Foldable Implantable Glucose Sensor 3D Electrode Layout
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Solution Overview
Problem
Conventional electrochemical sensors for analyte detection, such as glucose sensors, face challenges in reducing size, increasing sensitivity, and simplifying manufacturing processes while maintaining cost-effectiveness, particularly due to the complexity and cost of fabricating multilayer sensors with multiple electrodes.
Innovation Solution
The development of foldable analyte sensors with a base substrate that transitions from a planar configuration to a three-dimensional configuration, allowing for expansive 360° sensing by positioning electrodes on both sides of the substrate without the need for vias, simplifying the production process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multilayer sensors with multiple electrodes are fabricated to increase sensitivity and enable 360° sensing, then sensing performance is improved, but manufacturing complexity and cost increase due to requiring extra patterning steps and vias
Solution Approach 1:
The patent applies dimensionality change by transitioning from planar 2D electrode arrangement to a 3D folded configuration. The substrate is folded such that electrodes positioned on opposite sides of the fold create spatial separation and enable 360° sensing in the intracellular environment, achieving enhanced measurement precision without requiring multiple patterning layers or vias.
Solution Approach 2:
The patent segments the sensor substrate into distinct regions that are folded relative to each other. By dividing the substrate and folding it, electrodes are separated into different spatial zones (inside and outside the cell), allowing independent optimization of each electrode's function while simplifying the manufacturing process compared to traditional multilayer approaches.
2Volume of moving object
If multilayer sensors are fabricated to reduce sensor size, then miniaturization is achieved, but manufacturing cost increases due to complicated fabrication processes
Solution Approach 1:
The patent uses dimensional transformation by folding a single-layer substrate into a compact 3D structure. This approach achieves miniaturization of the sensor volume while avoiding the need for complex multilayer fabrication processes, thereby reducing manufacturing cost while maintaining the compact form factor.
Solution Approach 2:
The patent employs a flexible thin film substrate that can be folded without breaking. This flexible thin film allows the sensor to achieve a compact size suitable for intracellular implantation while being manufactured using simple single-sided patterning processes, avoiding the high costs associated with rigid multilayer fabrication.
3Volume of moving object
If electrodes are positioned close together to reduce sensor size, then miniaturization is achieved, but electrode interference increases reducing sensing accuracy
Solution Approach 1:
The patent resolves electrode interference by using the third dimension (folding) to separate electrodes spatially. electrodes that are close together on the planar substrate are separated in 3D space after folding, with some electrodes positioned inside the cell and others outside, thereby eliminating electrical interference while maintaining miniaturization.
Solution Approach 2:
The patent introduces asymmetry in electrode positioning by folding the substrate unevenly, creating distinct internal and external electrode zones. This asymmetric arrangement allows electrodes to be physically separated into different environmental zones, reducing interference while maintaining compact overall sensor dimensions.
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 enables cost-effective sensors with enhanced sensitivity and efficiency, facilitating easier implantation and improved accuracy in analyte detection by allowing electrodes to be placed on both sides of the substrate, reducing interference, and increasing spatial separation for better performance in vivo environments.
Implementation Method 1
a base substrate comprising a planar sheet of a flexible material adapted to transition from a first configuration to a second configuration when the base substrate is folded to form a fixed bend
Implementation Method 2
an analyte sensing layer disposed over the working electrode, wherein the analyte sensing layer detectably alters the electrical current at the working electrode in the presence of an analyte
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3(a)~3(b)
AI summary
The application disclosed herein includes implantable blood glucose sensors having three dimensional configurations that allow expansive "360°" sensing (i.e. sensing analyte from multiple directions) in the environments in which such sensors are disposed. Disclsed is an analyte sensor apparatus comprising: a base substrate comprising a planar sheet of a flexible material adapted to transition from a first configuration to a second configuration when the base substrate is folded to form a fixed bend; a working electrode, a counter electrode and a reference electrode disposed upon a first surface of the base substrate; a plurality of contact pads disposed upon the first surface of the base substrate; a plurality of electrical conduits disposed upon the first surface of the base substrate, wherein the plurality of electrical conduits are adapted to transmit electrical signals between electrodes and contact pads separated by the fixed bend; and an analyte sensing layer disposed over the working electrode, wherein the analyte sensing layer detectably alters the electrical current at the working electrode in the presence of an analyte; wherein: the base substrate comprises the fixed bend so as to form a configuration in which: at least one electrode is disposed on a first side of the fixed bend; and at least one electrode is disposed on a second side of the fixed bend.