Metal Atmospheric Corrosion Monitoring Sensor

Abstract

The metal atmospheric corrosion monitoring sensor of the present application includes a metal substrate, a hydrophobic insulating plate, a conductive material layer and a hydrophilic coating; the hydrophobic insulating plate is attached to the metal substrate, and the area of the hydrophobic insulating plate is smaller than the surface area of the metal substrate; the conductive material layer is provided on the hydrophobic insulating plate, the surface area of the conductive material layer is smaller than the surface area of the hydrophobic insulating plate, and the edge of the conductive material layer is located within the edge range of the hydrophobic insulating plate; the hydrophilic coating is coated between the edge of the conductive material layer and the edge of the hydrophobic insulating plate; wiring is respectively drawn out from the metal substrate and the conductive material layer, and a zero-resistance ammeter is connected to form a loop between the metal substrate, the zero-resistance ammeter and the conductive material layer. The processing technology of the present application is simple, the product consistency is easy to control, and the detection sensitivity is high.

Description

Technical field

[0001] The present application relates to the field of sensor technology, and in particular to a monitoring sensor for measuring corrosion variation patterns of metal materials when exposed to an atmospheric environment. [Background Technology]

[0002] Metal materials exposed to the atmospheric environment are prone to corrosion, which can degrade the mechanical and electrical properties of the equipment. To obtain information on the corrosion status of metals, an online atmospheric corrosion monitoring device can be installed. The core of the device is the atmospheric corrosion monitoring sensor, which is a key component that converts corrosion signals into electrical signals. The main principle of the atmospheric corrosion monitoring sensor is to capture the amount of charge transferred during the metal corrosion process and characterize the degree of corrosion by the amount of charge. The faster the metal corrosion rate, the higher the degree, and the greater the amount of corrosion charge, the more corrosive the environment is to the metal. The sensor itself is a consumable electrochemical device, and its performance changes significantly over time. Therefore, the performance of the sensor restricts the application of online metal corrosion monitoring technology.

[0003] The structure and process of sensors are key factors in improving their performance. Key challenges with these technologies include: structural features requiring high manufacturing process requirements, difficulty controlling the consistency of finished products, material size reducing measurement sensitivity, and structural shape affecting service life. These issues result in poor monitoring effectiveness and high costs for existing sensors, making them unsuitable for large-scale deployment. To improve the performance of metal atmospheric corrosion monitoring sensors, improvements in both structure and process are urgently needed.

[0004] Therefore, it is necessary to provide a metal atmospheric corrosion monitoring sensor with high sensitivity, long service life and accurate detection effect. [Summary of the invention]

[0005] The purpose of this application is to provide a metal atmospheric corrosion monitoring sensor with high sensitivity.

[0006] To achieve the purpose of this application, the following technical solutions are provided:

[0007] The present application provides a metal atmospheric corrosion monitoring sensor, which includes a metal substrate, a hydrophobic insulating plate, a conductive material layer and a hydrophilic coating; the hydrophobic insulating plate is attached to the metal substrate, and the area of the hydrophobic insulating plate is smaller than the surface area of the metal substrate; the conductive material layer is provided on the hydrophobic insulating plate, the surface area of the conductive material layer is smaller than the surface area of the hydrophobic insulating plate, and the edge of the conductive material layer is located within the edge range of the hydrophobic insulating plate; the hydrophilic coating is coated between the edge of the conductive material layer and the edge of the hydrophobic insulating plate; wiring is respectively drawn from the metal substrate and the conductive material layer, and a zero-resistance ammeter is connected to form a loop between the metal substrate, the zero-resistance ammeter and the conductive material layer. The technical solution of the present application adopts a simple stacking structure, a simple processing technology, and easy control of product consistency. The hydrophilic coating is used to improve the adhesion and ductility of the thin liquid film, increase the corrosion current under low humidity, and thus improve the detection sensitivity.

[0008] In some embodiments, the hydrophobic insulating plate and the conductive material layer are both comb-shaped structures, and the comb-shaped structure includes an integral base and at least two comb-shaped strips extending from one side of the base.

