Transforming Sensor Technology: The design of robust electrochemical (bio)sensors using "Inverted sandwich" cell architecture

The purpose of the proposed project is to investigate various types of electrochemical sensors and biosensors to improve their durability, longevity, and resistance to extreme environmental conditions while maintaining their detection limits. The research will be conducted on existing devices that use electroactive thin-film components applied on thin-sheet metal-based substrates, e.g. stainless steel, aluminum, or other metal foils. The research will be focused on integrating existing sensing materials into a new sensor architecture (so-called “inverted sandwich”) that can withstand adverse environmental conditions such as extreme temperatures, corrosive environments, and high external mechanical forces. Various types of sensing materials such as organic thin-film coatings, functionalized sol-gel ceramics, adherent proteins or enzymes, modified foods, and other commercially available biomaterials will be used to develop durable sensors that can be used in wearable electronics, portable diagnostics, and automated applications. The novelty of the proposed research project is that it will be focused on the architecture of the devices and their electrolyte-electrode interface, and will aim to use existing thin-film sensing materials that are scientifically mature, as well as incorporate industrially available components and processes. Research will also focus on the durability and stress resistance of the devices under study, with an emphasis on developing novel methods for testing the devices under extreme environmental conditions, ranging from chemical to mechanical stress. The main objective of the proposed research is to investigate methods and opportunities to ruggedize existing electrochemical (bio)sensors into a compact, robust unit. The investigation itself will be conducted in several phases: 1)      Analysis and review of current electrochemical and biosensor devices using established electrochemical, spectroscopic, and morphological methods. 2)      Implement architectural solutions developed for electrochromic devices and photosensors, such as “inverted sandwich” or fabric and mesh devices, to find appropriate engineering solutions that could be used for new ruggedized sensor devices that could be used in portable diagnostics, wearable electronics, and automated monitoring. 3)      Develop and document data and test protocols to study existing and new devices under adverse environmental conditions (high de-acceleration, temperature extremes, corrosion resistance) and publish results in peer-reviewed journals. 4)      Use of computational tools to digitize existing results and develop accurate simulations that can predict further modifications of electrochemical cells for chemical sensors and biosensors, and increase their technological readiness level (TRL) from conceptual form (TRL 1-2) to laboratory prototypes tested under simulated conditions (TRL 3-5) The project will focus on two parts in the development of electrochemical sensors and biosensors. First part is the interaction between the components of unmodified devices, focusing on the fabrication of electroactive film and studying the interactions between the electrode and electrolyte. This will also include testing of devices under adverse conditions and the preparation of test protocols and their verification. The second part will focus on computational methods for optimizing devices and predicting architectural solutions, as well as assembling new sensor devices and testing them according to established protocols. Results will be obtained in several ways, namely, material analysis (electrochemical, spectroscopic, morphological, and physical properties of liquids), device testing (both data acquisition and post-exposure analysis of the device), and computer simulations (simulation of the behavior of electroactive materials and the electrode-electrolyte interface).