Electropolymerized Polymer Coating for Sensor Fissure Passivation

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Solution Overview

Problem

Flow cell sensors, such as biosensors for DNA and RNA detection, are prone to failure due to corrosive solutions penetrating cracks or fissures in the metal-containing layers, leading to short or complete sensor failure.

Innovation Solution

A method involving the application of an aqueous solution with a polymer precursor and electrolyte to the sensor's flow channel, applying voltages to the metal-containing layer and electrode to form a polymer coating that fills fissures, creating a passivation layer to prevent corrosive solutions from reaching the metal layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a passivation layer is applied to protect metal containing layers, then sensor reliability is improved, but fissures in the passivation layer allow corrosive solutions to penetrate and cause sensor failure

Engineering Contradiction:

Improvesensor reliabilityVSAvoidcorrosive solution penetration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies electropolymerization to form a protective polymer coating on the metal containing layer before exposing the sensor to corrosive solutions. This preliminary protective action ensures that even if the passivation layer has fissures, the underlying metal layer is already protected by the polymer coating, preventing corrosive penetration and maintaining sensor reliability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a polymer coating as an intermediary protective layer between the metal containing layer and the corrosive solutions. This intermediate layer fills and seals fissures in the passivation layer, acting as a mediator that blocks harmful corrosive substances while allowing the passivation layer to maintain its structural integrity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the passivation layer is made thicker to prevent corrosive penetration, then sensor protection is improved, but manufacturing complexity and risk of fissures increase

Engineering Contradiction:

Improvecorrosive solution blockingVSAvoidpassivation layer structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent changes the protective mechanism from relying solely on physical thickness of the passivation layer to using electrochemical polymerization parameters. By controlling voltage, current, and polymerization time, a thin but highly effective protective polymer coating is formed, eliminating the need for thick passivation layers and reducing the associated manufacturing complexity and fissure risk

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical approach of using thick passivation layers with an electrochemical approach. Instead of relying on mechanical thickness to block corrosive solutions, the patent uses electropolymerization to create a chemically bonded protective layer that adheres to the metal surface, providing superior protection with reduced structural complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If conventional passivation methods are used, then manufacturing is simpler, but sensor failure occurs due to fissure penetration

Engineering Contradiction:

Improvepassivation processVSAvoidsensor integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent employs self-service through electropolymerization where the polymer coating forms automatically on the metal containing layer when voltage is applied. The system uses its own electrical energy to generate the protective layer in situ, eliminating the need for separate coating applications or complex multi-step manufacturing processes, thus maintaining ease of manufacture while significantly improving sensor reliability

Inventive Principle:

Principle #25Self-service

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 polymer coating effectively blocks corrosive solutions from penetrating fissures, significantly reducing sensor failure rates and maintaining sensor integrity during use.

Implementation Method 1

the polymer precursor oxidizes electrochemically under the applied voltage, forming a polymer chain growth at the metal containing layer within the fissure

Methodology Applied

Scientific EffectElectrochemical oxidation: Oxidation

Implementation Method 2

the polymer precursor oxidizes electrochemically under the applied voltage, forming a polymer chain growth

Methodology Applied

Scientific EffectElectropolymerization:

Implementation Method 3

the polymer chain growth deposits within the fissure, forming a coating

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS10793963B2Passivating fissures in substrates

Publication Date: 2020.10.06 ILLUMINA INC

AI summary

Provided in one example is a sensor having at least one fissure, the fissure being at least partially filled by at least one polymer formation extending vertically within a passivation layer. The polymer formation protects the underlying metal containing layer from corrosive solutions. Provided in another example is a method of forming the polymer formation in a fissure of a sensor.