Ion Detection Sensor Fabrication Using Graphene Mixed Layer
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Solution Overview
Problem
Current ion detection sensors, such as ISFETs, require complex fabrication processes and high equipment and manpower costs, making them unsuitable for low-cost, disposable sensors for rapid sodium ion detection in urine samples.
Innovation Solution
A simplified ion detection sensor fabrication method involving the preparation of an ion-sensitive film solution with graphene powder, applied through printing processes to form an ion-sensitive mixed layer between a source and drain, allowing for streamlined production and cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ISFETs are used for ion detection, then measurement precision and detection speed are improved, but fabrication complexity and production cost increase
Solution Approach 1:
The patent segments the complex ISFET fabrication process into essential steps only, eliminating unnecessary photolithography, sputtering, and dicing steps. The sensor is divided into simple components: source, drain, and ion-sensitive mixed layer that can be formed independently and assembled, reducing overall fabrication complexity while maintaining detection precision.
Solution Approach 2:
The patent adopts a disposable sensor design where the ion detection sensor is fabricated as a single-use device. This eliminates the need for complex, expensive fabrication processes required for reusable sensors, allowing simplified manufacturing while maintaining measurement precision for each use cycle.
2Measurement precision
If traditional ion detection methods (atomic absorption spectroscope, flame photometer) are used, then measurement precision is improved, but device size and operational complexity increase
Solution Approach 1:
The patent replaces complex mechanical and optical systems (atomic absorption spectroscope, flame photometer) with a solid-state ion detection sensor based on field-effect transistor principles. This substitution maintains measurement precision for sodium ion detection while dramatically simplifying device operation and enabling portability.
Solution Approach 2:
The patent changes the detection parameter from bulk optical measurement to surface potential measurement at the ion-sensitive mixed layer. This parameter change enables precise sodium ion detection through electrical signal measurement instead of complex optical systems, improving ease of operation while maintaining accuracy.
3Ease of operation
If ISEs are used for ion detection, then device portability is improved, but measurement precision deteriorates due to ion leakage
Solution Approach 1:
The patent uses an ion-sensitive mixed layer composed of ionophore, plasticizer, and polymer in specific ratios (ionophore:plasticizer:polymer = 1:2:7 to 1:3:6). This composite material structure provides both the portability of compact sensors and the measurement precision of laboratory equipment by preventing ion leakage while maintaining sensitivity to target ions.
Solution Approach 2:
The patent applies local quality by creating an ion-sensitive mixed layer with specific compositional properties at the sensor surface that is in direct contact with the sample. This localized optimization of material composition at the detection interface ensures high measurement precision while maintaining overall device portability.
4Manufacturing precision
If multi-step fabrication processes are used for ISFETs, then manufacturing precision is improved, but production cost and time increase
Solution Approach 1:
The patent merges multiple fabrication steps into a single printing process. The ion-sensitive mixed layer is formed by directly printing the mixed layer preparation solution, combining what would traditionally require separate sputtering, photolithography, and assembly steps. This merging maintains manufacturing precision while dramatically improving production efficiency.
Solution Approach 2:
The patent uses printing technology to create a precise copy or replica of the desired sensor structure directly from a digital or template pattern. This copying approach maintains manufacturing precision by ensuring consistent feature dimensions while enabling high-speed production through rapid printing processes.
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 method enables efficient and cost-effective production of ion detection sensors with improved sensitivity and selectivity, facilitating rapid and precise sodium ion detection without the need for extensive equipment or complex processes.
Implementation Method 1
forming an ion-sensitive mixed layer sensitive to a target ion by applying the ion-sensitive mixed layer preparation solution to fill a gap between a source and a drain spaced apart from each other
Data Source
AI summary
An ion detection sensor fabrication method includes: preparing an ion-sensitive film preparation solution; preparing an ion-sensitive mixed layer preparation solution by mixing the ion-sensitive film preparation solution with graphene powder; and forming an ion-sensitive mixed layer sensitive to a target ion by applying the ion-sensitive mixed layer preparation solution to fill a gap between a source and a drain spaced apart from each other and to cover at least a portion of an upper surface of each of the source and the drain.