Flexible Circuit Card Sensor for Analyte Concentration
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Solution Overview
Problem
Existing sensors for measuring analyte concentrations in industrial and laboratory settings are complex and costly to manufacture due to the need for multiple working steps and effective sealing of the sensor housing to prevent moisture penetration, especially around the sensor electronics and reference electrode.
Innovation Solution
A sensor design featuring a flexible circuit card that integrates both the sensor element and reference electrode connections, eliminating the need for internal tubes and separate compartments, thus simplifying manufacturing and enhancing sealing through a clamp seal mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sensor housing with separate internal tubes and compartments is used, then reliable electrical contacting and reference electrode positioning is achieved, but manufacturing complexity and cost increase due to multiple working steps and sealing requirements
Solution Approach 1:
The patent combines the functions of electrical contacting and reference electrode positioning into a single integrated circuit board structure. The circuit board serves both as the electrical connection pathway and as the structural element that positions the reference electrode, eliminating the need for separate internal tubes and multiple sealing interfaces. This merging reduces manufacturing complexity while maintaining reliability through fewer potential failure points.
Solution Approach 2:
The circuit board is designed to perform multiple functions simultaneously: it provides electrical contacting for the sensor element, positions the reference electrode, and serves as a structural support within the housing. This multi-functionality eliminates the need for separate dedicated components for each function, thereby reducing the overall device complexity and the number of sealing requirements while maintaining all necessary functions.
2Manufacturing precision
If traditional separate internal tubes and compartments are used, then reliable reference electrode positioning is achieved, but manufacturing costs and complexity increase
Solution Approach 1:
The circuit board integrates the reference electrode positioning function with the electrical contacting function. The reference electrode is positioned relative to the circuit board, which itself is positioned relative to the sensor element, creating a simplified hierarchical positioning system. This reduces the number of independent positioning mechanisms required while maintaining manufacturing precision through the rigid structural relationships between components.
Solution Approach 2:
The patent segments the positioning function into hierarchical levels: the circuit board provides a stable reference plane for electrode positioning, while the housing provides the outer structural framework. This segmentation allows each component to focus on specific positioning tasks, simplifying manufacturing while maintaining overall positioning precision through the cumulative effect of well-defined interfaces between segments.
3Object-affected harmful factors
If more sealing interfaces are implemented, then moisture penetration prevention is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The circuit board serves as both an electrical connection medium and a sealing interface. By integrating these functions, the patent reduces the number of separate sealing components required while maintaining effective moisture barrier properties. The circuit board's rigid structure and direct integration with the housing create reliable sealing without requiring additional sealing layers or complex sealing mechanisms.
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 reduces manufacturing complexity and costs while ensuring improved sealing, allowing for more versatile sensor configurations and increased space within the housing for longer flexible circuit cards, enhancing the reliability and efficiency of analyte concentration measurements.
Implementation Method 1
a flexible circuit card (12), which includes at least a first conductive trace (12a), which is connected with the at least one contact element of the sensor element, and at least a second conductive trace (12b), which serves as potential sensing element of the reference electrode
Implementation Method 2
enhancing the sealing through a clamp seal mechanism
Data Source
AI summary
A sensor for registering analyte concentration includes: a housing; arranged within the housing, a sensor element, which has a front surface pressed toward a housing wall of the housing, and the sensor element has at least one contact element for electrical contacting accommodated within the housing, an inner electrolyte, which is in contact with a medium surrounding the housing via an electrochemical, liquid junction arranged in a housing wall, and a reference electrode extending into the inner electrolyte, wherein there is arranged within the housing a flexible circuit card, which includes at least a first conductive trace, which is connected with the at least one contact element of the sensor element, and at least a second conductive trace, which serves as potential sensing element of the reference electrode.