Corrosive Gas Sensor Laminate for On-Site Type Identification
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Solution Overview
Problem
Conventional corrosive environment monitoring systems struggle to identify the type of corrosive gas causing corrosion without requiring specialized skills or instruments, especially in remote locations, leading to prolonged diagnosis times and inaccurate risk assessment.
Innovation Solution
A corrosive environment monitoring system with a laminate sensor comprising a base metal thin film and sensing metal thin film, along with a resistance value measurement unit and determination unit, allows for on-site identification of corrosive substances by measuring changes in electric resistance over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If gas is taken from the site and analyzed with a special instrument, then the gas type can be detected, but it requires special skills and takes a long time (about one month for overseas locations)
Solution Approach 1:
The patent creates a virtual copy of the gas analysis process by using a sensor that simulates corrosion behavior through electrical resistance changes. Instead of physically transporting gas samples to remote laboratories, the sensor locally replicates the diagnostic function by measuring resistance changes that correspond to different gas types, enabling immediate on-site identification without requiring specialized equipment or expertise.
Solution Approach 2:
The patent replaces the mechanical/physical system of gas sampling and transportation with an electrical measurement system. The sensor uses electrical resistance measurements to detect gas types, substituting the need for physical gas analysis instruments and specialized mechanical sampling equipment with a simpler electrical measurement approach that can be performed locally.
2Measurement precision
If an analytical instrument is brought to the site to identify the gas type, then the corrosion risk can be diagnosed more correctly, but it is extremely difficult to bring instruments to various environments especially remote places
Solution Approach 1:
The patent extracts the essential diagnostic function from complex analytical instruments and concentrates it into a simple sensor that measures only electrical resistance changes. By taking out only the necessary measurement capability (resistance measurement) and removing all unnecessary components of full analytical instruments, the system becomes portable and suitable for remote locations while maintaining diagnostic accuracy.
Solution Approach 2:
The sensor is designed as a simple, inexpensive device that can be deployed to remote locations without requiring expensive analytical instruments. The sensor accepts corrosion and provides accurate measurements throughout its service life, enabling corrosion risk diagnosis in environments where bringing expensive equipment would be impractical.
3Reliability
If conventional sensor with first and second metal thin films is used, then corrosion state can be monitored, but the type of corrosive gas cannot be detected
Solution Approach 1:
The patent applies local quality by using different metal thin films with specific corrosion characteristics in different regions of the sensor. The first metal thin film has high corrosion resistance for stable baseline measurements, while the second metal thin film is more susceptible to corrosion for detecting gas types. This spatial differentiation of material properties enables both reliable monitoring and gas type identification.
Solution Approach 2:
The patent utilizes parameter changes in electrical resistance as corrosion progresses differently in the first and second metal thin films. By measuring how resistance changes over time and comparing the rates of change between the two films, the system can identify gas types while maintaining reliable corrosion monitoring. The different corrosion rates serve as diagnostic parameters for gas identification.
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 and accurate determination of corrosive gas types without specialized skills, reducing labor and costs, and providing timely corrosion risk assessment.
Implementation Method 1
a sensing metal thin film formed in at least a partial region of the base metal thin film and formed of a metal that is more easily corroded by a corrosive substance compared to the base metal thin film
Implementation Method 2
a resistance value measurement unit that detects an electric resistance between two points on the base metal thin film of the corrosive environment monitoring sensor
Data Source
AI summary
Prepared is a layered body comprising: an insulation plate; a base metal thin film formed on the insulation plate; and a sensing metal thin film which is formed on at least a partial area of the base metal thin film, is more easily corroded by a corrosive substance than the base metal thin film, and has a lower resistance value than the base metal thin film. A corrosive environment monitoring sensor includes this layered body, and has an opening unit in a side surface direction, and a case having a gas passage of a corrosive substance therein. The present invention detects electric resistance between two positions on the base thin film of this sensor, and determines the type of the corrosive substance from a temporal change of the electric resistance.