Multilayer Metal TCO Construct for Stable Biosensors
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Solution Overview
Problem
Existing electrochemical test strips face challenges in maintaining electrochemical and mechanical stability, especially when exposed to environmental factors like heat, humidity, and degradation, while also requiring improved production methods for multilayer constructs used in biosensors.
Innovation Solution
The development of multilayer constructs comprising a non-conductive substrate layer, a metal conductor layer, and an oxidized Transparent Conducting Oxide (TCO) protective layer, which are produced using a high-speed single-pass process involving RF plasma treatment and sputtering, allowing for enhanced electrochemical response and mechanical robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multilayer constructs use pure metal conductors or metal alloy conductors, then electrical conductivity is achieved, but sensitivity to heat, humidity and degradation increases
Solution Approach 1:
The patent applies composite materials by combining metal conductor layers with transparent conducting oxide (TCO) layers to create a multilayer construct. The metal layer provides electrical conductivity while the TCO layer provides protection against heat, humidity and degradation, resulting in a composite structure that achieves both electrical functionality and environmental stability.
Solution Approach 2:
The transparent conducting oxide layer creates a protective barrier that effectively creates an inert environment for the underlying metal conductor. This protective layer shields the metal from harmful environmental factors such as oxidation, moisture, and thermal degradation, allowing the metal to maintain its conductivity without direct exposure to degrading conditions.
2Manufacturing precision
If multilayer constructs are produced using conventional multi-pass processes, then fabrication quality can be maintained, but production time and cost increase
Solution Approach 1:
The patent merges multiple fabrication steps into a single continuous process. By combining substrate preparation, metal layer deposition, and TCO layer deposition into one uninterrupted manufacturing pass, the system achieves both high fabrication quality and improved productivity, eliminating the time and cost penalties of conventional multi-pass processes.
Solution Approach 2:
The manufacturing process maintains continuity of useful action by performing all critical deposition steps without interruption or intermediate handling. The continuous single-pass process ensures that the multilayer construct is formed in one uninterrupted sequence, maintaining precision while maximizing production efficiency.
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 solution provides electrochemical test strips with improved stability and durability, reduced sensitivity to environmental factors, and cost-effective production, enabling their use in various sensor applications with consistent performance over time.
Implementation Method 1
RF plasma treatment
Implementation Method 2
sputtering
Implementation Method 3
oxidized Transparent Conducting Oxide (TCO) protective layer
Data Source
AI summary
The present disclosure relates to processes and apparatuses for optimizing the single pass production of multilayer constructs including metal/transparent conducting oxide (TCO) multilayers. Articles created from such methods are also disclosed. In particular, multilayer constructs are used as an electrochemical test strip, such as a biosensor, and will be described with particular reference thereto.