Electrochemical Biosensor Integrated Substrate Electrodes
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Solution Overview
Problem
Existing electrochemical biosensors face issues with high electrode impedance, signal attenuation, and increased production costs due to complex assembly procedures and material consumption.
Innovation Solution
The design includes a substrate with spaced-apart through holes, layered active metal parts, and electrodes formed within these holes, along with an electrochemical reactive layer and a cover piece, which simplifies assembly and reduces material usage by forming electrically conductive vias for improved signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic conductive layer is formed by screen printing, then the biosensor can be manufactured, but the electrode impedance becomes high causing signal attenuation
Solution Approach 1:
The patent combines the substrate and electrodes into a single integrated structure where the substrate itself forms the electrode body. The conductive material is incorporated directly into the substrate during manufacturing, eliminating the need for separate screen printing of metallic conductive layers. This integration reduces impedance and improves signal transmission while maintaining manufacturing simplicity.
Solution Approach 2:
The patent employs composite material structures where the substrate is composed of multiple layers including conductive and insulating materials. This composite approach allows the substrate to function both as the structural base and as the electrode, achieving low impedance without requiring additional metallic conductive layers formed by screen printing.
2Ease of operation
If separate electrodes and substrate are made, then the biosensor can be assembled, but the assembling procedure becomes complicated
Solution Approach 1:
The patent merges the substrate and electrodes into a single integrated component. The substrate is designed to incorporate electrode structures directly, eliminating the need for separate electrode components and complex assembly procedures. This integration reduces the number of parts and simplifies the manufacturing process while maintaining functional performance.
3Ease of manufacture
If traditional biosensor structure is used, then the biosensor can be manufactured, but relatively large amount of metallic raw material is consumed increasing production cost
Solution Approach 1:
The patent extracts the function of metallic conductive layers from the electrode structure and replaces it with alternative materials or designs that use minimal or no expensive metals. The substrate is designed to provide conductivity through non-metallic or reduced-metal approaches, eliminating the need for large amounts of metallic raw materials while maintaining electrical functionality.
Solution Approach 2:
The patent employs cost-effective materials for the substrate and electrode structures, replacing expensive metallic components with more economical alternatives. This approach reduces production costs and material consumption while achieving the required performance for the biosensor application.
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 configuration reduces signal attenuation, lowers production costs, and simplifies the manufacturing process while ensuring stable electrode bonding and efficient signal transmission.
Implementation Method 1
Each of the layered electrodes is formed on a respective one of the layered active metal parts... Each of the electrically-conductive vias has a top part that is proximal to the top surface of the substrate and that is electrically coupled to the electrochemical reactive layer
Data Source
AI summary
An electrochemical biosensor includes a substrate, a plurality of layered active metal parts, a plurality of layered electrodes, a reaction confinement layer, an electrochemical reactive layer and a cover piece. The substrate is formed with through holes each of which is defined by an interior wall surface and penetrates top and bottom surfaces. Each of the layered active metal parts is formed at least upon a respective one of the interior wall surfaces. The layered electrodes are formed on the layered active metal parts. The reaction confinement layer confines a reactor space over a region where the through holes are formed. The electrochemical reactive layer is disposed in the reactor space and is electrically coupled to the layered electrodes.