Flexible Electrochemical Glucose Sensor Using Silane Coupling Agent
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Solution Overview
Problem
Current continuous glucose monitoring systems face challenges such as high production costs, complex manufacturing processes, and implant trauma due to the use of needle-shaped electrodes and expensive materials, as well as issues with adhesion and precision in electrode deposition methods like photolithography and screen printing.
Innovation Solution
A continuous glucose monitoring sensor with an electrochemical electrode made from a polymer film, featuring a gold layer on both sides, a platinum black layer, a carbon nanotube/Nafion mesh layer, and a polyurethane protection layer, which simplifies the manufacturing process and reduces trauma through a surface metallization technology-based assembly without the need for photolithography or screen printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum magnetron sputtering is used to deposit metal layers on the electrode, then the metal layer can be formed, but the adhesion is poor and the metal layer easily falls off
Solution Approach 1:
The patent introduces a silane coupling agent as an intermediary substance between the substrate and the metal layer. The silane coupling agent contains both hydroxyl groups that bond with the substrate and reactive groups that form strong chemical bonds with metal oxides, thereby improving the adhesion of the metal layer and preventing it from falling off during use.
Solution Approach 2:
The patent modifies the surface properties of the substrate by treating it with silane coupling agents, changing the chemical composition and surface energy parameters. This creates a surface that has both strong substrate bonding and excellent metal layer adhesion, resolving the adhesion problem without compromising reliability.
2Manufacturing precision
If photolithography or screen printing is used for electrode assembly, then the electrodes can be formed, but the process becomes complicated and production cost increases
Solution Approach 1:
The patent extracts and eliminates the complex photolithography and screen printing processes from the electrode assembly method. Instead, it uses a simplified direct deposition approach where the silane coupling agent and metal layer are applied directly to the substrate in a single integrated process, maintaining precision while dramatically reducing process complexity.
Solution Approach 2:
The patent replaces the mechanical and chemical complex processes of photolithography (involving photoresist coating, exposure, development, etching) and screen printing (involving screen preparation, paste printing, drying, firing) with a simpler chemical vapor deposition or liquid-phase deposition method using silane coupling agents, which self-assemble into precise patterns without requiring complex equipment or multiple steps.
3Manufacturing precision
If strong oxidant surface etching is used in photolithography process, then the surface can be prepared, but the process becomes complicated and requires special control under ROHS and WEEE standards
Solution Approach 1:
The patent replaces the expensive and environmentally regulated strong oxidant etching processes with a simpler, less regulated surface preparation method using silane coupling agents. The silane-based process uses milder, more environmentally friendly chemicals that do not require the same level of regulatory control, simplifying manufacturing while maintaining surface preparation quality.
Solution Approach 2:
The patent converts the potential harm of using strong oxidants (environmental pollution, safety hazards, regulatory burden) into a benefit by using silane coupling agents that provide equivalent or superior surface preparation with minimal environmental impact. The silane process creates a reactive surface that enhances adhesion without the harmful effects of strong oxidant etching.
4Manufacturing precision
If expensive platinum iridium filaments are used for fine metal wire electrodes, then the electrode can be formed, but the raw material cost becomes very high
Solution Approach 1:
The patent replaces expensive platinum iridium filaments with a cost-effective alternative: a thin film electrode structure made by depositing metal layers (such as gold, silver, or other conductive metals) on a flexible substrate using silane coupling agents. This film-based electrode achieves comparable precision and performance at a fraction of the material cost, making the sensor economically viable for large-scale production.
Solution Approach 2:
The patent transitions from rigid wire-based electrodes to flexible thin film electrodes. The thin film structure, deposited on a flexible substrate, provides the necessary electrical conductivity and sensing capability while being significantly cheaper than precious metal filaments. The thin film can be precisely patterned and integrated directly into the sensor structure, eliminating the need for expensive wire fabrication.
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
The solution results in a cost-effective, sensitive, and stable glucose monitoring system with a linear range of up to 30 mM and a detection limit of less than 0.25 mM, offering fast response and reduced implant trauma, while the monolithic electrode structure enhances long-term stability and anti-interference capabilities.
Implementation Method 1
both ends of the silane coupling agent are respectively bonded to the substrate and the metal layer through chemical bonds
Implementation Method 2
an electrochemical three-electrode detection system is formed
Data Source
AI summary
Provided in the present invention are a flexible electrochemical electrode, a subcutaneous continuous glucose monitoring sensor equipped with the electrochemical electrode, and a preparation method thereof. The electrode directly uses gold layers on both sides of a chemically plated film, respectively as a working electrode and a reference-counter electrode, so as to form an electrochemical two-electrode system. Petaloid platinum nanoparticles are electrodeposited on a surface of the configured working electrode as a catalytic layer; a carbon nanotube/Nafion mesh layer functions as an anti-interference layer, and is formed thereon with an enzyme biochemical sensitive layer by means of electrostatic adsorption, after crosslinking and curing in glutaraldehyde, polyurethane mass transfer is coated to limit a protection layer, so as to prepare a flexible continuous glucose monitoring sensor. The sensor does not require photolithography, screen printing or other technologies to construct an electrochemical electrode system. The present invention effectively simplifies the processing technology, can easily achieve large-scale production and reduce production costs; and meanwhile, the present invention has characteristics such as a wide linear range, low detection limit, powerful anti-interference capacity, high response sensitivity and long-term stability.