Electrochemical Sensor Array with Porous Layer for Alignment-Free Detection
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Solution Overview
Problem
The production of electrochemical sensors for detecting chemical or biochemical substances in liquids is complicated and expensive due to the need for precise alignment of molecules with small electrode structures, making it difficult to coat sensors effectively, especially at the nanometer scale.
Innovation Solution
A device with a sensor array on a first carrier and a porous layer on a second carrier, where catcher molecules are immobilized in functional regions, allowing for direct or indirect linking without precise alignment, enabling electrochemical detection of substances through a liquid medium, similar to an optical camera's pixel array, with sensors assigned to specific regions for spatially resolved measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography is used to coat molecules onto nanometer-scale electrodes, then coating precision is improved, but device complexity and production cost increase due to expensive equipment and complicated alignment requirements
Solution Approach 1:
The device is divided into two separate carriers: a first carrier holding the sensor array and a second carrier holding the porous layer with catcher molecules. This segmentation allows each carrier to be produced and prepared independently, eliminating the need for precise alignment between them during operation. The functional regions on the second carrier are designed to be larger than the sensor structures, creating a tolerance zone that accommodates misalignment.
Solution Approach 2:
The porous layer is divided into functional regions with catcher molecules and non-functionalized regions without catcher molecules. Each region has distinct properties: functional regions for specific substance capture and non-functionalized regions for reference measurements. This local differentiation enables simplified coating processes while maintaining detection accuracy through comparative measurement between regions.
2Length of moving object
If sensor structure size is reduced to nanometer range, then sensor miniaturization is achieved, but coating difficulty increases due to inability to use spotting methods and requirement for expensive photolithography
Solution Approach 1:
The invention transitions from a two-dimensional planar coating problem to a three-dimensional solution by using a porous layer with vertical depth. The functional regions extend through the porous matrix, providing a larger effective target area for molecule attachment. This dimensional approach allows less precise coating methods to still achieve sufficient molecule-sensor interaction.
Solution Approach 2:
A porous layer is introduced as the medium containing catcher molecules. The porous structure provides large surface area within a compact volume, enabling effective molecule immobilization without requiring precise alignment with nanometer-scale sensors. The porous matrix allows liquid transport and molecular diffusion while maintaining structural integrity and functional regions.
3Manufacturing precision
If precise alignment is required during coating, then coating accuracy is improved, but production time and susceptibility to faults increase
Solution Approach 1:
The functional regions are pre-formed on the second carrier with catcher molecules immobilized in advance, before assembly with the sensor array. This preliminary preparation allows the coating process to occur independently of the sensor structures, eliminating the need for real-time alignment during assembly and significantly improving production efficiency.
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 simplifies the production and use of electrochemical sensors, providing high signal-to-noise ratios and precise spatial resolution of chemical or biochemical reactions without the need for complex alignment, allowing for efficient detection of substances with a simple and cost-effective construction.
Implementation Method 1
specific binding of catcher molecules (8) for substances (9) to be detected to the substances (9)
Implementation Method 2
The liquid is in contact with the surface of the first carrier and the porous layer directly or indirectly
Implementation Method 3
transport of the liquid, in particular by capillary forces
Implementation Method 4
electrochemical detection of substances to be detected (9) bound by the catcher molecules (8)
Data Source
AI summary
A device for detecting chemical or biochemical substances in fluids for use in an electrochemical camera. The device includes a first carrier having a sensor array with a plurality of electrochemical sensors. A second carrier includes a porous layer having at least one functional region, in which specifically binding capturing molecules are immobilized. The at least one functional region is arranged directly adjacent to at least one non-functionalized region. Assigned to the at least one functional region and the at least one non-functionalized region are several sensors of the sensor array, for use as the electrochemical camera.