[0009] In some embodiments, the comb-like strips of the comb-like structure of the conductive material layer are centrally disposed on the comb-like strips of the comb-like structure of the hydrophobic insulating plate. Furthermore, the distance between the side edges of the comb-like strips of the conductive material layer and the side edges of the comb-like strips of the hydrophobic insulating plate is 0.05 mm to 0.5 mm.

[0010] In a specific embodiment, the hydrophilic coating is applied between the edges of the comb-like strips of the comb-like structure of the conductive material layer and the edges of the comb-like strips of the comb-like structure of the hydrophobic insulating plate. Furthermore, the hydrophilic coating is rectangular and covers the gaps between the edges of the comb-like strips of the comb-like structure of the conductive material layer and the edges of the comb-like strips of the comb-like structure of the hydrophobic insulating plate.

[0011] In some embodiments, the connections between the comb-like bars of the comb-like structure of the hydrophobic insulating plate are provided with inwardly rounded corners to prevent water droplets from settling at sharp corners. Furthermore, the ends of the comb-like bars of the comb-like structure of the hydrophobic insulating plate are provided with rounded corners.

[0012] In a specific embodiment, the metal substrate is a metal or alloy material with a smooth surface and no corrosion.

[0013] In a specific embodiment, the conductive material layer can be a conductive material that is not easily corroded in air, such as gold, silver, copper, nickel, or carbon film. The hydrophobic insulating plate can be made of epoxy resin, silicone rubber, or Teflon, and the hydrophilic coating can be made of an organic glue containing polar groups.

[0014] In some embodiments, the hydrophobic insulating plate has a thickness of 0.02 mm to 0.1 mm.

[0015] Compared with the existing technology, this application has the following advantages:

[0016] (1) Simple laminated structure and simple processing technology. The conductive material layer and hydrophilic coating can be coated on the surface of the hydrophobic insulating board through factory production;

[0017] (2) Product consistency is easy to control, and the insulating board, conductive material layer and hydrophilic coating can be designed and manufactured with the help of printed circuit board design software and processing methods;

[0018] (3) The material size can reach 0.01 mm, and the hydrophilic coating is used to improve the adhesion and ductility of the thin liquid film, thereby increasing the corrosion current under low humidity;

[0019] (4) The comb-like structure prevents water droplets from accumulating on the sensor surface, slowing down the corrosion and consumption of the measured metal and extending the service life of the sensor.

Brief Description of the Drawings

[0020] Figure 1 A schematic diagram of the structure of a metal atmospheric corrosion monitoring sensor provided in an embodiment of the present application;

[0021] Figure 2 A cross-sectional view of a metal atmospheric corrosion monitoring sensor provided in an embodiment of the present application;

[0022] Figure 3 This is a diagram showing the working principle of the metal atmospheric corrosion monitoring sensor provided in an embodiment of the present application. [Specific implementation method]

[0023] See also Figure 1 and Figure 2 The schematic structural diagram and cross-sectional view of a specific embodiment of a metal atmospheric corrosion monitoring sensor of the present application are shown. The metal atmospheric corrosion monitoring sensor comprises a metal substrate 100, a hydrophobic insulating plate 200, a conductive material layer, and a hydrophilic coating 400. The metal substrate 100 is the metal material to be measured and is a flat, uncorroded metal or alloy material, such as iron, aluminum, copper, zinc, or galvanized steel. The conductive material layer is a gold-plated layer 300. The hydrophobic insulating plate can be made of an epoxy resin plate, a silicone rubber plate, or a Teflon plate, and the hydrophilic coating can be made of an organic glue containing polar groups.

[0024] The hydrophobic insulating plate 200 is attached to the metal substrate 100, and the area of the hydrophobic insulating plate 200 is smaller than the surface area of the metal substrate 100. Specifically, the hydrophobic insulating plate 200 is attached to the metal substrate 100, and the edge does not exceed the surface of the metal substrate 100.

[0025] The gold-plated layer 300 is disposed on the hydrophobic insulating plate 200 . The surface area of the gold-plated layer 300 is smaller than that of the hydrophobic insulating plate 200 , and the edge of the gold-plated layer 300 is located within the edge range of the hydrophobic insulating plate 200 .

