Porous Electrochemical Sensor Electrode Resist Coating for Stable Resistance
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Solution Overview
Problem
Existing electrochemical sensors face inaccuracies in hematocrit measurement due to changes in resistance values of the hematocrit electrode, which are influenced by variations in printing and drying conditions, leading to non-uniform electrode areas and substrate deformation, and require additional components for resistance value correction, increasing manufacturing costs and time.
Innovation Solution
A manufacturing method for electrochemical sensors that adjusts the resistance value of electrodes by coating a porous material with a non-electroconductive resist to control the resistance within a predetermined range, using index information from a test sensor to determine the coating region based on the actual resistance value, ensuring accurate measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If printing conditions or drying conditions are changed to adjust resistance value, then resistance value can be adjusted, but electrode shape uniformity and surface roughness deteriorate
Solution Approach 1:
The electrode is divided into a measurement portion and a lead portion, with the resist coating applied selectively only to the lead portion. This segmentation allows independent optimization of resistance adjustment in the lead portion without affecting the measurement portion's geometric uniformity and surface properties.
Solution Approach 2:
The resist coating is applied locally only to the lead portion of the electrode rather than the entire electrode. This local application adjusts the resistance value in the specific area where it is needed while preserving the uniform shape and surface roughness of the measurement portion.
2Manufacturing precision
If drying temperature is changed to adjust resistance value, then resistance value can be adjusted, but insulating substrate deformation occurs
Solution Approach 1:
The resist coating is applied to the lead portion before the electrode drying process. This preliminary action allows the resist to be in place before drying, so that the subsequent drying process does not cause substrate deformation while still achieving the desired resistance adjustment.
Solution Approach 2:
The resist coating is applied locally only to the lead portion rather than the entire electrode and substrate. This localized application minimizes the total heat exposure area during drying, reducing the risk of insulating substrate deformation while still achieving the required resistance adjustment.
3Measurement precision
If separate resistance value holding portion and measurement means are added, then resistance value can be corrected, but device complexity and manufacturing cost increase
Solution Approach 1:
The resistance adjustment function is merged with the existing electrode structure by applying resist coating to the lead portion of the electrode itself. This eliminates the need for separate resistance value holding portions and additional measurement means, thereby reducing device complexity while maintaining resistance correction capability.
Solution Approach 2:
The lead portion of the electrode serves multiple functions: it provides electrical connection and simultaneously serves as the site for resist coating to adjust resistance value. This multi-functionality eliminates the need for separate dedicated components, reducing overall device complexity.
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 method stabilizes resistance values, allowing for precise measurement of analytes by controlling resistance through resist coating, reducing manufacturing complexity and costs while maintaining measurement accuracy.
Implementation Method 1
permeating communicating pores of the porous material with the resist
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A manufacturing method for an electrochemical sensor includes an electrode forming step of forming an electrode, made of a porous electroconductive material, on an insulating substrate, and a resist forming step of coating a coating region on the electrode by a resist with non-electroconductivity in a solution state, and permeating communicating pores of the porous electroconductive material with the resist, thereby adjusting a resistance value of the electrode.