Colorimetric Sensor for Gas Leakage Detection
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Solution Overview
Problem
Existing gas sensors in product manufacturing processes, such as semiconductor and display processes, are ineffective in real-time detection of harmful gas leakage due to their reliance on electrical conductivity changes, which require regular patrols and are costly and less accurate.
Innovation Solution
A colorimetric sensor utilizing submicron fibers bound with a dye that changes color upon reaction with harmful gases, integrated with an adhesive band having a mesh structure for wide-area application, allowing for visual detection of gas leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If semiconductor type gas sensors are used to detect harmful gas leakage, then gas detection capability is provided, but real-time detection cannot be achieved and regular patrols are required
Solution Approach 1:
The patent applies colorimetric detection principle where the sensor changes color when exposed to harmful gases. The colorimetric composition includes dyes or indicators that undergo visible color changes upon reacting with specific gases, enabling immediate visual detection without requiring electronic processing or regular patrols, thus achieving real-time monitoring.
2Reliability
If fixed semiconductor gas sensors are deployed for continuous monitoring, then gas detection is available, but the cost is high and the degree of determination is low
Solution Approach 1:
The patent employs inexpensive colorimetric compositions that can be manufactured at low cost using simple materials such as dyes, indicators, and porous substrates. These sensors are designed to be disposable or easily replaceable, eliminating the need for expensive electronic components while maintaining effective detection capability for continuous monitoring applications.
Solution Approach 2:
The sensor utilizes porous materials with high surface area to volume ratio, such as activated carbon, silica gel, or porous polymers, to enhance gas adsorption capacity. This increases the sensitivity and response speed of the sensor while keeping the material cost low, achieving both continuous monitoring capability and cost-effectiveness.
3Reliability
If portable gas sensors are used for patrols, then gas detection is possible, but accurate identification of leakage portions is difficult
Solution Approach 1:
The patent applies the principle of local quality by creating sensors with spatially distributed colorimetric zones or patterns that can indicate the specific location of gas leakage. Different regions of the sensor may contain indicators sensitive to different gases or show varying color intensities based on local gas concentration, enabling precise identification of leakage portions.
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
Enables rapid, accurate, and cost-effective detection of harmful gas leaks by visualizing color changes, improving safety through high-speed monitoring of toxic gases like Cl2, BCl3, and NH3 in manufacturing processes.
Implementation Method 1
a dye including a metal component having a unique color changed upon reaction with a harmful gas
Implementation Method 2
a space for a spread and adsorption of a gas may be formed between the first fibers by the second fiber
Data Source
AI summary
Disclosed are a colorimetric sensor for detecting harmful gas leakage in a product manufacturing process and a method for manufacturing the colorimetric sensor. The colorimetric sensor according to an embodiment may comprise: a colorimetric composition formed such that a dye including a metal component of which the own color changes when reacting with a harmful gas is bound to submicron fibers in the form of fine particles; and an adhesive band of a mesh structure to which the colorimetric composition is bound.