Electrochemical Sensor Dual-Side Electrodes Minimize Insertion Pain
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Solution Overview
Problem
The challenge is to design an electrochemical sensor that minimizes size while maintaining a sufficient electrode area to avoid signal disturbance and discomfort during insertion into the body, balancing size reduction with electrode area requirements.
Innovation Solution
The electrochemical sensor features via-holes extending through a flexible base layer to electrically connect sensor pads on the proximal portion with electrodes on both surfaces of the distal portion, optimizing electrode placement and reducing the width of the invasive distal portion to minimize pain and foreign body feeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the size of the electrochemical sensor is reduced, then the pain caused by invasion and foreign body feeling are reduced, but the area of the electrode provided on the distal portion becomes insufficient
Solution Approach 1:
The patent transitions from a single-sided electrode configuration to a dual-sided electrode configuration on the distal portion. By placing electrodes on both the top and bottom surfaces of the distal portion, the total electrode area is effectively doubled without increasing the sensor's width or length, thus resolving the contradiction between small size and sufficient electrode area.
Solution Approach 2:
The sensor is segmented into distinct functional regions: the distal portion with electrodes on both surfaces for analyte detection, the intermediate portion for electrical connection, and the proximal portion for signal processing. This segmentation allows optimal allocation of electrode area in the distal portion while maintaining overall compact dimensions.
2Reliability
If the area of the electrode is increased, then signal disturbance by noise is avoided, but the size of the electrochemical sensor increases
Solution Approach 1:
The patent utilizes the third dimension (z-axis) by configuring electrodes on both the top and bottom surfaces of the distal portion. This vertical stacking approach increases the effective electrode area for reliable signal detection while maintaining a compact footprint in the x-y plane, thus avoiding signal disturbance without increasing overall sensor size.
Solution Approach 2:
The sensor employs a flexible base layer that allows thin-film electrode structures to be deposited on both surfaces of the distal portion. This flexible substrate enables the integration of sufficient electrode area within a thin, compact profile, ensuring signal stability without bulk increase.
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 design enhances electrical reliability, reduces defective rates, and increases sensitivity by providing a wide electrode area, improving reactivity with in vivo analytes while minimizing the sensor's size and discomfort during insertion.
Implementation Method 1
a distal portion on which a plurality of electrodes configured to react with an in vivo analyte are provided
Data Source
AI summary
An electrochemical sensor includes a distal portion on which a plurality of electrodes configured to react with an in vivo analyte are provided, a proximal portion on which sensor pads connected to the electrodes are provided, and an intermediate portion positioned between the distal portion and the proximal portion. A transmitter includes a main substrate on which at least one of a power source, a communication unit, and a controller is provided and a housing in which the main substrate is accommodated. The transmitter is configured to be attached to the skin. A method of fabricating an electrochemical sensor includes applying a conductive layer on a flexible base layer of the electrochemical sensor and attaching insulating layers to the conductive layer.