention
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Solution Overview
Problem
Existing electrochemical biosensors face issues of batch-to-batch variations and short circuits due to mechanical shear during cutting, leading to inaccurate test results and scrapped products.
Innovation Solution
A biosensor design with a short-circuit-proof region formed by engraved lines and edge lines on the conductive layer, preventing electrical conduction between electrodes and non-electrode conductive block domains, achieved through laser etching and customized engraved line patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen printing method is used to form electrodes, then manufacturing process is simple, but batch-to-batch variations occur affecting test result accuracy
Solution Approach 1:
The patent replaces the mechanical screen printing process with a chemical etching process using ferric chloride solution. This substitution eliminates the mechanical variability inherent in screen printing while maintaining ease of manufacture, achieving both simple processing and high batch-to-batch consistency.
2Manufacturing precision
If laser etching method is used to form electrodes, then manufacturing precision is high with no batch-to-batch variations, but the conductive layer may generate particles during cutting causing short circuits
Solution Approach 1:
The patent extracts and removes the conductive layer material along the cutting trajectory using ferric chloride etching. This creates a groove that completely eliminates conductive particles that would otherwise remain after cutting, preventing short circuits while maintaining the precision benefits of laser etching.
Solution Approach 2:
The patent converts the potentially harmful conductive particles generated during cutting into a beneficial groove structure. By etching away the material along the cutting path, the would-be污染源 becomes a clean separation groove that actively prevents short circuits.
3Productivity
If cutter is used to cut semi-finished film sensors, then production efficiency is high, but mechanical shear force causes conductive particles to remain in engraved lines causing short circuits
Solution Approach 1:
The patent performs preliminary etching of the cutting trajectory before the actual cutting process. By pre-removing the conductive material along the intended cut path, the subsequent cutting operation generates no conductive particles, eliminating short circuit risks while maintaining high productivity.
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 design effectively avoids short circuits and improves the accuracy and yield of finished biosensors by ensuring electrodes remain disconnected, even with residual conductive particles, enhancing product reliability.
Implementation Method 1
utilizing a ferric chloride solution to etch a groove along a cutting trajectory on a conductive layer
Implementation Method 2
engraved lines being distributed on the conductive layer, and electrodes being formed on the conductive layer and divided by the engraved lines
Data Source
AI summary
The present invention also provides a biosensor and a preparation method thereof. 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 divided 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 a short-circuit-proof region being disposed at the edge of the biosensor. The present invention can effectively overcome the risk of a short circuit between electrodes of the biosensor.