Electrochemical sensor and method of forming thereof

A sensor package, comprising:

• a substrate;
• two or more electrodes formed over the substrate;
• a cap;
• an electrolyte, wherein the electrolyte is held within the gas sensor package, in use, in a space encapsulated by the substrate and the cap, and wherein the electrolyte is held over an active sensing region of the electrodes by at least a one of a hydrophobic or a hydrophilic material;
• and
• a hydrophobic material, including a hydrophobic layer arranged on the inner surface of the cap of the electrochemical sensor so as to repel electrolyte away from the inner surface of the cap.

A method of manufacturing an electrochemical sensor, the method comprising:

• providing a housing;
• forming two or more electrodes within the housing so as to define an active region;
• forming an electrolyte over the two or more electrodes;
• and
• forming a hydrophobic material within the housing so as to encourage the electrolyte to be positioned over the active region;
• and
• forming a hydrophobic layer arranged on the inner surface of a cap of the electrochemical sensor so as to repel electrolyte away from the inner surface of the cap.