Atmospheric Corrosion Sensor With Segmented Metal Film
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Solution Overview
Problem
Existing corrosion sensors are costly and complex, providing limited information on atmospheric corrosion in electrical equipment due to corrosive gases, and often require multiple sensing elements and precise environmental control.
Innovation Solution
A low-cost atmospheric corrosion sensor with a gas permeable layer that allows corrosive gas molecules to reach a corrodible metal film, causing corrosion and increasing electrical resistance, enabling continuous monitoring of corrosion progress without the need for multiple metal films of different thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If multiple metal films of different thicknesses are used to detect atmospheric corrosion, then comprehensive corrosion information can be obtained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies segmentation by dividing the single metal film into multiple distinct layers: a base metal film layer and a corrosion-sensitive metal layer. This segmentation allows each layer to serve a specific function - the base layer provides structural support and initial corrosion resistance, while the corrosion-sensitive layer undergoes controlled corrosion to generate detection signals. This resolves the contradiction by achieving comprehensive corrosion information without requiring multiple complete metal films of different thicknesses.
Solution Approach 2:
The patent implements local quality by creating a metal film structure where different regions have different properties. The base metal film layer has high thickness and strong corrosion resistance, while the corrosion-sensitive metal layer has lower thickness and is designed to corrode preferentially. This local differentiation allows the sensor to provide comprehensive corrosion information through a single integrated structure rather than multiple complete films, reducing device complexity while maintaining information completeness.
2Loss of information
If multiple metal films of different thicknesses are used to detect atmospheric corrosion, then comprehensive corrosion information can be obtained, but manufacturing cost increases
Solution Approach 1:
The patent merges the functions of multiple metal films into a single integrated metal film structure consisting of a base metal film layer and a corrosion-sensitive metal layer. This merging eliminates the need to manufacture, handle, and assemble multiple separate metal films of different thicknesses, significantly reducing manufacturing complexity and cost. The combined structure provides comprehensive corrosion information through the differential corrosion behavior of its layers, achieving the same information completeness as multiple separate films would provide.
Solution Approach 2:
The single metal film structure in the patent performs multiple functions simultaneously: the base metal film layer provides structural support and initial corrosion protection, while the corrosion-sensitive metal layer provides corrosion detection functionality. This multi-functionality within a single integrated structure eliminates the need for multiple separate components, reducing manufacturing cost while maintaining comprehensive corrosion information capability.
3Device complexity
If a single metal film is used to detect atmospheric corrosion, then manufacturing cost and device complexity are reduced, but corrosion information completeness is limited
Solution Approach 1:
The patent applies segmentation by dividing the single metal film into multiple distinct layers: a base metal film layer and a corrosion-sensitive metal layer. This segmentation allows each layer to serve a specific function - the base layer provides structural support and initial corrosion resistance, while the corrosion-sensitive layer undergoes controlled corrosion to generate detection signals. This resolves the contradiction by achieving comprehensive corrosion information without requiring multiple complete metal films of different thicknesses.
Solution Approach 2:
The patent implements local quality by creating a metal film structure where different regions have different properties. The base metal film layer has high thickness and strong corrosion resistance, while the corrosion-sensitive metal layer has lower thickness and is designed to corrode preferentially. This local differentiation allows the sensor to provide comprehensive corrosion information through a single integrated structure rather than multiple complete films, reducing device complexity while maintaining information completeness.
4Duration of action of stationary object
If thicker metal film is used to detect atmospheric corrosion, then sensor durability is improved, but corrosion detection sensitivity decreases
Solution Approach 1:
The patent applies segmentation by dividing the single metal film into multiple distinct layers: a base metal film layer and a corrosion-sensitive metal layer. This segmentation allows each layer to serve a specific function - the base layer provides structural support and initial corrosion resistance, while the corrosion-sensitive layer undergoes controlled corrosion to generate detection signals. This resolves the contradiction by achieving comprehensive corrosion information without requiring multiple complete metal films of different thicknesses.
Solution Approach 2:
The patent implements local quality by creating a metal film structure where different regions have different properties. The base metal film layer has high thickness and strong corrosion resistance, while the corrosion-sensitive metal layer has lower thickness and is designed to corrode preferentially. This local differentiation allows the sensor to provide comprehensive corrosion information through a single integrated structure rather than multiple complete films, reducing device complexity while maintaining information completeness.
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 sensor provides comprehensive information on atmospheric corrosion, allowing for accurate prediction of equipment lifetime and effective maintenance planning, while reducing manufacturing costs and sensor complexity.
Implementation Method 1
A low-cost atmospheric corrosion sensor with a gas permeable layer that allows corrosive gas molecules to reach a corrodible metal film
Implementation Method 2
Atmospheric corrosion is an electrochemical process of degradation of materials exposed to corrosive atmosphere
Implementation Method 3
electrical resistance increases until the continuity is broken
Data Source
AI summary
An atmospheric corrosion sensor for detecting corrosion of electrical equipment due to corrosive gas comprising at least one atmospheric corrosion sensing structure placed on at least one insulated corrosion sensor substrate, wherein the atmospheric corrosion sensor comprises at least one gas permeable layer placed on the corrosion sensing structure, wherein the gas permeable layer allows for transferring the molecules of corrosive gases present in the atmosphere to the surface of the sensing structure, opposite to the insulated corrosion sensor substrate, causing it to corrode.