Laser-Shaped Working Electrode for Homogeneous Sensor Sensitivity
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Solution Overview
Problem
Existing methods for manufacturing analyte sensors result in inhomogeneous application of sensing material, leading to varying sensor sensitivity across charges and requiring time-consuming and expensive fine adaptation of manufacturing parameters.
Innovation Solution
A method involving laser irradiation of a sensing material layer applied onto a conductive trace on a sensor substrate, where a portion of the layer is removed to create a homogenous working electrode, reducing the need for detailed parameter monitoring and enabling reproducible sensor sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen printing, dip-coating, or dispensing methods are used to apply sensing material, then the manufacturing process is simple, but the sensing material cannot be applied sufficiently homogenously leading to edge effects and varying sensor sensitivity
Solution Approach 1:
The patent replaces mechanical application methods (screen printing, dip-coating, dispensing) with laser irradiation to remove excess sensing material. This substitution allows precise control of sensing material distribution by using laser energy to ablate material selectively, achieving homogeneous application while maintaining manufacturing simplicity.
Solution Approach 2:
The patent changes the state of the sensing material through laser irradiation, transforming it from an inhomogeneous deposited layer to a homogeneous working electrode surface. By controlling laser parameters (energy, duration, scanning pattern), the process removes excess material and creates uniform thickness, resolving the homogeneity issue while keeping the overall process simple.
2Reliability
If detailed monitoring and fine adaptation of manufacturing parameters is performed to reduce sensor signal sensitivity variation, then sensor sensitivity consistency improves, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces complex parameter monitoring and adaptation processes with a laser-based removal process. Instead of trying to control deposition parameters precisely, the method applies sensing material and then uses laser irradiation to remove excess, which is inherently more controllable and faster, reducing manufacturing time while improving sensitivity consistency.
Solution Approach 2:
The patent performs the sensing material application first, then uses laser irradiation to remove excess material as a corrective step. This preliminary action approach allows for simpler initial deposition without requiring precise parameter control, and the laser step ensures final homogeneity, thereby reducing overall manufacturing time.
3Ease of manufacture
If conventional methods are used to apply sensing material, then manufacturing cost is reduced, but sensor drift increases due to inhomogeneous sensing material application
Solution Approach 1:
The patent replaces conventional mechanical application methods with laser-based processing. While laser equipment has cost, it eliminates the need for expensive fine adaptation and monitoring systems. The laser process creates homogeneous sensing material application, reducing sensor drift, while maintaining overall cost-effectiveness by simplifying the manufacturing workflow.
Solution Approach 2:
The patent uses laser parameters (energy density, pulse duration, scanning speed) to control the removal of sensing material. By optimizing these parameters, the process achieves homogeneous sensing material distribution and stable sensor performance without requiring expensive additional equipment or complex process control systems.
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 achieves high and reproducible sensor sensitivity across charges while reducing manufacturing costs and sensor drift, allowing for factory calibration and minimizing edge effects.
Implementation Method 1
irradiating the layer of the sensing material with at least one laser beam, wherein at least a first portion of the layer of the sensing material is at least partially removed
Data Source
AI summary
A method of preparing a working electrode on a sensor substrate is disclosed. A sensor substrate is provided and has a first side with at least one conductive trace. A layer of sensing material is applied onto the first side and covers at least a portion of the at least one conductive trace. The sensing material is irradiated with a laser beam to partially remove the layer of the sensing material while preserving a portion of the sensing material covering the at least one conductive trace, resulting in a working electrode on the sensor substrate. A membrane layer is applied that at least partially covers the working electrode. The membrane layer includes a cross-linker that cross-links at least a part of the sensing material. A diffusion step is performed during which the cross-linker in the membrane layer at least partially diffuses into the sensing material.