Microwell Microelectrode Filtration Sensor Layered Fabrication
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Solution Overview
Problem
Current analyte detection microwells with size exclusion filters and electrochemical detectors face issues such as high sensor failure rates and costly fabrication due to complex and slow manufacturing processes, limiting their sensitivity and cost-effectiveness for biomolecule capture and detection in complex samples.
Innovation Solution
The development of analyte detection microwells with multiple layers, including a filtration membrane with pores as a reactive metal surface for the working electrode and non-reactive metal layers for counter and reference electrodes, allows for efficient biomolecule capture and detection under low hydrodynamic force, using inert materials like plastics or ceramics for the non-reactive layers and reactive metals like gold for the working electrode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used for analyte detection microwells, then fabrication complexity and cost increase, but manufacturing precision and reliability improve
Solution Approach 1:
The microwell structure is divided into multiple separate layers (filtration membrane layer, intermediate layer, electrode layer, sealing layer) that are manufactured independently and then assembled. This segmentation allows each layer to be optimized and manufactured separately using appropriate processes, reducing overall manufacturing complexity while maintaining precision through specialized fabrication of each component.
Solution Approach 2:
The device uses composite construction combining different materials for different functions: filtration membrane (polymer or cellulose), intermediate layer (inert material), electrodes (conductive material), and sealing layer (elastomer). This composite approach allows each material to be selected for its optimal properties, improving manufacturing precision for each component while the modular assembly reduces overall process complexity.
2Manufacturing precision
If traditional manufacturing processes are used for analyte detection microwells, then manufacturing precision improves, but production time and cost increase
Solution Approach 1:
By dividing the microwell into pre-manufacturable layers that can be produced independently and assembled quickly, the segmentation principle enables parallel manufacturing of components. This maintains the precision of each layer through specialized processes while dramatically increasing overall production speed through modular assembly, resolving the contradiction between precision and productivity.
3Reliability
If complex manufacturing processes are used, then sensor reliability improves, but fabrication cost and time increase
Solution Approach 1:
The segmented layered structure allows critical components (filtration membrane, electrodes, sealing layer) to be manufactured with high reliability through specialized processes, then assembled using simple alignment and bonding. This maintains sensor reliability while dramatically improving fabrication efficiency by eliminating complex monolithic manufacturing processes.
Solution Approach 2:
The microwell is designed as a disposable single-use device with a simplified manufacturing process. Rather than creating a complex reusable instrument, the invention uses a simple layered structure that can be rapidly fabricated and discarded after one use, improving fabrication efficiency while maintaining adequate reliability for the intended application lifecycle.
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 approach enables rapid and cost-effective fabrication of sensitive biomolecule detection microwells with reduced sensor failures, capable of processing complex biological samples like whole blood and serum, while maintaining high sensitivity and reliability for electrochemical reactions.
Implementation Method 1
a size exclusion filter with one or more pores
Implementation Method 2
The reactive metal surface layer serves as a working electrode... The electrochemical label is detected by a working electrode
Data Source
AI summary
A microwell microelectrode filtration sensor created by using an inert planar surface, which can be a metal pattern dry etched, to generate a filtration membrane with pores, generating a reactive metal surface layer as a working electrode. The electrode is within an area covering a filtration membrane, and makes one or more microwells added by a first layer of inert plastic of an effective working distance height and a second layer of a non-reactive metal of an effective microwell surface area to serve counter and/or reference an electrode. This is followed by at least one layer of inert plastic or metal.