Biosensor Test Strip Metal Layer Sintering
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Solution Overview
Problem
Current biosensor test strip manufacturing methods, such as sputtering and laser ablation, are inefficient due to metal wastage and high energy usage, while additive methods like inkjet printing lack detailed features and benefits.
Innovation Solution
A method involving the application of a first layer of copper and a second layer of gold on a substrate, with high-energy broad spectrum light pulses for sintering, and differential curing of reference traces for machine-readable calibration, reducing metal waste and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sputtering and laser ablation are used to produce metal tracks, then manufacturing precision is improved, but loss of substance and use of energy worsen
Solution Approach 1:
The patent changes the physical state and application method of metal materials from vapor deposition (sputtering) and subtractive processing (laser ablation) to liquid inkjet printing and thermal sintering. This parameter change enables precise material placement without waste, as metal particles are deposited only where needed in the circuit pattern
Solution Approach 2:
The patent replaces the mechanical sputtering process and laser ablation system with an inkjet printing system that uses digital control to deposit metal particles. This substitution eliminates the need for bulk metal deposition and subsequent removal, achieving both precision and material efficiency
2Manufacturing precision
If sputtering and laser ablation are used to produce metal tracks, then manufacturing precision is improved, but use of energy worsens
Solution Approach 1:
The patent changes the energy application method from continuous high-power laser ablation to pulsed low-power thermal sintering. The inkjet-printed metal particles are sintered using brief thermal pulses that fuse particles together with minimal energy input, compared to the sustained high energy required for laser ablation
Solution Approach 2:
The patent employs periodic pulsed action for both inkjet deposition and thermal sintering. The inkjet system deposits metal particles in controlled pulses, and the sintering process uses intermittent thermal pulses to fuse particles. This periodic action reduces overall energy consumption compared to continuous laser processing
3Loss of substance
If inkjet printing is used to apply metal layers, then loss of substance is reduced, but manufacturing precision worsens
Solution Approach 1:
The patent replaces conventional inkjet printing with a specialized inkjet system capable of depositing metal particles with high precision. The substitution includes using piezoelectric or thermal inkjet technology that can place metal particles in exact positions with controlled droplet sizes, achieving both material efficiency and pattern accuracy
Solution Approach 2:
The patent applies local quality control by varying inkjet deposition parameters (droplet size, frequency, spacing) according to the specific requirements of different circuit regions. This enables precise metal particle placement in critical areas while optimizing material usage across the entire substrate
4Manufacturing precision
If high-energy light pulses are used for sintering metal layers, then manufacturing precision is improved, but use of energy worsens
Solution Approach 1:
The patent optimizes the sintering process by changing parameters such as pulse duration, intensity, and wavelength to match the absorption characteristics of metal particles. This enables effective sintering with minimal energy input, as the light parameters are tuned to maximize heating efficiency of the metal particles while minimizing substrate heating
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 approach enhances the accuracy and efficiency of biosensor test strip production by minimizing metal loss and energy usage while enabling machine-readable calibration and lot coding.
Implementation Method 1
sintering said first metal and said second metal at least partially together by exposing them to one or more pulses of a high-energy broad spectrum light
Implementation Method 2
exposing them to one or more pulses of a high-energy broad spectrum light that maintains the temperature of said substrate below a substrate damage temperature
Data Source
Figure 1A-1
Figure 1A-2
Figure 1B
AI summary
A biological test member, and method of making the same, is disclosed with the member including a substrate. The test member has usefulness, for example, in testing a person's blood glucose level. A first layer and a second layer of conductive metal are printed or otherwise applied on the substrate in an electrode pattern. The metal or metals are cured or sintered at a low, non-damaging temperature, such as by applying one or more pulses of a high-energy broad spectrum light. A layer of reagent may be provided on said second metal layer.