Wear-Resistant Electrochemical Sensor Hard Conductive Layer
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Solution Overview
Problem
Existing electrochemical test sensors have reduced wear resistance due to thin metallic electrodes, leading to decreased robustness and increased susceptibility to scratching and reduced usability, as they are prone to damage during handling and insertion into meter openings.
Innovation Solution
The development of an electrochemical test sensor with a base, a generally hard electrically-conductive layer, and an electrochemically-active layer made of different materials, forming an electrode pattern, which includes a reagent to determine analyte information, with the conductive layer being made of materials like indium zinc oxide or carbon to enhance wear resistance and usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thin metallic electrodes are used to reduce cost, then manufacturing cost is reduced, but wear resistance and robustness are decreased
Solution Approach 1:
The patent applies composite materials by combining a thin metallic electrode layer with a harder protective coating layer. The metallic layer maintains cost-effectiveness and electrochemical functionality, while the protective coating layer (such as diamond-like carbon or other hard coatings) provides enhanced wear resistance and robustness. This composite structure resolves the contradiction by integrating the advantages of both materials: the low cost and electrical properties of metal with the high hardness and scratch resistance of protective coatings.
2Ease of manufacture
If thin metallic electrodes are used to reduce cost, then manufacturing cost is reduced, but susceptibility to scratching is increased
Solution Approach 1:
The protective coating layer serves as an intermediary between the thin metallic electrode and the external environment. This intermediate layer protects the vulnerable metallic electrode from scratching and mechanical damage during handling and insertion, while allowing the electrode to maintain its thin, cost-effective structure. The coating acts as a shield that absorbs mechanical stresses and prevents direct contact between the soft metal and abrasive surfaces.
3Ease of manufacture
If thin metallic electrodes are used to reduce cost, then manufacturing cost is reduced, but robustness during handling and insertion is decreased
Solution Approach 1:
The electrode structure is segmented into distinct functional layers: a thin metallic layer for electrochemical functionality and a separate protective coating layer for mechanical strength. This segmentation allows each layer to be optimized for its specific purpose - the metal for cost and electrical performance, and the coating for robustness and scratch resistance - thereby resolving the contradiction between low cost and high strength.
Data Source
AI summary
An electrochemical test sensor includes a base, a generally hard electrically-conductive layer, an electrochemically-active layer, and a lid. The electrically-conductive layer is located between the base and the electrochemically-active layer. The electrically-conductive layer and the electrochemically-active layer are made of a different material. The electrically-conductive layer and the electrochemically-active layer form an electrode pattern. The electrochemical test sensor includes a reagent adapted to assist in determining information related to an analyte of a fluid sample.