3D ISE Sensor Arrays on PCBs for Reliable Miniaturization
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Solution Overview
Problem
Existing ion-selective electrodes (ISEs) are large and expensive, making them unsuitable for size-constrained applications and disposable devices, and solid-state ISEs are unreliable due to short circuits and electrical instability.
Innovation Solution
A miniature, disposable array of ISE sensors fabricated on a standard printed-circuit board with a robust seal and tall, high-aspect-ratio membranes, incorporating both inner filling solution-based and solid-state ISEs in a three-dimensional well structure, allowing for accurate and reliable detection of multiple analytes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-ion ISE probes are used, then ion detection capability is achieved, but device size becomes large and cost becomes high
Solution Approach 1:
The patent divides the ISE probe into separate functional components: the ion-selective membrane is separated from the internal filling solution and reference electrode system. This segmentation allows each component to be optimized independently and assembled in a compact configuration, reducing overall device size while maintaining detection capability.
Solution Approach 2:
The patent implements a nested structure where the internal filling solution and reference electrode are contained within a miniaturized housing that integrates with the ion-selective membrane assembly. This nesting approach allows multiple functional elements to be packed into a compact volume, achieving high functionality in a small form factor.
2Reliability
If traditional single-ion ISE probes are used, then ion detection capability is achieved, but manufacturing cost becomes prohibitively high
Solution Approach 1:
The patent combines multiple ISE sensors into an array configuration on a single substrate, allowing simultaneous detection of multiple ions. This merging approach reduces per-sensor cost through economies of scale in manufacturing and enables multi-analyte detection with a single device unit.
Solution Approach 2:
The patent designs a universal sensor array platform that can detect multiple different ions using the same basic structure and materials. By making the system multi-functional, the patent eliminates the need for multiple separate probes, reducing overall system cost while maintaining comprehensive detection capability.
3Volume of moving object
If solid-state ISEs are used to reduce size, then device size is reduced, but reliability decreases due to short circuits and electrical instability
Solution Approach 1:
The patent introduces an intermediary liquid filling solution that separates the ion-selective membrane from the solid reference electrode components. This liquid intermediary provides stable ionic conduction and electrical isolation, preventing short circuits while maintaining the compact solid-state form factor. The filling solution acts as a buffer that ensures electrical stability.
Solution Approach 2:
The patent employs composite construction combining solid components (substrate, membrane support) with liquid components (filling solution, ion-selective membrane). This composite approach leverages the mechanical stability of solids and the electrical stability of liquids, achieving both miniaturization and reliable electrical performance.
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 a cost-effective, reliable, and high-density array of ISE sensors capable of detecting various analytes in constrained environments, improving stability and reducing the risk of short circuits, enabling accurate and reproducible measurements.
Implementation Method 1
An ion-to-electron transducer layer may then convert the ion-based potential to an electron-based potential
Implementation Method 2
The inner filling solution 110 may include or consist essentially of conductive polymers, electrolytic solutions, and/or hydrogels, and may work with the ion-to-electron transducing material to convert ions, passed from the solution 102 through the membrane 108, to electrons
Implementation Method 3
the solution is exposed to an ion-selective membrane
Data Source
AI summary
An electronic device includes a substrate and a plurality of sensors. Each sensor is disposed in a well over the substrate and includes a working electrode, an inner filling solution disposed thereover, and an ion-selective membrane. The working electrode is in contact with the substrate and the ion-selective membrane is disposed over the inner filling solution and substantially seals the well.