Electrochemical Sensor Array Flow Channel Design
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Solution Overview
Problem
Existing electrochemical sensor arrays face challenges in minimizing electrode interaction, ensuring uniform sample distribution, and reducing sample volume while maintaining cost-effectiveness and accuracy in analyte measurement.
Innovation Solution
The sensor array apparatus features a design with a flow channel formed by adhesive membranes, allowing for efficient sample flow between working, reference, and counter electrodes, with a conductive line connecting the working electrode to a communication channel that transfers reaction currents to a measuring device, ensuring all electrodes receive the same electrochemical reaction and minimizing the detection area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a flow cell is designed with small volume to reduce sample amount, then sample volume is reduced, but it becomes difficult to ensure uniform fluid distribution to all electrodes
Solution Approach 1:
The flow cell is divided into multiple flow channels, each serving specific electrodes. This segmentation allows optimized fluid distribution paths for different electrode groups, ensuring uniform sample delivery to all electrodes even within a compact overall volume.
Solution Approach 2:
The patent transitions from a planar electrode arrangement to a three-dimensional configuration with electrodes positioned at different heights and depths within the flow cell. This dimensional change enables more efficient sample distribution and reduces the required flow cell volume while maintaining uniform analyte delivery to all electrodes.
2Productivity
If the distance between electrodes and upper wall of flow cell is reduced to increase analyte diffusion, then mass transfer effects are reduced, but the flow cell volume becomes even smaller
Solution Approach 1:
The flow cell design creates different local geometries for different regions. The distance between electrodes and upper wall varies spatially, with smaller distances positioned strategically to enhance analyte diffusion and mass transfer efficiency in critical measurement zones, while other regions maintain larger volumes for sample reservoir functions.
3Ease of manufacture
If electrodes are placed on a planar surface with simple structure, then manufacturing is easier and cost is lower, but electrode interaction cannot be minimized and measurement accuracy is reduced
Solution Approach 1:
The patent moves from two-dimensional planar electrode placement to three-dimensional spatial arrangement. Electrodes are positioned at different heights, depths, and angular orientations within the flow cell, which minimizes electromagnetic interference and cross-talk between electrodes while maintaining manufacturing feasibility through modular assembly techniques.
4Ease of manufacture
If a disposable sensor design is used to reduce cost, then manufacturing cost is lowered, but ensuring proper connection with electrodes and easy mounting becomes more challenging
Solution Approach 1:
The flow cell is designed to integrate multiple functions into a single disposable unit: sample reservoir, flow distribution channels, electrode mounting structure, and sealing mechanisms are all combined in one piece. This merging eliminates the need for separate components, simplifying both manufacturing and user operation while maintaining cost-effectiveness.
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 design reduces the sample volume required, lowers production costs, and enhances analysis accuracy by ensuring all electrodes participate in the same electrochemical reaction, while allowing for efficient sample handling and analysis.
Implementation Method 1
a conductive line (12) providing a connection between the working electrode (8) and the communication channel (11) on at least one plate (13)
Implementation Method 2
at least one flow channel (15) formed as a result of the space between the adhesive membranes (7, 7a) and associated with the inlet (3) and outlet openings (4) located on the upper layer (2) for carrying the sample
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
This invention relates to an apparatus (1) suitable to be used for analyzing at least one sample with an electrochemical sensor array and comprising at least one upper layer (2); at least one inlet (3) and at least one outlet opening (4) provided on the upper layer; at least one lower layer (6) having at least one recess (5) thereon; at least one two-sided adhesive membrane (7) matching to the recess (5) on the lower layer (6); at least one sensor array (14) secured to the lower layer (6) by means of the said adhesive membrane (7) and composed of positioning at least one working electrode (8), at least one reference electrode (9), at least one counter electrode (10), at least one communication channel (11), at least one conductive line (12) providing a connection between the working electrode (8) and the communication channel (11) on at least one plate (13); at least one measuring device associated with the communication channel (11); at least one further two-sided adhesive membrane (7a) spaced from the adhesive membrane (7) positioned on the lower layer (6) and enabling the sensor array (14) to be secured to the upper layer (2), and at least one flow channel (15) formed as a result of the space between the said adhesive membranes (7, 7a) and associated with the inlet (3) and outlet openings (4) located on the upper layer (2) for carrying the sample.