Electrode Sensing Structures With Fluid Barriers for Uniform Analyte Detection

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Solution Overview

Problem

Existing analyte sensors face challenges in manufacturing with high accuracy and reduced sensor-to-sensor variation, particularly for in vivo use.

Innovation Solution

Electrochemical analyte sensors with sensing structures delimited by fluid barrier perimeters control the spread of analyte sensing solution during manufacturing, ensuring uniform diameters and minimizing variation, leading to factory-only calibration without user calibration needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional manufacturing methods are used for analyte sensors, then production can proceed with standard processes, but sensor-to-sensor variation increases and manufacturing precision decreases

Engineering Contradiction:

Improvesensing structure uniformityVSAvoidfluid barrier perimeter structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The electrode is divided into multiple discrete sensing structures, each surrounded by its own fluid barrier perimeter. This segmentation isolates the analyte sensing solution within each structure, preventing spread to adjacent areas and ensuring uniform diameters across all sensing structures, thereby improving manufacturing precision and reducing sensor-to-sensor variation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A fluid barrier perimeter acts as an intermediary element between adjacent sensing structures. This barrier prevents the analyte sensing solution from spreading beyond the intended sensing structure boundaries during manufacturing, enabling precise control over sensing structure dimensions and ensuring uniformity across multiple sensors.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If fluid barrier perimeters are added to sensing structures, then manufacturing precision and uniformity improve, but device complexity and fabrication difficulty increase

Engineering Contradiction:

Improvesensing structure diameter uniformityVSAvoidelectrode fabrication process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The fluid barrier perimeter is integrated directly into the electrode substrate structure, merging the barrier function with the existing electrode fabrication process. This integration allows the fluid barrier to be formed using standard electrode manufacturing techniques, reducing the need for separate fabrication steps and minimizing the increase in manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If sensing structures are not delimited, then manufacturing process is simpler, but analyte sensing solution spreads causing variation in sensing structure diameter

Engineering Contradiction:

Improveelectrode fabrication simplicityVSAvoidanalyte detection accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The fluid barrier perimeter is pre-formed on the electrode substrate before the analyte sensing solution is applied. This preliminary action establishes defined boundaries that confine the solution during the manufacturing process, preventing spread and ensuring uniform sensing structure diameters are achieved consistently across all sensors.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12436127B2Electrodes having at least one sensing structure and methods for making and using the same

Publication Date: 2025.10.07 ABBOTT DIABETES CARE INC

AI summary

An analyte sensor comprising: a non-conductive material; a conductive material disposed on the non-conductive material; and at least two sensing structures defined by a removed portion of the conductive material, the at least two sensing structures comprising a reagent composition.