Stackable Multi-Electrode Arrays for Simpler Multi-Analyte Fabrication
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Solution Overview
Problem
Current analyte sensors require numerous wafer-scale chemical processing steps, leading to high complexity, cost, and decreased yield, particularly when fabricating multiple sensors for different analytes due to incompatibilities in materials and processes.
Innovation Solution
A multi-electrode sensor array design where each electrode is fabricated using incompatible processes separately, allowing for modular stacking and integration of electrodes for sensing multiple analytes, reducing the need for complex wafer-level processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple analyte sensors are fabricated on a single wafer using traditional wafer-scale chemical processing, then the sensing capability for multiple analytes is achieved, but the fabrication complexity and cost increase significantly while yield decreases
Solution Approach 1:
The patent divides the multi-analyte sensor system into separate individual electrode sensors, each fabricated independently on separate wafers using their own optimized processes. These segmented electrodes are then stacked and bonded together to form the complete multi-analyte sensor array, eliminating the need for complex multi-analyte fabrication on a single wafer
2Reliability
If traditional wafer-scale processing is used for single analyte sensors, then sensing functionality is achieved, but manufacturing cost and process steps increase
Solution Approach 1:
Each electrode is segmented as an independent manufacturing unit that can be fabricated using simple, optimized processes for its specific analyte. This segmentation allows each electrode to be manufactured independently with fewer process steps compared to traditional integrated multi-analyte approaches
Solution Approach 2:
The patent transitions from planar wafer-scale integration to three-dimensional stacking of individual electrodes. By moving to the vertical dimension through stacking and bonding, the system achieves multi-analyte capability without requiring complex lateral integration on a single wafer
3Adaptability or versatility
If incompatible materials and processes are used for different analyte sensors, then specialized sensing performance is achieved, but integration becomes more difficult and expensive
Solution Approach 1:
Electrodes with incompatible material requirements are segmented into separate manufacturing units, each optimized for its specific analyte. The segmentation allows incompatible processes to be used independently without interfering with other electrodes, and the final stacking integrates these diverse electrodes into a single functional array
Solution Approach 2:
The patent uses bonding interfaces as intermediaries to connect electrodes fabricated with incompatible processes. These bonding interfaces serve as mediators that join differently manufactured electrodes into a cohesive multi-analyte sensor system, allowing material incompatibilities to be resolved at the interface level rather than requiring universal compatibility across the entire device
Data Source
AI summary
A multi-electrode sensor array includes a first electrode configured for sensing a first analyte, and a second electrode configured for sensing a second analyte. The first electrode includes a first electrical connection pad on a first end portion of the first electrode, and a first enzyme on a second portion of the first electrode, the first enzyme configured for sensing the first analyte. The second electrode includes a second electrical connection pad on a first end portion of the second electrode, and a second enzyme on a second portion of the second electrode, the second enzyme configured for sensing the second analyte.