Biosensor Electrodes via Physical Vapor Deposition

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Solution Overview

Problem

Current biosensors using non-noble metal electrodes face challenges with inconsistent and inaccurate measurements due to electrochemical response deviations and inadequate electron transfer kinetics, leading to high background currents and poor mechanical robustness.

Innovation Solution

A biosensor electrode comprising a substrate with a conductive layer of nickel and chromium, optionally including iron, and a resistive material layer of amorphous carbon, which enhances anodic stability and electron transfer kinetics, reducing manufacturing costs while maintaining accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If non-noble metal electrodes are used to reduce manufacturing costs, then cost is reduced, but measurement accuracy and electrochemical response consistency deteriorate

Engineering Contradiction:

Improvemanufacturing costVSAvoidmeasurement accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent uses composite material structures combining non-noble metal alloys (such as nickel-chromium-iron) with noble metal particles or coatings. This composite approach allows the electrode to maintain the cost advantages of non-noble metals while incorporating the superior electrochemical properties of noble metals, thereby improving measurement accuracy without significantly increasing manufacturing cost.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the compositional parameters of the electrode material by controlling the ratios of different metals in the alloy (e.g., nickel:chromium:iron ratios) and adjusting the thickness and distribution of noble metal coatings. By optimizing these parameters, the electrode achieves a balance between cost reduction and maintained measurement accuracy.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If non-noble metal electrodes are used, then manufacturing cost is reduced, but electron transfer kinetics and anodic stability deteriorate

Engineering Contradiction:

Improvemanufacturing costVSAvoidelectron transfer kinetics

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces noble metal particles or coatings as intermediary elements on the non-noble metal electrode surface. These noble metal components act as mediators that facilitate electron transfer reactions, improving the electrode's electrochemical performance and anodic stability while the bulk non-noble metal structure maintains cost effectiveness.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If non-noble metal electrodes are used, then manufacturing cost is reduced, but mechanical robustness and structural integrity deteriorate

Engineering Contradiction:

Improvemanufacturing costVSAvoidmechanical robustness

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent employs composite material structures where non-noble metal alloys are combined with noble metal particles or coatings. This composite structure provides both the cost benefits of non-noble metals and the mechanical robustness and structural integrity associated with noble metals, as the noble metal components reinforce the overall electrode structure.

Inventive Principle:

Principle #40Composite materials

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 proposed electrode configuration provides consistent and accurate biological sample measurements, improving electron transfer kinetics and mechanical robustness, thus overcoming the limitations of non-noble metal electrodes in biosensors.

Implementation Method 1

physical vapor depositing at least a portion of the substrate with material from the conductive layer target to thereby form a conductive layer on the substrate

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Implementation Method 2

physical vapor depositing at least a portion of the conductive layer with material from the resistive material target to thereby form a resistive material layer on the conductive layer

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS11630075B2Biosensor electrodes prepared by physical vapor deposition

Publication Date: 2023.04.18 EASTMAN CHEM CO

AI summary

A biosensor component is provided that provides enhanced characteristics for use in biosensors, such as blood glucose sensors. The biosensor component comprises a substrate, a conductive layer deposited on the substrate, and a resistive material layer deposited on the conductive layer. The conductive layer includes nickel, chromium, and iron, such that a combined weight percent of the nickel and chromium in the conductive layer is in the range of 25 to less than 95 weight percent, the weight percent of nickel in the conductive layer is at least 4 weight percent, the weight percent of chromium in the conductive layer is at least 10 weight percent, the weight percent of iron in the conductive layer at least 2 weight percent, and such that the conductive layer comprises 0 to 20 weight percent molybdenum.