Stacked Sensor Assembly for Low-Volume Blood Analysis
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Solution Overview
Problem
Current sensor assemblies for measuring blood parameters require larger sample volumes and are complex to produce, leading to inefficiencies in sampling, particularly in intensive care settings where frequent and precise measurements are needed with limited blood samples.
Innovation Solution
A compact sensor assembly with analyte sensors positioned on opposing walls of a measuring cell, allowing for simultaneous measurement of multiple parameters without interference, using a plate-like substrate with conductive wiring and a spacer to form a small volume measuring cell with inlet and outlet ports for fluid sample handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sensors are arranged on a substrate to measure multiple parameters, then the number of sensors increases, but the sample volume required increases and device complexity increases
Solution Approach 1:
The patent transitions from planar sensor arrangement to three-dimensional stacking by placing sensors on opposing surfaces of a substrate separated by a thin spacer layer. This vertical arrangement allows multiple sensors to share the same sample volume without increasing the lateral footprint, thereby resolving the contradiction between sensor quantity and sample volume requirement.
Solution Approach 2:
The spacer layer is positioned between opposing substrate surfaces to create a confined measuring cell volume. This nesting structure allows multiple sensors on different surfaces to share a common, compact sample volume, effectively reducing the total sample required while maintaining high sensor density.
2Adaptability or versatility
If multiple sensors are arranged on a substrate to measure multiple parameters, then the number of sensors increases, but the device complexity increases
Solution Approach 1:
The patent merges multiple sensor assemblies into a single integrated structure where substrates with sensors are stacked and separated by spacers to form a unified measuring cell. This consolidation reduces device complexity by eliminating the need for multiple separate flow cells and sampling systems while maintaining the ability to measure multiple parameters simultaneously.
Solution Approach 2:
The measuring cell structure serves multiple functions: it confines the sample volume, provides spacing between sensors, enables fluid flow through common inlet/outlet ports, and allows optical or electrical interaction between opposing sensors. This multi-functionality reduces the number of separate components needed, thereby reducing overall device complexity.
3Quantity of substance
If a zig-zag flow channel configuration is used to connect measuring cells, then the sample volume is reduced, but the manufacturing complexity increases
Solution Approach 1:
Instead of using a complex zig-zag channel configuration, the patent segments the flow path into simple linear inlet and outlet ports on opposing surfaces of the spacer. This segmentation allows for straightforward manufacturing while still achieving compact sample volume utilization through the three-dimensional stacked architecture.
Data Source
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AI summary
The invention relates to a sensor assembly (1) comprising a first electronic wiring substrate (2) having a first and a second surface and at least one analyte sensor formed on the first surface thereof, the at least one analyte sensor being connected with one or more electrical contact points (5c), a second electronic wiring substrate (3) having a first and a second surface and at least one analyte sensor (6) formed on the first surface part thereof, the at least one analyte sensor being connected with one or more electrical contact points (5c), and a spacer (4) having a through-going recess (7) with a first and a second opening, wherein the first substrate (2), the second substrate (3) and the spacer (4) are arranged in a layered structure, where the first surface of the first substrate (2) closes the first opening of the spacer (4) and the first surface of the second substrate (3) closes the second opening of the spacer (4), thereby forming a measuring cell which is faced by at least one sensor from each of the substrates (2,3).