Sensor and method for manufacturing same
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Solution Overview
Problem
Existing electrochemical sensors for measuring analytes such as glucose lack the accuracy required for precise measurements.
Innovation Solution
A sensor design with a three-electrode configuration, including a working electrode, a counter electrode, and a reference electrode, where the reference electrode is covered by a film to minimize contact with the analyte, and a manufacturing process that involves forming and trimming reagent and electrode layers to ensure uniformity and prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the reference layer is exposed to analyte, then the sensor can perform electrochemical measurement, but the reference layer degrades over time reducing measurement accuracy
Solution Approach 1:
The sensor structure is segmented into distinct functional zones: the reference layer is separated from direct analyte contact by being positioned adjacent to the conductive layer within the dielectric layer, while the sensing layer remains exposed to analyte for measurement. This spatial segmentation protects the reference layer while maintaining sensing functionality.
Solution Approach 2:
The dielectric layer acts as an intermediary barrier between the reference layer and the analyte. The dielectric layer with void allows the reference layer to be electrically connected to the conductive layer while physically isolating it from direct contact with the analyte, preventing degradation.
2Productivity
If the sensor components are manufactured with standard processes, then production is efficient, but performance variations between sensors are high
Solution Approach 1:
Multiple functional layers (sensing layer, reference layer, conductive layer, dielectric layer) are combined into a single integrated sensor structure manufactured in one process sequence. The sensing layer and reference layer are formed simultaneously on the substrate, eliminating variability introduced by separate assembly steps and improving sensor-to-sensor uniformity.
Solution Approach 2:
The sensing layer and reference layer are pre-formed on the substrate before final sensor assembly. This preliminary formation of layers with controlled thickness and composition ensures consistent starting conditions for all sensors in a batch, reducing performance variations.
Data Source
Figure 1~2
Figure 3(A)~3(B)
Figure 4A~4C
AI summary
This sensor has a probe to be inserted into a living body and measures an analyte. The probe has a substrate, an electrode formed on the substrate, and a reference layer formed on the electrode. The upper surface of the reference layer is covered with a film, and the side surfaces thereof are exposed.