[0026] In this embodiment, the hydrophobic insulating plate 200 and the gold-plated layer 300 are both comb-shaped structures, and the comb-shaped structures respectively include an integral base 201, 301 and at least two comb-shaped strips 202, 302 extending from one side of the base. In this embodiment, four comb-like bars 202 and 302 extend from one side of the comb-like structure bases 201 and 301 of the hydrophobic insulating plate 200 and the gold-plated layer 300, respectively. The spacing between the four comb-like bars 302 of the gold-plated layer 300 matches the spacing between the four comb-like bars 202 of the hydrophobic insulating plate 200, so that the four comb-like bars 302 of the gold-plated layer 300 are respectively arranged on the four comb-like bars 202 of the hydrophobic insulating plate 200, and the area of each comb-like bar 302 of the gold-plated layer 300 is smaller than the area of the comb-like bar 202 of the hydrophobic insulating plate 200 below it. The edges of the comb-like bars 302 of the gold-plated layer 300 are located within the edge range of the comb-like bars 202 of the hydrophobic insulating plate 200.

[0027] In this embodiment, the comb strips 302 of the comb-like structure of the gold-plated layer 300 are centrally disposed on the comb strips 202 of the comb-like structure of the hydrophobic insulating plate 200. That is, the side edges of the comb strips 302 of the comb-like structure of the gold-plated layer 300 are equidistant or approximately equidistant from the side edges of the comb strips 202 of the comb-like structure of the hydrophobic insulating plate 200. Furthermore, the side edges of the comb strips 302 of the gold-plated layer are 0.05 mm to 0.5 mm apart from the side edges of the comb strips 202 of the hydrophobic insulating plate. In a specific embodiment, the thickness of the hydrophobic insulating plate 200 can range from 0.02 mm to 0.1 mm. The gold-plated layer 300 can be coated on the surface of the hydrophobic insulating plate 200 through factory production.

[0028] The hydrophilic coating 400 is coated between the side edges of the comb strips 302 of the gold-plated layer 300 and the side edges of the comb strips 202 of the hydrophobic insulating plate 200; in a specific embodiment, the hydrophilic coating 400 coated between the side edges of the comb strips 302 of the comb-like structure of the gold-plated layer and the side edges of the comb strips 202 of the comb-like structure of the hydrophobic insulating plate is rectangular, and is factory-produced and coated in the gaps between the side edges of the comb strips of the comb-like structure of the gold-plated layer and the side edges of the comb strips of the comb-like structure of the hydrophobic insulating plate.

[0029] In this embodiment, the connections between the comb bars 202 of the hydrophobic insulating plate 200 are provided with inwardly curved chamfered corners 203, specifically forming semicircular indentations to prevent water droplets from accumulating at sharp corners. Furthermore, the ends of the comb bars 202 of the hydrophobic insulating plate 200 are provided with curved rounded corners 204, specifically forming semicircular ends at the ends of each comb bar 202. The hydrophilic coating 400 is applied along the straight edges of the comb bars 202 of the hydrophobic insulating plate 200, flush with the ends of the comb bars 302 of the gold-plated layer 300.

[0030] Please refer to Figure 3 Wires 700 are drawn from the metal substrate 100 and the gold-plated layer 300, respectively, and connected to a zero-resistance ammeter 600, forming a circuit between the metal substrate 100, the zero-resistance ammeter 600, and the gold-plated layer 300. The gold-plated layer 300 serves as the positive electrode of the metal atmospheric corrosion monitoring sensor, and the metal substrate 100 serves as the negative electrode of the metal atmospheric corrosion monitoring sensor. Both the positive and negative electrodes are crimped using gold-plated probes and connected to the zero-resistance ammeter 600.

[0031] Figure 3 In the illustrated embodiment, the metal substrate 100 is iron. When the surface of the metal atmospheric corrosion monitoring sensor is wetted to form a water film 500, which bridges the gold-plated layer 300 and the metal substrate 100 being tested, the sensor forms a corrosion couple. The metal substrate 100 being tested, in contact with the water film 500, loses electrons to form cations. Current is transferred to the gold-plated layer 300 via a zero-resistance ammeter 600. The gold-plated layer 300, in contact with the water film 500, gains electrons, which combine with oxygen and water to form hydroxide ions. By detecting the amount of charge transfer, the corrosion rate and extent of the metal substrate being tested can be measured.

