Corrosion Sensor with Seamless Conductive Joints
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Solution Overview
Problem
Conventional corrosion sensors are prone to crevice corrosion, which degrades their sensitivity and accuracy over time due to the degradation of the bond between electrodes and dielectric material, leading to inaccurate monitoring of corrosion rates in harsh environments.
Innovation Solution
The development of a corrosion sensor with smaller, closely spaced conductive portions and a seamless joint between conductive and non-conductive materials, manufactured using direct write deposition techniques such as dip pen nanolithography or thermal spraying, to prevent crevice corrosion and maintain accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional corrosion sensors use alternating layers of electrodes and dielectric material, then the sensor can monitor general corrosion rates, but the bond between electrodes and dielectric material degrades over time creating gaps that lead to crevice corrosion
Solution Approach 1:
The patent merges the conductive and non-conductive portions into a single integrated structure where the non-conductive material directly contacts the metal surface and the conductive portions are formed within or as part of this continuous structure. This eliminates the separate bonding interface between electrodes and dielectric material that causes degradation and crevice corrosion in conventional sensors.
Solution Approach 2:
The sensor uses composite material structures where conductive portions (such as metal or conductive ceramic) are integrated with non-conductive portions (such as ceramic or polymer) in a seamless manner. This composite approach allows the sensor to maintain both electrical conductivity where needed and corrosion resistance at the metal interface, preventing the separation and crevice formation that occurs in layered conventional designs.
2Measurement precision
If crevice corrosion occurs between electrodes and dielectric material, then larger surface area of electrodes is exposed to hot gas path increasing electrical potential, but this changes calibration and reduces sensor accuracy
Solution Approach 1:
The patent applies preliminary anti-action by designing a sensor structure that prevents crevice corrosion from occurring in the first place. The seamless integration of conductive and non-conductive portions with direct contact between the non-conductive material and metal surface eliminates the crevice-prone interfaces before corrosion can initiate, rather than attempting to correct calibration drift after crevice corrosion has occurred.
Solution Approach 2:
The patent converts the potential harm of material interfaces into a benefit by using the interface between conductive and non-conductive portions as a controlled, seamless transition zone rather than a separate bonding interface. This design transforms what would traditionally be a vulnerability point into a strengthened, integrated structure that actually enhances corrosion resistance while maintaining measurement functionality.
3Reliability
If direct write deposition techniques are used to create seamless joints, then crevice corrosion is prevented, but the manufacturing process complexity increases
Solution Approach 1:
The patent replaces traditional mechanical assembly processes (such as separate bonding of electrodes and dielectric layers) with direct write deposition techniques. This substitution allows for the creation of seamless joints between conductive and non-conductive portions through additive manufacturing methods, eliminating the need for complex multi-step assembly and bonding operations while achieving superior corrosion resistance.
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 new corrosion sensor design enhances sensitivity and resistance to crevice corrosion, providing reliable and accurate monitoring of corrosion rates on metallic substrates, reducing the occurrence of crevice corrosion and maintaining calibration over time.
Implementation Method 1
The general corrosion rate occurring on the metal surfaces 12 may thus be determined using a sensor 18 to measure the electrical potential or current flow across the electrodes 14
Implementation Method 2
The general corrosion is characterized by an oxidation-reduction reaction in which the metal surfaces are oxidized, producing an anode at the oxidation site and a cathode at the reduction site
Data Source
Figure 1
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Figure 4
AI summary
A corrosion sensor (20) includes a plurality of conductive portions (24) and at least one non-conductive portion (26) between adjacent conductive portions (24), wherein the at least one non-conductive portion (26) has a dimension less than approximately 500 microns. A method for manufacturing a corrosion sensor (20) includes applying a non-conductive material (52) to a substrate and applying a conductive material (54) to discrete locations on the non-conductive material (52). The method further includes applying a brazing material (56) around each discrete location of the conductive material (54).