Copper Oxide-Enamel Potentiometric Sensor Element for Robust Manufacture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacture of potentiometric sensors with solid terminal leads is complex and requires multiple steps, and existing designs lack robustness under mechanical and thermal loads.
Innovation Solution
A method involving conditioning a copper or copper-based alloy substrate to form a monovalent copper oxide layer, followed by applying an ion-selective enamel layer, which forms a stable and conductive connection through a transition zone, allowing for a simple and robust sensor element construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional designs with multiple layers and intermediate layers are used, then electrical conductivity and adhesion are improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent removes the intermediate layer from the conventional multi-layer structure. By extracting this component, the design achieves electrical conductivity and adhesion without requiring the additional layer, thus reducing device complexity while maintaining functionality.
Solution Approach 2:
The enamel layer is designed to perform multiple functions simultaneously: it provides ion-selective sensing, ensures adhesion to the substrate, and maintains electrical conductivity. This multi-functionality eliminates the need for separate intermediate layers, reducing overall structure complexity.
2Ease of manufacture
If conventional sensor element construction is used, then manufacturing process is established, but mechanical and thermal stability are insufficient
Solution Approach 1:
The patent employs a composite structure combining copper-based substrate with enamel coating. This composite material approach provides both mechanical strength and thermal stability while maintaining ease of manufacture through a simplified two-component system rather than multiple layers.
3Ease of manufacture
If conventional sensor element construction is used, then manufacturing process is established, but manufacturing complexity increases
Solution Approach 1:
The patent merges the functions of multiple separate layers into a single enamel coating layer. This consolidation reduces the number of manufacturing steps while maintaining the necessary electrical and mechanical properties, thus simplifying the production process.
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 method results in a sensor element with improved mechanical and thermal stability, reduced manufacturing complexity, and enhanced sensor performance, enabling efficient ion concentration or pH value measurement with minimal defects and reduced impedance.
Implementation Method 1
conditioning at least one region of a substrate consisting of copper or of a copper-based alloy having a mass fraction of at least 60% copper, for producing an oxide layer comprising monovalent copper
Implementation Method 2
applying an ion-selective, especially a pH-selective, enamel layer at least to the region of the substrate... which forms a stable and conductive connection through a transition zone
Data Source
AI summary
A method for producing a sensor element for a potentiometric sensor includes conditioning at least one region of a substrate, which consists of copper or a copper-based alloy having a mass fraction of at least 60% of copper, for producing an oxide layer comprising monovalent copper (Cu(I)), and applying an ion-selective, in particular a pH-selective enamel layer at least onto the region of the substrate.