Electrochemical Sensor Layering for Reagent and Film Control
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Solution Overview
Problem
Conventional electrochemical sensors face challenges in controlling the characteristics of the protective film and reagent layer on the working electrode, leading to variance and decreased measurement accuracy.
Innovation Solution
The sensor design includes a working electrode with a conductive layer, a first insulating layer with a water-repellent surface and a second insulating layer that is alcohol-repellent, allowing for precise placement of a reagent layer and protective film through controlled droplet application in specific openings, followed by drying to achieve desired characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a protective film is formed by dip coating or casting on the working electrode, then the protective film can cover the electrode, but the characteristics of the protective film (thickness, amount of polymer compound) cannot be controlled within the designed range
Solution Approach 1:
The protective film formation process is segmented into multiple steps: first forming a first protective film layer, then forming a second protective film layer on top. This segmentation allows independent control of each layer's characteristics (thickness, composition) to achieve precise control over the overall protective film properties while maintaining manufacturing feasibility through sequential coating processes.
Solution Approach 2:
Different regions of the protective film are given different properties by using multiple layers with different compositions and thicknesses. The first protective film layer and second protective film layer can have different polymer compounds, crosslinking densities, and thicknesses to create local variations in protective characteristics, enabling precise control over film properties in different areas.
2Manufacturing precision
If a reagent layer is formed on the surface of a flat electrode, then the reagent layer can be applied, but the characteristics of the reagent layer (thickness, amount of reagent) cannot be controlled within the designed range
Solution Approach 1:
The reagent layer is nested within a cavity structure formed between the first and second protective film layers. The cavity acts as a container that holds the reagent layer, allowing precise control over reagent amount and distribution. The reagent layer is effectively 'nested' within the protective film structure rather than being applied on a flat surface, enabling better control characteristics.
Solution Approach 2:
The reagent layer formation transitions from a two-dimensional surface application to a three-dimensional cavity-filled structure. By creating a cavity between protective film layers and filling it with reagent, the system gains control over reagent volume, distribution, and thickness in the vertical dimension, enabling precise control of reagent layer characteristics.
3Measurement precision
If the protective film and reagent layer characteristics are not controlled precisely, then the manufacturing process is simpler, but the measurement accuracy of the sensor decreases
Solution Approach 1:
The sensor structure is segmented into multiple functional layers with specific functions: first protective film layer, second protective film layer, reagent layer, and conductive layer. Each layer can be independently optimized and controlled for its specific function, allowing precise control of characteristics that directly impact measurement accuracy while maintaining manageable manufacturing complexity through modular assembly.
Solution Approach 2:
The invention controls measurement accuracy by precisely adjusting parameters of the protective film layers (thickness, polymer compound composition, crosslinking degree) and reagent layer (volume, reagent concentration, distribution). These parameter changes are achieved through controlled coating processes and cavity formation, enabling optimization of sensor performance without excessive manufacturing 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
This method enables easy control of the reagent layer and protective film characteristics within the desired range, enhancing measurement accuracy and consistency.
Implementation Method 1
a first insulating layer that is at least partially disposed on the conductive layer and that has a water-repellent surface
Implementation Method 2
a second insulating layer that is disposed on the first insulating layer and that has a surface that is liquid-repellent to alcohol
Implementation Method 3
forming a droplet of a liquid composition A containing the reagent in water in the first opening of the first insulating layer of the substrate on which the conductive layer, the first insulating layer, and the second insulating layer are disposed, and then drying this droplet to form the reagent layer
Data Source
AI summary
The present invention provides a sensor comprising a working electrode including a reagent layer and a protective film, with which the characteristics can be easily controlled within the desired range, as well as a method for manufacturing this sensor. A sensor (1) comprises an insulating substrate (2) and a working electrode (10a). The working electrode (10a) comprises a conductive layer (11a) on the substrate (2), a first insulating layer (3a) disposed on the conductive layer (11a) and having a first opening (3a1) and a water-repellent surface (3a2), a second insulating layer (4a) disposed on the first insulating layer (3a) and having a second opening (4a1) and a surface (4a2) that is liquid-repellent to alcohol (4a2), a reagent layer (15a) disposed in the first opening (3a1) of the first insulating layer (3a), and a protective film (16a) disposed in the second opening (4a1) of the second insulating layer (4a).