Disposable Electrochemical Sensor Strip Noble Metal Reduction

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Solution Overview

Problem

The high cost and wastage of noble metals in disposable electrochemical sensor strips, particularly in medical applications like glucose and uric acid testing, due to the need for extensive noble metal surfaces, limit their widespread use in family medical treatments.

Innovation Solution

A disposable electrochemical sensor strip design featuring a conductive raw material with a metal film coating, where the metal film is applied only to the electrode area within a through hole of an isolating sheet, reducing noble metal usage and enabling efficient assembly and manufacturing, while allowing for accurate electrode area control and increased reproducibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a noble metal is used as an electrode material to achieve high stability and high reproducibility of detection, then the detection performance is improved, but the cost and material wastage increase significantly

Engineering Contradiction:

Improvedetection stability and reproducibilityVSAvoidnoble metal wastage

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The electrode is divided into two parts: a conductive raw material base (which provides structural support and electrical conductivity) and a noble metal film coating (which provides the necessary electrochemical activity). This segmentation allows the expensive noble metal to be applied only where functionally required, rather than using it throughout the entire electrode structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrode is constructed as a composite structure combining a conductive raw material (such as copper, aluminum, or stainless steel) with a thin noble metal film coating. This composite approach leverages the advantages of both materials: the base material provides mechanical strength and conductivity, while the thin noble metal layer provides the necessary electrochemical properties for stable and reproducible detection.

Inventive Principle:

Principle #40Composite materials

2Productivity

If a noble metal surface is used throughout the electrode to ensure high detection performance, then the electrochemical reaction efficiency is improved, but the manufacturing cost increases

Engineering Contradiction:

Improveelectrochemical reaction efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The noble metal coating is applied locally only to the electrode surface that contacts the sample and participates in electrochemical reactions, rather than coating the entire electrode structure. This local application maintains high electrochemical reaction efficiency at the active sites while significantly reducing overall material cost.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The electrode is designed as a disposable component where the expensive noble metal is used in minimal amounts through the film coating approach. The base conductive material serves as a cost-effective substrate that can be easily manufactured and discarded after single use, reducing the overall manufacturing cost while maintaining acceptable performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Power

If the entire noble metal surface is utilized in the electrode structure, then the electrochemical activity is maximized, but the amount of noble metal required increases

Engineering Contradiction:

Improveelectrochemical activityVSAvoidnoble metal quantity

Core Design Contradiction:

PowerVSQuantity of substance

Solution Approach 1:

Instead of using sufficient noble metal to cover the entire electrode surface, the invention applies a thin film coating that provides just enough noble metal to ensure adequate electrochemical activity at the reaction interface. This partial action approach maintains necessary electrochemical power while dramatically reducing the quantity of expensive noble metal material required.

Inventive Principle:

Principle #16Partial or excessive action

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 approach significantly reduces the cost and wastage of noble metals, enhances the accuracy and reproducibility of electrochemical sensors, and makes them more suitable for domestic medical applications by minimizing unnecessary metal usage and streamlining the manufacturing process.

Implementation Method 1

a metal film is coated on a conductive raw material through a mass electroplating process

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS8187446B2Method of manufacturing a disposable electrochemical sensor strip

Publication Date: 2012.05.29 HUANG CHUN MU

AI summary

A disposable electrochemical sensor strip is provided. The sensor strip includes an isolating sheet having at least a through hole, at least a conductive raw material mounted in the through hole, a metal film covered on the conductive raw material to form an electrode which comprises an electrode working surface for processing an electrode action, and an electrode connecting surface, at least a printed conductive film mounted on the isolating sheet and having a connecting terminal for being electrically connected to the electrode connecting surface, and a signal output terminal for outputting a measured signal produced by the electrode action.