[0032] In other embodiments, the conductive material layer may also be a conductive material that is not easily corroded in the air, such as silver plating, copper plating, nickel plating, or carbon film.

[0033] The technical solution of this application adopts a simple stacking structure, simple processing technology, and easy to control product consistency. It uses a hydrophilic coating to improve the adhesion and ductility of the thin liquid film, increase the corrosion current under low humidity, and thus improve the detection sensitivity.

[0034] The above description is only a preferred embodiment of the present application, and the protection scope of the present application is not limited thereto. Any equivalent transformation based on the technical solution of the present application falls within the protection scope of the present application.

Claims

1. A metal atmospheric corrosion monitoring sensor, characterized in that: It includes a metal substrate, a hydrophobic insulating plate, a conductive material layer and a hydrophilic coating. The hydrophobic insulating plate is attached to the metal substrate, and the area of the hydrophobic insulating plate is smaller than the surface area of the metal substrate; The conductive material layer is disposed on the hydrophobic insulating plate, the surface area of the conductive material layer being smaller than the surface area of the hydrophobic insulating plate, and the edge of the conductive material layer being located within the edge range of the hydrophobic insulating plate; the hydrophobic insulating plate and the conductive material layer both have a comb-like structure, the comb-like structure comprising an integrally connected base and at least two comb-like strips extending from one side of the base; the junctions between the comb-like strips of the comb-like structure of the hydrophobic insulating plate are provided with inwardly rounded corners to form a semicircular concave vacancy; The hydrophilic coating is coated between the edge of the conductive material layer and the edge of the hydrophobic insulating plate; Wiring is led out from the metal substrate and the conductive material layer respectively, and a zero-resistance ammeter is connected to form a loop between the metal substrate, the zero-resistance ammeter and the conductive material layer; wherein, when the surface of the metal atmospheric corrosion monitoring sensor is moistened to form a water film, and the water film bridges the conductive material layer and the metal substrate, the metal atmospheric corrosion monitoring sensor forms a corrosion couple; the metal substrate in contact with the water film loses electrons to form cations, and the current is transferred to the conductive material layer through the zero-resistance ammeter, and the conductive material layer in contact with the water film obtains electrons, thereby realizing the detection of the charge transfer amount through the loop.

2. The metal atmospheric corrosion monitoring sensor according to claim 1, characterized in that: The hydrophilic coating is coated between the edges on both sides of the comb-like strips of the comb-like structure of the conductive material layer and the edges on both sides of the comb-like strips of the comb-like structure of the hydrophobic insulating plate.

3. The metal atmospheric corrosion monitoring sensor according to claim 2, characterized in that: The hydrophilic coating is rectangular and covers the gaps between the edges of the comb-like strips of the comb-like structure of the conductive material layer and the edges of the comb-like strips of the comb-like structure of the hydrophobic insulating plate.

4. The metal atmospheric corrosion monitoring sensor according to claim 1, characterized in that: The ends of the comb-shaped bars of the comb-shaped structure of the hydrophobic insulating plate are provided with arc-shaped rounded corners.

5. The metal atmospheric corrosion monitoring sensor according to any one of claims 1 to 3, characterized in that: The metal substrate is a metal or alloy material with a smooth surface and no corrosion, and the conductive material layer is made of one of gold-plated material, silver-plated material, copper-plated material, nickel-plated material, and carbon film conductive material.

6. The metal atmospheric corrosion monitoring sensor according to any one of claims 1 to 3, characterized in that: The hydrophobic insulating plate has a thickness of 0.02 mm to 0.1 mm.

7. The metal atmospheric corrosion monitoring sensor according to any one of claims 1 to 3, characterized in that: The comb-like bars of the comb-like structure of the conductive material layer are centrally arranged on the comb-like bars of the comb-like structure of the hydrophobic insulating plate.

8. The metal atmospheric corrosion monitoring sensor according to claim 7, characterized in that: The distance between the side edge of the comb-shaped strips of the conductive material layer and the side edge of the comb-shaped strips of the hydrophobic insulating plate is 0.05 mm to 0.5 mm.

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