Laser-Formed Graphite Biosensor Circuit for Reproducible Detection
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Solution Overview
Problem
There is a need for improved carbon-based sensors, such as chemiresistive or field-effect sensors, that demonstrate high-quality and reproducible conductivity changes in response to analyte concentrations, particularly for applications like gas, pH, and protein measurements, with efficient and reproducible manufacturing processes.
Innovation Solution
A method involving a polymer substrate capable of producing graphite upon energy application, where electrodes are separated by a gap, and energy is applied using a laser to form graphite microdots in electrical contact, potentially with an insulating layer that ablates to surround the graphite, enabling sensitive analyte detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used for carbon-based sensors, then manufacturing complexity is reduced, but manufacturing precision and reproducibility of conductivity changes deteriorate
Solution Approach 1:
The patent replaces conventional mechanical and chemical graphite formation processes with laser-induced plasma processing. The laser creates a plasma state in the polymer substrate that transforms carbon atoms into graphite structure, achieving precise and reproducible conductivity changes without complex mechanical assembly or chemical treatment steps
Solution Approach 2:
The patent utilizes changes in physical parameters (temperature, pressure, energy density) during laser processing to control graphite formation. By adjusting laser parameters such as pulse duration, power density, and scanning speed, the process achieves precise control over graphite structure and electrical properties, improving manufacturing precision
2Measurement precision
If laser energy is applied to form graphite mass, then sensor sensitivity is improved, but energy consumption increases
Solution Approach 1:
The patent employs pulsed laser processing instead of continuous laser application. The periodic pulsed delivery of energy allows graphite formation with controlled energy input, reducing overall energy consumption while maintaining the high sensitivity achieved through precise graphite structure formation at each pulse
Solution Approach 2:
The laser induces phase transitions in the polymer substrate, transforming it from solid polymer to plasma state and then to graphite structure. This phase transition approach concentrates energy efficiently into the material, achieving high sensor sensitivity with reduced total energy consumption compared to gradual heating methods
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 approach results in high-sensitivity sensors capable of detecting attomolar concentrations of biomolecules and gases, with rapid response times, suitable for various analyte measurements, including humidity and protein concentrations, and can be efficiently fabricated for diverse applications.
Implementation Method 1
applying energy with a laser. Applying energy with a laser can include applying energy with a pulsed argon laser
Implementation Method 2
providing a polymer substrate capable of producing graphite in response to the application of energy
Implementation Method 3
applying energy through the insulating layer to form the mass of graphite that simultaneously ablates the insulating layer where the mass of graphite is formed
Data Source
AI summary
Embodiments of the invention include a method for manufacturing sensors and circuit structures. The method can include providing a substrate including a layer of polymer capable of producing graphite in response to the application of energy, a first electrode adjacent to a first via location on the layer of polymer, and an insulating layer over at least a portion of the first electrode and the layer of polymer at the first via location; and applying sufficient energy to the layer of polymer at the first via location through the insulating layer to ablate the insulating layer and to form a first via as mass of graphite that extends into electrical contact with the first electrode and is surrounded by the insulating layer in a plane of the insulating layer.