Corrosion Sensor Using Segmented Metal Films
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Solution Overview
Problem
Existing corrosive environment monitoring devices face challenges in accurately measuring corrosion on-site within electronic device housings without specialized analyzers or power sources, particularly in varying environments, and struggle to correct for large variations in corrosion data.
Innovation Solution
A corrosive environment monitoring device featuring multiple sets of metal thin films with different dimensions and exposure configurations, allowing for simultaneous measurement of corrosion thickness using both ASHRAE and ISO11844-1 standards without requiring a power source, by utilizing the difference in corrosion behavior between wider and narrower sensors and higher and lower openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single metal thin film sensor is used, then the device structure is simple, but the measurement accuracy is insufficient due to large variations in corrosion data across different environments
Solution Approach 1:
The patent divides the single sensor into multiple segments with different characteristics. Specifically, it uses multiple metal thin film sensors with different widths (wider and narrower sensors) and different opening configurations (higher and lower openings) to segment the measurement function, allowing each segment to capture different aspects of corrosion behavior under varying environmental conditions.
Solution Approach 2:
The patent applies local quality by creating sensors with non-uniform properties. The metal thin films have different local characteristics including varying widths, different positions relative to openings, and different exposure configurations. This allows each local region of the sensor system to respond differently to corrosive environments, enabling more accurate overall measurement through comparison and averaging.
2Measurement precision
If multiple metal thin films with different dimensions are used, then measurement accuracy improves, but the device complexity increases
Solution Approach 1:
The patent achieves universality by designing a multi-functional sensor system where multiple metal thin film sensors serve different measurement purposes simultaneously. The wider and narrower sensors, along with higher and lower opening configurations, collectively provide measurement capabilities for both ASHRAE and ISO11844-1 standards, making the device universally applicable to different measurement standards and environmental conditions.
Solution Approach 2:
The patent merges multiple sensor types and configurations into a single integrated device. Instead of using separate devices for different measurement standards, it combines wider and narrower metal thin film sensors with different opening configurations into one unified monitoring device, allowing simultaneous measurement and comparison across multiple parameters.
3Measurement precision
If specialized analyzers are used for corrosion measurement, then measurement accuracy improves, but the device cannot be used on-site without power source
Solution Approach 1:
The patent implements self-service by enabling the corrosion sensors to function autonomously without requiring external power sources or specialized analyzers. The metal thin film sensors naturally undergo corrosion in the environment, and the corrosion products themselves serve as the measurement signal, eliminating the need for powered analytical equipment and enabling true on-site deployment.
Solution Approach 2:
The patent replaces complex mechanical or electronic analytical systems with a simpler chemical-physical process. Instead of using powered analyzers that require electricity and complex mechanisms, it relies on the natural corrosion process and optical observation of corrosion products, substituting a passive chemical-physical measurement system for an active mechanical-electronic one.
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 accurate, on-site measurement of corrosion in electronic device housings for short to long-term exposure periods, effectively diagnosing corrosiveness in both clean and polluted environments by averaging multiple measurement methods, improving measurement accuracy and applicability to diverse standards.
Implementation Method 1
copper, silver, aluminum, iron, and zinc corrode with any of corrosive gases such as SO 2 , NO 2 , and H 2 S
Implementation Method 2
a prescribed period, through the transparent substrate, and the metal thin film of the first corrosive environment monitoring device
Data Source
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AI summary
An object of the present invention is to provide a corrosive environment monitoring device which can measure the degree of corrosion of metal in a tiny space inside an electronic device housing as an object of diagnosis on the spot for a short to long term without the need for a special analyzer and without the need for a power source such as a commercial power supply or battery. The corrosive environment monitoring device includes a sensor part in which a box-shaped passage structure with one end closed and the other end as an opening has a metal thin film 2 located on one face of the top, bottom or side face of the opening and the metal thin film is covered by a transparent substrate. The corrosive environment monitoring device includes a plurality of corrosive environment monitoring parts located adjacent to the opening and corrosion detection conditions of the metal thin film in the plural corrosive environment monitoring parts are differentiated.