Diamond-like Carbon Coated Electrodes for Corrosion Sensors

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Solution Overview

Problem

Existing electrochemical corrosion monitoring sensors face challenges in maintaining accurate corrosion rate calculations due to surface area changes caused by crevice formation between electrode and housing materials in corrosive environments, leading to premature failure.

Innovation Solution

A diamond-like carbon coating is applied to electrodes with a thickness of greater than 10 nanometers, ensuring the exposed surface area remains substantially constant, thereby preventing corrosion on non-exposed surfaces and maintaining accurate corrosion rate calculations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If no coating is applied to electrodes, then the sensor is simpler and cheaper, but crevices form between electrode and housing materials causing surface area changes and inaccurate corrosion rate calculations

Engineering Contradiction:

Improvecorrosion rate calculation accuracyVSAvoidsensor structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

A diamond-like carbon coating is applied as an intermediary layer between the electrode and the corrosive environment. This coating prevents direct contact between the electrode material and corrosive substances, eliminating crevice formation while maintaining electrical conductivity for accurate corrosion rate measurements.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The electrode is constructed as a composite structure with a diamond-like carbon coating layer deposited on the base electrode material. This composite structure combines the corrosion resistance of diamond-like carbon with the electrical conductivity needed for electrochemical measurements, resolving the contradiction between protection and measurement accuracy.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a coating is applied to electrodes, then corrosion resistance improves and surface area remains constant, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvesensor durability in corrosive environmentVSAvoidsensor fabrication process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The traditional mechanical sealing method between electrode and housing is replaced by a diamond-like carbon coating process. This coating is applied through vapor deposition or chemical vapor deposition techniques, creating a protective layer that eliminates the need for complex mechanical sealing structures and maintains surface area consistency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The surface properties of the electrode are changed by depositing a diamond-like carbon coating with specific thickness and composition parameters. This coating modification transforms the electrode surface to be both corrosion-resistant and electrically conductive, improving reliability without requiring complex manufacturing assemblies.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If the exposed surface area increases to compensate for crevice formation, then more measurement surface is available, but corrosion rate calculations become inaccurate due to changing surface area

Engineering Contradiction:

Improvecorrosion rate calculation accuracyVSAvoidexposed surface area consistency

Core Design Contradiction:

Measurement precisionVSStability of the object's composition

Solution Approach 1:

The diamond-like carbon coating is applied preliminarily to the electrode surface before the electrode is installed in the corrosive environment. This pre-protection ensures that the exposed surface area remains constant during service, as the coating prevents crevice formation and material degradation, thereby maintaining measurement accuracy throughout the sensor's operational life.

Inventive Principle:

Principle #10Preliminary action

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 diamond-like carbon coating effectively confines corrosion to the exposed surface area, maintaining a consistent surface area and ensuring accurate corrosion rate calculations, reducing the risk of premature sensor failure in corrosive environments.

Implementation Method 1

The sensor may include a plurality of electrodes including a diamond like coating on at least a portion of the electrodes. The coating may have a thickness of greater than 10 nanometers.

Methodology Applied

Scientific EffectDiamond-like carbon coating: Diamond-like Carbon

Data Source

PatentUS7722748B2Apparatus for measuring electrochemical corrosion

Publication Date: 2010.05.25 SOUTHWEST RES INST

AI summary

Disclosed herein is an electrochemical corrosion sensor. The sensor may include an array of electrodes wherein each electrode may include a diamond like carbon coating disposed on at least a portion of the electrodes. The coating thickness may be at least about 1 micron. The electrodes may therefore provide relatively more accurate determination of electrode corrosion rates that may be more consistent with coupon type gravimetric testing.