Biosensor Engraved-Line Layout for Cutting Quality Control
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Solution Overview
Problem
Existing electrochemical biosensors face batch-to-batch variations and production inefficiencies due to cutting deviations during the manufacturing process, leading to damaged electrodes and inaccurate test results, which are compounded by the need for complex calibration processes.
Innovation Solution
Incorporation of engraved lines on the biosensor design to identify cutting deviations, ensuring electrodes are not damaged and enabling efficient screening of defective products, with a design that includes π-shaped engraved lines for uninterrupted laser etching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slits are extended to the end edges at both sample contacting end and contact contacting end to ensure electrode protection during cutting, then manufacturing precision is improved, but production time is greatly increased due to longer laser travel line
Solution Approach 1:
The patent extracts the quality control function from the electrode protection structure by introducing a separate mark line that does not extend to the edges. This mark line serves purely as a visual indicator for cutting position, while the actual electrode protection is achieved by controlling the cutting process to stop before reaching the electrode edges, thus reducing unnecessary laser travel time.
Solution Approach 2:
The patent introduces a mark line as an intermediary element between the cutting process and the electrode. This mark line acts as a visual mediator that guides the cutting position without being part of the electrode structure itself, allowing operators to identify the correct cutting position without the mark line interfering with or extending into the electrode area.
2Measurement precision
If calibration chip is inserted to correct batch-to-batch variations, then test result accuracy is improved, but operation complexity is increased
Solution Approach 1:
The patent applies self-service by designing the sensor to automatically compensate for batch-to-batch variations through built-in reference electrodes and temperature compensation circuits. The sensor performs self-calibration using internal reference elements, eliminating the need for external calibration chips and manual correction operations.
Solution Approach 2:
The patent integrates multiple functions into the sensor structure, including reference electrodes that serve both as electrical references and as visual alignment marks. The insulating substrate patterns serve dual purposes as both structural elements and cutting guides, reducing the need for separate calibration components.
3Ease of manufacture
If screen printing method is used to form electrodes, then manufacturing ease is improved, but batch-to-batch variations are increased
Solution Approach 1:
The patent merges the electrode formation process with the insulating substrate fabrication by using the substrate patterns themselves as electrode guides and alignment marks. The conductive layers are deposited and patterned in direct registration with the insulating substrate features, ensuring consistent positioning across batches without requiring separate calibration procedures.
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 lines allow for easy identification and removal of defective products, ensuring product quality and improving production efficiency by reducing laser etching time and enhancing the overall manufacturing capacity.
Implementation Method 1
a thin film-like conductor layer is uniformly spread on an insulating substrate in advance, and then the electrode is formed by a laser ablation method
Data Source
AI summary
The present invention provides a biosensor and method. The biosensor includes an insulating substrate, a conductive layer disposed on the insulating substrate, a sample injection port, and a fluid channel for entrance of a test sample. Engraved lines and electrodes divided by the engraved lines are distributed on the conductive layer. A reagent layer is disposed on part or all of the electrodes located in the region of the fluid channel, a transverse engraved line is disposed on the other side opposite to the sample injection port, and at least one end of the transverse engraved line extends towards, but does not intersect with a longitudinal side edge of the biosensor. Through the arrangement of the engraved line at the contact end of the biosensor described in the present invention, the quality inspection process of the production process can be effectively simplified, and the pass rate of the biosensor can be improved.