LTCC Electrochemical Sensor for Flow Rate and Concentration Detection
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Solution Overview
Problem
Existing electrochemical flow sensors face challenges in accurately measuring flow rates and concentrations of electroactive species, particularly in drug delivery systems, where occlusions, leaks, and mechanical failures can go undetected due to limitations in sensor design and bubble trapping.
Innovation Solution
The development of an electrochemical sensor with annular ring electrodes embedded in the walls of a channel, fabricated using Low Temperature Co-fired Ceramic (LTCC) methods, which allows for efficient fluid flow and reduces bubble trapping, enabling measurement of flow rates and concentrations by analyzing the change in electrochemical signals generated by electroactive species.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrodes are placed in a cylinder-shaped cavity with bottom plate, then electrochemical detection is enabled, but solution flow is blocked and bubble trapping occurs
Solution Approach 1:
The patent transitions from a 3D cavity structure with bottom plate to a 2D planar electrode array embedded in the channel wall. This dimensional change eliminates the blocking effect while maintaining detection capability, as solution flows parallel to the electrode plane rather than through a confined cavity.
Solution Approach 2:
The patent divides the single cavity structure into multiple discrete electrode segments arranged in an array along the channel wall. This segmentation allows solution to flow continuously past each electrode without obstruction, while each electrode independently contributes to the overall detection function.
2Reliability
If occlusion sensors are used in drug delivery pumps, then flow monitoring is enabled, but immediate detection of occlusions and mechanical failures is not achieved
Solution Approach 1:
The patent implements continuous electrochemical measurement by maintaining constant solution flow past the electrode array. This continuous action enables real-time detection of flow changes, immediately signaling occlusions or failures without the time delays inherent in periodic or threshold-based sensing mechanisms.
Solution Approach 2:
The patent establishes a feedback mechanism where changes in electrochemical signal directly indicate flow status. The continuous monitoring provides immediate feedback about occlusions, leaks, or mechanical failures, enabling prompt system response without delayed detection.
3Measurement precision
If complex sensor designs are implemented to improve detection accuracy, then measurement precision increases, but device complexity and cost increase
Solution Approach 1:
The patent makes the electrochemical sensor serve multiple functions: it detects flow rate, monitors for occlusions, identifies leaks, and tracks mechanical failures. This multi-functionality eliminates the need for separate sensors for each detection purpose, reducing overall device complexity while maintaining high measurement precision through the electrochemical measurement principle.
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 solution provides immediate detection of altered or no-flow conditions, enabling robust and inexpensive monitoring of flow rates in the nanoliter to microliter range, effectively preventing occlusions, leaks, and mechanical failures in drug delivery systems, while maintaining sensitivity to low volume analytes.
Implementation Method 1
When electroactive species are present in solution, electrodes can be used to measure the flow of electrons to or from the electrode from or to ions in the solution. The electric signal measured will vary by concentration of electroactive specie(s) and by flow rate.
Data Source
Figure 1A~1B
Figure 2~3A
Figure 3B~3C
AI summary
An electrochemical sensor may measure the flow of ions and/or electrochemical species in a solution passing the sensor because the electroactive species will continually come into contact with the electrode and an electric signal will be generated by the combination of diffusion and convection bringing the electroactive species to the electrode. The electric signal measured will vary by concentration of ions and/or electrochemical specie(s) and by flow rate. Flow rate may be measured if the concentration of ions and/or electrochemical specie(s) is known; conversely, the concentration of ions and/or electrochemical species may be measured if the flow rate is known. The sensor may also be used to confirm the delivery of a fluid containing ions and/or electrochemical specie(s).