Kinked Biosensor Substrate for Electrode Density
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Solution Overview
Problem
Conventional methods for producing biosensors with multiple electrodes are complex and cost-intensive, as they require repeated process steps on both sides of a substrate, limiting the efficient application of electrical components and restricting the number of electrodes that can be applied along the length of a biosensor inserted into the body.
Innovation Solution
A biosensor design featuring a flexible substrate with a kink that subdivides its surface into interconnected outer surfaces, allowing for the application of multiple electrodes and contacting elements on both sides without the need for extensive dual-sided processing, enabling more efficient production and increased electrode density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional methods are used to produce biosensors with multiple electrodes, then the biosensor can be manufactured, but the production process becomes complex and cost-intensive due to repeated process steps on both sides of the substrate
Solution Approach 1:
The substrate is folded along a fold line to create a three-dimensional structure from a two-dimensional planar substrate. This folding transforms the geometry so that electrodes applied on a single side of the substrate become distributed across multiple spatial locations and orientations, effectively increasing electrode density without requiring dual-sided processing
Solution Approach 2:
All electrodes and electrical components are applied to the substrate in advance, on a single side, before the folding step. This preliminary application eliminates the need for subsequent dual-sided processing, simplifying the manufacturing workflow while maintaining the capability to have multiple electrodes in final configuration
2Quantity of substance
If conventional methods are used to produce biosensors with multiple electrodes, then the biosensor can be manufactured, but costs increase due to extensive dual-sided processing
Solution Approach 1:
By folding the substrate along a fold line, the invention creates a multi-faceted structure where a single processing side becomes effectively multiple sides in three-dimensional space. This geometric transformation allows multiple electrodes to be positioned along the length of the biosensor using only single-sided electrode application, thereby reducing manufacturing costs
Solution Approach 2:
Electrodes are applied to the substrate in advance on a single side before folding occurs. This preliminary action consolidates all electrode deposition steps into one phase of manufacturing, eliminating the need for costly dual-sided processing equipment and operations while still achieving multi-electrode functionality
3Quantity of substance
If the substrate is folded to increase electrode density, then more electrodes can be placed on the same surface area, but the substrate structure becomes more complex
Solution Approach 1:
The substrate transitions from a two-dimensional planar configuration to a three-dimensional folded structure along a fold line. This dimensional change enables the substrate to occupy more spatial volume while maintaining a compact form, allowing electrodes to be distributed along the folded length to achieve higher effective electrode density
Solution Approach 2:
The substrate is divided into multiple segments or sections by the fold line, creating distinct folded portions that can each accommodate electrodes. This segmentation allows the substrate to be processed and equipped with electrodes more efficiently, as electrodes can be applied to individual segments before or after folding
Data Source
AI summary
A biosensor is proposed for insertion into the subcutaneous tissue of a user wherein the biosensor includes at least one flexible substrate and at least one electrode on at least one surface of the substrate and at least one contacting element. The contacting element is connected to the electrode. The substrate has at least one kink, at which the substrate is at least partly kinked such that the surface is subdivided into at least two interconnected outer surfaces.