Interdigitated Sensor Arrays via Hybrid Jetting
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Solution Overview
Problem
Current methods for manufacturing interdigitated biosensor arrays are costly and not suitable for mass production, limiting their use as disposable sensors for biological specimens like blood and urine.
Innovation Solution
A hybrid manufacturing approach using a combination of non-aerosol jetting and aerosol jetting technologies to form interdigitated sensor arrays on flexible substrates, enabling precise control over electrode dimensions and spacing for enhanced signal amplification, with conductive inks and biomolecule receptors applied to create cost-effective biosensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard screen printing, electrodeposition or laser ablation approaches are used to manufacture interdigitated sensor arrays, then manufacturing is simpler and faster, but trace dimensions and space dimensions cannot be sufficiently controlled
Solution Approach 1:
The patent divides the manufacturing process into multiple stages: first forming conductive traces using screen printing or electrodeposition, then selectively removing material via laser ablation to create the interdigitated finger patterns. This segmentation allows each process to optimize for its specific function, achieving precise dimensions without requiring the entire process to be high-precision.
Solution Approach 2:
The patent introduces a conductive ink layer as an intermediary material that can be precisely deposited and then selectively removed. This intermediary layer enables the transfer of patterns from a mask to the substrate with high precision, bridging the gap between simple manufacturing processes and precise dimensional requirements.
2Manufacturing precision
If semiconductor type fabrication techniques including photolithography are used, then trace dimensions and space dimensions are precisely controlled, but manufacturing cost increases and mass production becomes difficult
Solution Approach 1:
The patent extracts the high-precision patterning step from the complete manufacturing process by using laser ablation only for selective removal of conductive material where fingers should be separated, rather than using photolithography for the entire pattern formation. This allows most of the manufacturing to use simpler, more cost-effective processes.
Solution Approach 2:
The patent employs disposable masks that can be easily replaced, allowing for rapid reconfiguration of production lines without expensive tooling changes. The masks are simple physical stencils that define the interdigitated patterns and can be manufactured cheaply and discarded after use, enabling cost-effective mass production.
3Reliability
If interdigitated sensor arrays are manufactured with precise trace and space dimensions, then signal amplification is enhanced, but manufacturing complexity and cost increase
Solution Approach 1:
The patent optimizes specific parameters such as trace width (5-50 micrometers) and space between fingers (5-50 micrometers) to achieve signal amplification. By carefully controlling these dimensional parameters through the hybrid manufacturing process, the interdigitated array achieves enhanced electrochemical response and signal amplification without requiring complex device architecture.
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 method allows for the cost-effective production of biosensors with improved signal amplification capabilities, making them suitable for mass production and widespread use as disposable devices for testing biological specimens.
Implementation Method 1
aerosol jetting technologies to form interdigitated sensor arrays
Implementation Method 2
non-aerosol jetting and aerosol jetting technologies to form interdigitated sensor arrays
Data Source
Figure 1~2
Figure 3
Figure 4A~5C
AI summary
An automated feed manufacturing product is disclosed. The automated feed manufacturing product is provided with a flexible substrate having a plurality of card zones with the card zones defining sensing areas with sensor units formed within the sensing areas. The sensor units have a first electrode having first fingers, and a second electrode having second fingers and with the first fingers interleaved with the second fingers and with the first fingers spaced away from the second fingers. The sensor units also comprising biomolecule receptors on the flexible web between the first electrode and the second electrode such that a physical property of the first electrode relative to the second electrode is effected upon one or more of the biomolecule receptors binding to a biomolecule. The automated feed manufacturing product can be formed as a continuous web, or discrete sheets formed using a sheet feeder that picks up and processes the discrete sheets.