Working Electrode Coating for Uniform Sensing Layer Thickness
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Solution Overview
Problem
Existing methods for applying sensing material on a conductive layer of an analyte sensor result in non-uniform thickness, leading to increased edge thickness and potential sensitivity issues, which can affect sensor performance and increase manufacturing costs.
Innovation Solution
A method for preparing a working electrode involves applying sensing material in multiple layers with controlled wet thickness, followed by drying and crosslinking, ensuring a uniform dry thickness of 1-10 μm across the application area, including edges, using laser irradiation to remove excess material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sensing material is applied in a single layer with high wet thickness to achieve sufficient dry thickness, then the manufacturing process is simplified, but the edge thickness increases significantly resulting in non-uniform dry thickness
Solution Approach 1:
The sensing material application process is divided into multiple sequential steps, where a first layer is applied with a first wet thickness, dried to achieve a first dry thickness, then a second layer is applied with a second wet thickness, and dried to achieve a second dry thickness. This segmentation allows control over the final uniform dry thickness by optimizing each layer's parameters independently, preventing the edge thickness problem that occurs with single high-thickness applications.
2Reliability
If the thickness of sensing material layer is increased to improve sensor sensitivity, then detection capability is enhanced, but edge thickness increases causing non-uniformity and potential laser ablation issues
Solution Approach 1:
Instead of applying one thick layer that causes edge accumulation, the sensing material is applied in multiple layers with controlled wet thicknesses. Each layer is dried to achieve a controlled dry thickness, and the cumulative effect of multiple thin layers provides the desired total thickness with uniform distribution, maintaining both sensitivity and thickness uniformity.
Solution Approach 2:
Each individual layer is applied with a wet thickness that is deliberately kept below the final desired dry thickness (partial action), knowing that the cumulative effect of multiple dried layers will achieve the target thickness. This prevents over-application at edges that would occur with a single excessive thickness application.
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 results in a sensor with high and reproducible sensitivity, reduced sensor drift, and lower manufacturing costs, while maintaining uniformity and stability of the sensing material.
Implementation Method 1
using laser irradiation to remove excess material
Implementation Method 2
followed by drying and crosslinking
Data Source
AI summary
The present invention relates to a method for the preparation of a working electrode, the method comprising application of a sensing material in several steps. Further, the present invention relates to an analyte sensor comprising the working electrode as well as to the use of the analyte sensor for detecting at least one analyte in a sample.