Analyte Sensor Protective Layer Opening Formation
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Solution Overview
Problem
Existing analyte sensors for measuring body fluids, particularly those designed for implantation, face challenges in manufacturability and long-term stability, with complex and costly production processes and limited durability.
Innovation Solution
The analyte sensor features a substrate with two conductive materials, a working electrode, and a protective layer covering a silver-based second electrode, allowing access through openings, facilitating easy manufacturing via roll-to-roll and screen printing processes, and ensuring improved biocompatibility and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex layered structure with multiple electrodes and protective layers is used, then the sensor functionality and stability are improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the protective layer and the second electrode into a single integrated component. The protective layer is formed directly on the substrate with the second electrode embedded within it, eliminating the need for separate electrode fabrication and assembly steps. This merging reduces manufacturing complexity while maintaining sensor reliability.
Solution Approach 2:
The second electrode is formed within the protective layer during the initial manufacturing process, before the sensor is assembled or implanted. This preliminary formation of the electrode structure within the protective matrix simplifies subsequent manufacturing steps and ensures proper positioning and integration of electrical components.
2Measurement precision
If traditional electrode fabrication methods are used, then measurement precision is achieved, but manufacturing time and cost increase
Solution Approach 1:
The protective layer structure itself serves the dual function of protection and electrode formation. The conductive material within the protective layer is positioned and configured to provide the necessary electrical functionality without requiring separate electrode fabrication processes. The protective layer 'services' both protective and electrical functions simultaneously.
Solution Approach 2:
The patent changes the physical and chemical parameters of the protective layer by incorporating conductive materials and forming openings with specific geometric characteristics. These parameter changes enable the protective layer to serve as both a protective barrier and an functional electrode, improving manufacturing efficiency while maintaining measurement precision.
3Reliability
If multiple separate components are assembled, then functional performance is optimized, but manufacturing cost and time increase
Solution Approach 1:
The patent merges multiple functional components into a single integrated structure where the protective layer contains both protective and electrical functions. This integration reduces the number of separate components that need to be manufactured and assembled, thereby reducing manufacturing cost and time while maintaining sensor performance through proper design of the integrated structure.
Solution Approach 2:
The protective layer is designed with multi-functionality, serving as both a protective barrier against environmental factors and as a functional electrode for measurements. This universal component approach eliminates the need for separate protective and electrical components, reducing overall manufacturing complexity and cost.
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 configuration results in a cost-efficient, stable, and biocompatible analyte sensor with prolonged measurement capabilities, maintaining sensitivity during use and storage.
Implementation Method 1
The protective layer (128) has a width (142) which is larger than the width (138) of the second electrode (120) and a length (144) which is larger than the length (140) of the second electrode (120). The protective layer (128) comprises at least one opening (136).
Implementation Method 2
The working electrodes of such a sensor have electrically conductive enzyme layers in which enzyme molecules are bound which release charge carriers by catalytic conversion of the analyte molecules.
Data Source
AI summary
The present invention relates to an analyte sensor comprising a substrate, at least one first electrode, at least one second electrode and at least one protective layer covering the at least one second electrode. The present invention further relates to a process for manufacturing the inventive analyte sensor as well as to an analyte sensor system comprising an analyte sensor according to the present invention and an electronics unit. The analyte sensor according to the present invention may mainly be used for conducting analyte measurements in a body fluid of a user.