Porous Plunger Sensor Array Sealing
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Solution Overview
Problem
Existing sensor array technologies face measurement errors due to indefinite flow conditions above sensors, which require complex and costly production of precise dimensions for walls between sensors to maintain stationary liquids, leading to sensitivity and accuracy issues.
Innovation Solution
A sensor array apparatus with a porous plunger layer that is impermeable to liquids, allowing for mechanical contact with the sensor array and forming closed-off reaction spaces, reducing liquid exchange and measurement errors by using elevations and pores to control liquid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If walls between sensors are made with precise dimensions to prevent liquid flow, then measurement accuracy is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent employs a porous plunger layer made of elastomeric material with controlled pore structure. The porosity allows the material to be compressed and form seals against the sensor array walls, preventing liquid flow between reaction spaces. This porous elastomeric approach replaces the need for precisely dimensioned rigid walls, simplifying manufacturing while maintaining measurement accuracy through effective liquid flow prevention.
Solution Approach 2:
The invention changes the physical state and properties of the sealing mechanism from rigid precise-dimension walls to a compressible porous elastomeric material. By controlling parameters such as pore size, porosity percentage, and elastomeric hardness, the system achieves effective sealing without requiring precise dimensional tolerances in the overall device structure, thus reducing manufacturing complexity.
2Reliability
If walls project from the surface to create reaction spaces, then liquid exchange between sensors is prevented, but the housing upper part may seat on sensors at high plunger pressure corrupting measurements
Solution Approach 1:
The porous elastomeric plunger layer acts as a compliant sealing element that distributes plunger pressure uniformly across the sensor array surface. The porous structure allows controlled deformation and pressure equalization, preventing localized high-pressure contact points that could corrupt sensor measurements while still maintaining effective seals between reaction spaces.
Solution Approach 2:
The elastomeric plunger layer functions as a flexible sealing film that conforms to the sensor array surface topology. This flexibility allows the sealing surface to adapt to minor surface variations without transmitting excessive pressure to the sensors, thereby preventing measurement corruption while maintaining reliable liquid exchange prevention.
3Reliability
If a plunger is pressed against the sensor array to prevent liquid flow, then closed-off reaction spaces are formed, but complex apparatus and high outlay are required
Solution Approach 1:
The porous elastomeric plunger layer provides inherent compliance and sealing capability that simplifies the overall apparatus design. The material's porous structure enables it to deform and seal effectively under moderate pressure, eliminating the need for complex positioning mechanisms, precise alignment systems, or high-pressure actuators, thereby reducing apparatus complexity and cost.
Solution Approach 2:
The elastomeric plunger layer exhibits self-sealing properties through its porous compliant structure. When pressed against the sensor array, the material automatically conforms to surface variations and forms effective seals without requiring complex control systems or additional sealing components, enabling the system to achieve closed-off reaction spaces with simpler apparatus.
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 simplifies production, reduces measurement errors, and increases accuracy by allowing for greater manufacturing tolerances and reduced dependence on precise dimensions, while maintaining stationary liquids for accurate detection of substances.
Implementation Method 1
The plunger (2) has at its surface lying opposite the sensor array a plunger layer (9) having at least partly or completely porous properties and which is impermeable to liquids or substances from liquids relative to the total layer thickness of the plunger layer (9)
Implementation Method 2
The space between the sensor array and the plunger layer can be filled or is filled partly or completely with liquid and/or only pores, at the surface of the porous plunger layer can be filled or are filled with liquid
Data Source
AI summary
Disclosed is an apparatus that is used for detecting liquids or substances from liquids and includes a plunger that has a porous plunger layer which is pressed onto a sensor array. Each sensor of the sensor array is surrounded by elevations which spatially separate the sensors from each other like walls. In at least one embodiment, when the plunger layer is pressed onto the sensor array, the walls are pressed into the pores of the plunger layer. Liquid-tight connections are created between the walls and the plunger layer while liquid remains over the sensors. The liquid can be measured. In at least one embodiment, when there is direct mechanical contact between the plunger layer and the sensors, the liquid over the sensors is located in open pores on the surface of the plunger layer. No liquid flows between the pores and across the walls when pressure is applied to the plunger layer such that closed reaction chambers are created.