Miniaturization of a biomedical gas sensor

In a previous study, we concluded that a conductivity based PCO2 sensor is an attractive solution for early detection of ischemia and presented two design geometries. For organ surface measurements, the planar design was suitable but it was difficult to insert the sensor into the tissue. A cylindrical design solution was favored for insertion due to the large membrane contact area and easy placement in a medical catheter. Since the previous cylindrical prototype was large and could damage the tissue, a more miniaturized sensor was needed. In the current paper, we present a miniaturized sensor with an outer diameter of 1 mm. The applied technology for manufacturing the sensor was a combination of mechanical turning, excimer laser drilling and conventional molding technique. The materials applied were PEEK (polyetherether ketone), PI (polyimide) with gold layers and polysiloxane. The membrane had to be gas permeable while acting as a barrier for ion transport, and was made of polysiloxane and had a thickness of 100-150 microm. The miniaturized sensor was tested for calibration, response time, drifting and pressure sensitivity. The results show that the miniaturized PCO2 sensor is capable of rapid and stable measurements both in vitro and ex vivo. The result from this study will be applied for the industrial manufacturing of such a biomedical sensor as a clinical product.