Flexible multi-moduled nanoparticle-structured sensor array on polymer substrate and methods for manufacture

Patent metadata

Field	Value
Publication number	US-2016018350-A1
Application number	US-201514797371-A
Country	US
Kind code	A1
Filing date	Jul 13, 2015
Priority date	Apr 18, 2007
Publication date	Jan 21, 2016
Grant date	—

Abstract

A flexible chemiresistor (CR) sensor for sensing a molecule of interest in a fluid (liquid or gas) is provided. The flexible CR sensor comprises a flexible chemiresistor (CR) module. The flexible CR module comprises a flexible substrate such polyethylene terephthalate (PET), polyethylene naphthalate (PEN) or polyimide (PI), and a thin film nanoparticle assembly assembled on the flexible substrate. The thin film nanoparticle assembly comprises metal or metal alloy core, ligand-capped nanoparticles and molecular linkers connecting the nanoparticles. The flexible CR sensor and an intelligent pattern recognition engine can be incorporated in a handheld device that can detect a molecule of interest in a fluid (e.g., a liquid or gas) accurately, rapidly, and without false positives. Any sensing array nanomaterial, pattern recognition, and compact/or electronic hardware can be integrated to achieve a desired detection limit and response speed.

First claim

What is claimed is:

1 . A method of manufacturing a sensor, said method comprising:
introducing a solution onto a flexible substrate comprising microelectrodes, the solution comprising metal or metal alloy core, ligand-capped nanoparticles comprising a nanoparticle capping ligand and molecular linkers connecting adjacent ones of the metal or metal alloy core, ligand-capped nanoparticles, the molecular linkers comprising mercaptocarboxylic acid with a carboxyl end forming hydrogen bonds with the metal or metal alloy core, ligand-capped nanoparticles; and curing the flexible substrate and solution to form a thin film that adheres to the flexible substrate via bonding that occurs between the flexible substrate, the microelectrodes, and the nanoparticle capping ligand of the ligand-capped nanoparticles.

2 . The method of claim 1 , further comprising:
translating the flexible substrate transverse to the solution.

3 . The method of claim 2 , further comprising:
transferring the flexible substrate from a first roller to a second roller.

4 . The method of claim 3 , further comprising:
forming the solution into a stream, wherein the stream is directed at a location on the flexible substrate between the first roller and the second roller.

5 . The method of claim 3 , further comprising:
disposing the solution on a stamp; and contacting the stamp with the flexible substrate.

6 . The method of claim 5 ,
forming a monolayer on the flexible substrate, wherein the monolayer receives the solution.

7 . The method of claim 5 , wherein the stamp comprises a poly(dimethylsiloxane) stamp with pre-patterned features to locate the solution in contact with the microelectrode of the flexible substrate.

8 . The method of claim 9 , further comprising:
using photolithography, patterning the microelectrodes so that the microelectrodes are coupled to the metal or metal alloy core, ligand-capped nanoparticles to conduct an electrical signal.

9 . A process to form a sensor, said process comprising:
performing a patterning step to form microelectrodes in a flexible substrate; performing a deposition step to introduce a solution onto the flexible substrate, the solution comprising metal or metal alloy core, ligand-capped nanoparticles comprising a nanoparticle capping ligand and molecular linkers connecting adjacent ones of the metal or metal alloy core, ligand-capped nanoparticles, the molecular linkers comprising mercaptocarboxylic acid with a carboxyl end forming hydrogen bonds with the metal or metal alloy core, ligand-capped nanoparticles; and performing a curing step to form a thin film that adheres to the flexible substrate via bonding that occurs between the flexible substrate, the microelectrodes, and the nanoparticle capping ligand of the ligand-capped nanoparticles.

10 . The process of claim 9 , wherein the deposition step includes stamping the solution onto the flexible substrate.

11 . The process of claim 9 , wherein the deposition step includes forming a monolayer on the flexible substrate, wherein the monolayer receives the solution.

12 . The process of claim 9 , wherein the deposition step includes pipetting the solution onto the flexible substrate.

13 . The process of claim 9 , wherein the deposition step includes printing the solution onto the flexible substrate.

14 . The process of claim 13 , further comprising:
using a roll-to-roll transfer step to move the flexible substrate transverse to the solution.

15 . The process of claim 14 , wherein the roll-to-roll transfer step includes:
rolling the flexible substrate from a first roller before the deposition step; and re-rolling the flexible substrate onto a second roller after the deposition step.

16 . The process of claim 9 , wherein the patterning step includes using photolithography to form the microelectrodes.

17 . A method, comprising:
providing a solution, the solution comprising metal or metal alloy core, ligand-capped nanoparticles comprising a nanoparticle capping ligand and molecular linkers connecting adjacent ones of the metal or metal alloy core, ligand-capped nanoparticles, the molecular linkers comprising mercaptocarboxylic acid with a carboxyl end forming hydrogen bonds with the metal or metal alloy core, ligand-capped nanoparticles; providing a substrate with a plurality of microelectrodes; and forming a film on the substrate with the solution, wherein the film adheres to the flexible substrate via hydrophobic and hydrophilic interactions between the flexible substrate (and microelectrode pattern) and the nanoparticle capping ligand of the ligand-capped nanoparticles, wherein the flexible substrate and the film are configured to bend from a first orientation to a second orientation, which is different than the first orientation, and wherein the thin film nanoparticle assembly is configured to maintain chemical sensitivity in response to exposure to the molecule of interest to induce an electrical signal across the plurality of microelectrodes in the second orientation.

18 . The method of claim 17 , further comprising:
stamping the solution onto the substrate.

19 . The method of claim 17 , further comprising:
printing the solution onto the substrate.

20 . The method of claim 17 , further comprising:
directing the solution in a first direction onto the substrate; and translating the substrate in a second direction that is transverse to the first direction.

Assignees

• Univ New York State Res Found

Inventors

• Zhong Chuan-Jian
• Luo Jin
• Wang Lingyan

Classifications

• B05D1/26

  performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface · CPC title

• B82Y15/00

  Nanotechnology for interacting, sensing or actuating, e.g. quantum dots as markers in protein assays or molecular motors · CPC title

• B82Y30/00

  Nanotechnology for materials or surface science, e.g. nanocomposites · CPC title

• G01N27/127 Primary

  comprising nanoparticles · CPC title

• B05D1/28

  performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers · CPC title