Ceramic Gas Sensor Element With One-Sided Suspension
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Solution Overview
Problem
Ceramic sensors face challenges in achieving mechanical stability, low energy consumption, and dynamic performance, particularly in high-temperature gas sensor applications, where rapid heating and cooling cause mechanical stress and high thermal energy requirements.
Innovation Solution
A ceramic sensor element with a membrane-based design featuring a one-sided suspension of the ceramic carrier, meandering conductor structures, and a carrier foot with recesses for improved heat dissipation, allowing for efficient energy release and reduced mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick wires are used to contact self-supporting chips, then mechanical stability is improved, but thermal capacity increases leading to high energy consumption
Solution Approach 1:
The patent employs a membrane structure with thickness of 10-50 μm instead of thick-wired self-supporting chips. This thin-film membrane provides sufficient mechanical stability while minimizing thermal capacity, enabling rapid heating and cooling with low energy consumption in the temperature range of 200-300 °C.
Solution Approach 2:
The patent changes the structural parameters by transitioning from thick-wired chips to thin-film membranes with controlled thickness (10-50 μm). This parameter change reduces thermal capacity while maintaining mechanical stability through the membrane design and suspension structure.
2Productivity
If membrane systems are used for rapid heating and cooling, then dynamic performance is improved, but mechanical stress increases due to longitudinal expansion
Solution Approach 1:
The patent segments the membrane structure by suspending it on one side only, creating a cantilevered configuration. This segmentation allows the membrane to expand and contract freely in the longitudinal direction during rapid heating and cooling cycles, preventing mechanical stress accumulation while maintaining dynamic performance.
Solution Approach 2:
The one-sided suspension creates an asymmetric structure where the membrane is supported at one end but free at the other. This asymmetry enables differential thermal expansion without generating stress, as the unsupported portion can move freely during temperature changes.
3Speed
If the membrane is heated rapidly, then heating speed is improved, but thermal stress increases leading to sensor destruction
Solution Approach 1:
The patent employs a dynamic membrane structure with one-sided suspension that can adapt to rapid temperature changes. The membrane's flexible support structure allows it to expand and contract dynamically during heating and cooling cycles, preventing thermal stress accumulation while maintaining high heating and cooling speeds.
Solution Approach 2:
The thin-film membrane (10-50 μm) with one-sided suspension acts as a flexible structure that can accommodate rapid thermal expansion and contraction. This flexibility prevents thermal stress buildup during rapid heating, ensuring sensor durability while achieving fast response times.
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
The solution provides enhanced mechanical stability, reduced energy consumption, and improved dynamic performance by minimizing thermal stress and optimizing heat dissipation, enabling efficient operation in harsh environments.
Implementation Method 1
The sensor component consists of a membrane in which the sensitive layers and the contact surfaces are applied to a ceramic carrier designed as a membrane, which is firmly connected to a carrier foot in a one-sided suspension
Implementation Method 2
The disadvantage here is that the heating of the membrane due to the longitudinal expansion of this creates mechanical stress, which can lead to the destruction of the sensors
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a ceramic sensor element with a membrane on which sensitive layers and contact surfaces (4) are attached, wherein the sensitive layers and the contact surfaces (4) are applied to a ceramic support (1) which is firmly connected on one side to a support component, wherein meandering conductor structures (5) and the contact surfaces (4) are arranged on the ceramic support (1).