Ceramic Probe Electrochemical Sensor for Gap-Free Sealing
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Solution Overview
Problem
Existing electrochemical sensors face issues with complex construction, susceptibility to medium penetration due to gaps between electrodes and seal support bodies, and thermal expansion discrepancies between synthetic materials and metal electrodes, leading to sealing failures and hygiene concerns, especially in food and pharmaceutical applications.
Innovation Solution
The electrodes are embedded partially in a ceramic probe body with thin, conductive material layers and connection elements, ensuring a gap-free material transition and sealing, using materials with similar thermal expansion coefficients to maintain stability across temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If synthetic materials are used for the probe body, then manufacturing is easier and costs are lower, but thermal expansion discrepancies cause gaps between electrodes and probe body leading to sealing failures
Solution Approach 1:
The patent changes the material parameter of the probe body from synthetic material to ceramic material specifically to match the thermal expansion coefficient of metal electrodes. This parameter change eliminates thermal expansion discrepancies and prevents gap formation during temperature fluctuations, thereby maintaining sealing reliability while still allowing for manufacturing through established ceramic processes.
Solution Approach 2:
The patent employs a composite material solution by using ceramic material that combines the properties of thermal expansion matching with metal electrodes and electrical insulation. This composite approach creates a material system where the ceramic body provides both the necessary thermal stability and electrical non-conductivity, resolving the contradiction between ease of manufacture and sealing reliability.
2Reliability
If conventional seals are used to prevent medium penetration, then sealing is achieved, but construction complexity increases and assembly becomes more complex
Solution Approach 1:
The patent extracts and eliminates the separate seal components from the sensor construction. By designing the probe body and electrodes to form an integral, gap-free structure, the invention removes the need for additional seals and seal support bodies, thereby reducing construction complexity and assembly steps while maintaining sealing reliability.
Solution Approach 2:
The patent merges the probe body and electrodes into a unified, integrated structure where the ceramic probe body directly contacts and seals around the electrodes without intermediate sealing components. This merging eliminates the complexity of assembling multiple parts and reduces the number of components, while the gap-free design ensures reliable sealing against medium penetration.
3Ease of manufacture
If synthetic materials are used for the probe body, then manufacturing is simpler, but long term durability decreases due to aging and increased porosity
Solution Approach 1:
The patent uses ceramic material as a more durable alternative to synthetic materials while maintaining manufacturability. The ceramic probe body resists aging, maintains low porosity, and withstands aggressive media and temperature changes, thereby significantly improving long-term durability without requiring complex manufacturing processes.
Solution Approach 2:
The patent changes the material parameter from synthetic polymer to ceramic, which fundamentally improves durability characteristics. The ceramic material exhibits resistance to chemical degradation, maintains structural integrity under temperature cycling, and prevents medium diffusion, thereby extending the service life of the sensor while remaining manufacturable through standard ceramic processing techniques.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design provides a stable, gap-free seal and improved durability, meeting high hygiene standards while reducing manufacturing costs and minimizing gaps, suitable for process measurements in demanding environments.
Implementation Method 1
at least one probe body of a second, electrically non-conductive material... the electrodes are embedded in the probe body and insulated from one another by the probe body
Implementation Method 2
the electrodes are electrically contacted via connection elements extending through the probe body
Data Source
AI summary
An electrochemical sensor comprising a probe immersible in a measured medium and having at least two electrodes of a first electrically conductive material and at least one probe body of a second, electrically non-conductive material. The electrodes are at least partially embedded in the probe body and insulated from one another by the probe body, wherein the at least two electrodes are embodied of at least one conductive material and the probe body of at least one electrically insulating ceramic, wherein the electrodes are embodied of thin, measuring active layers of a conductive material and sit in an end face of the probe body of a ceramic material, and wherein the electrodes are electrically contacted via connection elements extending through the probe body.