Graphene Sensor Device with Selective Plastic Encapsulation

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Solution Overview

Problem

Existing sensor devices, particularly fluid, chemical, and biocomponent sensors, face challenges in achieving sensitivity and compactness while maintaining cost-effectiveness and reduced size, often resulting in complex and expensive designs.

Innovation Solution

The development of a sensor device that incorporates a graphene layer on a substrate, covered by a selective plastic material, which enhances sensitivity and selectivity by controlling the exposure of substances to the environment, allowing for the detection of specific chemicals or biocomponents through changes in electrical conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional sensor packages are used to ensure sensitivity and substance detection capability, then detection functionality is achieved, but device size and complexity increase

Engineering Contradiction:

Improvedetection sensitivityVSAvoidpackage complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent combines the sensor element, encapsulation, and substance access pathways into a single integrated package structure. The graphene sensor is deposited directly on the substrate and encapsulated with plastic material that provides both protection and controlled substance access, eliminating the need for separate components and reducing overall device complexity while maintaining detection sensitivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses thin plastic material layers to encapsulate the graphene sensor element. These thin films provide the necessary encapsulation and protection while allowing controlled diffusion of target substances to the sensor surface, enabling compact design without compromising detection capability.

Inventive Principle:

Principle #30Flexible shells and thin films

2Measurement precision

If conventional sensor packages with openings are used to allow substance application, then detection capability is maintained, but device size increases

Engineering Contradiction:

Improvedetection capabilityVSAvoiddevice size

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

The patent employs thin plastic material encapsulation layers that provide substance access pathways without requiring large openings. The plastic material is configured to allow diffusion of target substances while maintaining a compact device footprint, thus reducing device size while preserving detection capability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The plastic material encapsulation is designed with properties that allow controlled diffusion of gases and vapors to the graphene sensor surface. This porous or semi-permeable characteristic enables substance access through the encapsulation layer itself, eliminating the need for separate large openings and reducing overall device volume.

Inventive Principle:

Principle #31Porous materials

3Reliability

If conventional sensor designs are used to ensure functionality, then detection performance is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvedetection performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces complex mechanical sensor structures with a graphene-based sensor that utilizes electrical conductivity changes for detection. This substitution of mechanical systems with electrical/chemical sensing mechanisms simplifies manufacturing processes and reduces costs while maintaining or improving detection performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses composite structures combining graphene with plastic material encapsulation. This composite approach leverages the unique properties of graphene for sensitive detection and the plastic material for protection and substance access, creating a cost-effective solution that achieves reliable detection performance through material properties rather than complex engineering.

Inventive Principle:

Principle #40Composite materials

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 the creation of cost-effective, compact sensor devices with increased sensitivity and selectivity, effectively addressing the need for efficient detection of substances like CO2, O2, and other gases or biocomponents, while maintaining a reduced size and simplified design.

Implementation Method 1

allowing for the detection of specific chemicals or biocomponents through changes in electrical conductivity

Methodology Applied

Scientific EffectElectrical conductivity change: Conduction (electrical)

Implementation Method 2

covered by a selective plastic material, which enhances sensitivity and selectivity by controlling the exposure of substances to the environment

Methodology Applied

Scientific EffectPermeation: Permeation

Data Source

PatentUS9536953B2Method for making a sensor device using a graphene layer

Publication Date: 2017.01.03 INFINEON TECHNOLOGIES AG

AI summary

A graphene layer is generated on a substrate. A plastic material is deposited on the graphene layer to at least partially cover the graphene layer. The substrate is separated into at least two substrate pieces.