Gas Sensor Substrate Electrode Alignment
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Solution Overview
Problem
Conventional gas sensors face issues with sensitivity, durability, and gas exchange efficiency due to poor coupling between the detecting portion and electrodes, as well as restricted diffusion caused by protective housing, leading to decreased sensitivity and prolonged gas retention.
Innovation Solution
A gas sensor design featuring a first and second substrate with electrodes and pad electrodes, where the pad electrodes are electrically coupled, and a bonding pad is used to improve alignment and prevent electrical shorts, allowing for efficient gas exchange through strategically positioned openings and eliminating the need for separate housing, thereby enhancing sensitivity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional sensor design with separate electrode connections is used, then the sensor can detect analytes, but the sensor size increases and integration density decreases
Solution Approach 1:
The patent combines multiple electrode connections (first and second connections) and their associated electrodes onto a single substrate, integrating them in close proximity. This merging approach enables the sensor to maintain analyte detection functionality while significantly reducing the overall sensor footprint and increasing integration density.
2Ease of manufacture
If the sensor structure is simplified to reduce size, then manufacturing becomes easier, but manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The patent introduces a substrate as an intermediary platform that provides structured support and precise positioning features. This substrate acts as a mediator that enables accurate alignment of multiple electrode connections during manufacturing, maintaining high manufacturing precision even as the sensor structure is optimized for easier fabrication and reduced size.
3Area of stationary object
If multiple electrode connections are placed close together, then sensor area is reduced, but cross-contamination between measurements increases
Solution Approach 1:
The patent extracts and isolates potential sources of cross-contamination through carefully designed separation structures and isolation zones between adjacent electrode connections. By removing or mitigating contamination pathways while maintaining close proximity for area reduction, the sensor achieves both compact size and resistance to cross-contamination between measurements.
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 improved gas sensor design enhances sensitivity and durability by ensuring effective gas exchange and reducing the risk of electrical shorts, while eliminating the need for wire bonding, which can cause physical or thermal impacts.
Implementation Method 1
The sensor according to the invention comprises a support, a recognition element which is immobilised on the support and is capable of specifically binding to an analyte, and a label which is bound to the recognition element and generates a signal in response to binding to the analyte
Data Source
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AI summary
A sensor is disclosed. The sensor comprises a first substrate; a second substrate positioned relative to the first substrate; a first electrode located between the first substrate and the second substrate, the first electrode formed on the second substrate; a sensing portion covering at least a part of the first electrode and further covering at least a portion of the second substrate; a pad electrode located between the first substrate and the second substrate, wherein the pad electrode is formed on the second substrate and is electrically coupled to the first electrode; and a bonding pad located between the first substrate and the second substrate, wherein the bonding pad is formed on the first substrate and is electrically coupled to the pad electrode.