Printed Sensor Membrane Deposition for Reproducible Thickness Control
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Solution Overview
Problem
Existing sensor manufacturing methods, particularly drop casting, suffer from low reproducibility, labor intensity, and limited parameter control, leading to inconsistent membrane thickness and poor sensor performance, making them unsuitable for scalable and portable applications.
Innovation Solution
A system for additively manufacturing sensors using a membrane head directly connected to a container, allowing precise control of parameters such as pressure, delivery speed, and distance, eliminating intermediate connectors to enhance reproducibility and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If drop casting is used to form membranes on electrodes, then the process is simple and can be performed manually, but the reproducibility is highly dependent on operator skill and the membrane thickness is inconsistent
Solution Approach 1:
The patent replaces the manual mechanical drop casting process with an automated material jetting system that uses controlled fluid delivery through a nozzle to deposit membrane agent composition. This substitution eliminates operator skill dependency and enables precise control of deposition parameters including volume, speed, and positioning, thereby achieving consistent membrane thickness while maintaining ease of manufacture through automation.
2Device complexity
If drop casting is used to deliver membrane agent composition, then only the volume parameter is controlled, but the reproducibility remains low due to limited parameter control
Solution Approach 1:
The patent implements a dynamic material jetting system where the nozzle can move in multiple dimensions (x, y, z axes) with programmable trajectories. The system dynamically adjusts deposition parameters including jetting speed, nozzle height, and material flow rate during the manufacturing process. This dynamic control enables precise delivery of membrane agent composition with reproducible results while maintaining reasonable system complexity through automated control.
3Adaptability or versatility
If multiple sensors are stacked to detect various features of interest, then comprehensive sensing is achieved, but the sensing device becomes bulky and unsuitable for portable applications
Solution Approach 1:
The patent merges multiple sensing functions onto a single integrated electrode substrate using additive manufacturing. Different sensor types (pH, redox, free chlorine, conductivity, temperature) are manufactured on the same substrate with shared infrastructure, eliminating the need for separate sensor stacks. This merging approach maintains comprehensive sensing capability while dramatically reducing device volume and enabling portable applications.
4Measurement precision
If glass electrodes are used for pH sensing, then accurate pH measurement is achieved, but the electrodes are bulky, fragile, and require calibration and cleaning between measurements
Solution Approach 1:
The patent changes the material parameters and construction approach of pH sensors by using additive manufacturing to create planar pH sensors with printed electrodes and membranes. This parameter change transforms the traditional bulky glass electrode into a compact, robust printed structure that eliminates fragility issues. The additive manufacturing process also integrates calibration features and reduces the need for cleaning between measurements, thereby improving ease of operation while maintaining measurement precision.
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 system improves reproducibility and reduces manufacturing costs by enabling precise control of membrane thickness and sensor performance, making it suitable for scalable and portable sensor assemblies.
Implementation Method 1
a membrane head for delivering a membrane agent composition onto the electrode through a nozzle
Data Source
AI summary
A method of additively manufacturing a sensor including providing a working electrode and a reference electrode, wherein the reference electrode and the working electrode include a conductive agent composition. The method further includes delivering a membrane agent composition onto the reference electrode to form a membrane, wherein the formed membrane onto the reference electrode is an ion-saturated membrane. In addition, a system for additively manufacturing a sensor includes a receiving region configured to receive the electrode; a membrane head for delivering the membrane agent composition onto the electrode through a nozzle; a container carrier attached to the membrane head; a driving arm configured to drive the membrane head at least over the receiving region; and a membrane head actuator configured to feed the nozzle with the membrane agent composition.