Electrochemical Conductive Sensor for Non-Destructive Coating Inspection
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Solution Overview
Problem
Existing methods for inspecting the integrity and uniformity of coatings and three-dimensional structures in components like automobiles and aircraft often require destructive testing, and there is a need for non-destructive systems to detect degradation and foreign material formation.
Innovation Solution
An electrochemical sensor system with a sensor body comprising a first and second container, electrodes, and a conductive media, which allows for non-destructive testing by depositing conductive media on the component surface to evaluate material properties and detect corrosion or foreign materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive testing methods are used to detect corrosion and degradation, then measurement precision is improved, but the component integrity is compromised and maintenance time increases
Solution Approach 1:
The patent replaces destructive mechanical testing methods with electrochemical sensing methods. The sensor system uses electrochemical reactions between conductive media and metal surfaces to detect corrosion and degradation without physically damaging the component, thereby maintaining component integrity while achieving accurate measurement of material properties
Solution Approach 2:
The patent introduces conductive media as an intermediary substance that facilitates the detection process. The conductive media serves as a mediator between the sensor electrodes and the metal surface, enabling electrochemical measurement of corrosion and degradation without direct contact that would cause damage, thus resolving the contradiction between measurement accuracy and component preservation
2Reliability
If non-destructive testing methods are used to preserve component integrity, then reliability is improved, but measurement precision for detecting degradation and foreign materials deteriorates
Solution Approach 1:
The patent changes the measurement parameters by using electrochemical parameters (current, voltage, impedance) instead of mechanical parameters. By measuring electrochemical responses of the conductive media to corrosion products and foreign materials, the system achieves high detection precision while maintaining component integrity through non-contact or minimal-contact measurement
3Measurement precision
If complex sensor systems with multiple containers and movable elements are used, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The patent divides the sensor system into segmented functional modules: a first container for holding conductive media, a second container for receiving it, electrodes for measurement, and movable elements for controlled dispensing. This segmentation allows each component to perform a specific function, improving measurement capability while keeping individual components simple and manageable
4Measurement precision
If conductive media is deposited on component surfaces for testing, then measurement precision is improved, but the component surface may be contaminated or damaged
Solution Approach 1:
The patent changes the physical state and composition parameters of the conductive media to minimize harmful effects. By carefully controlling the chemical composition, viscosity, and conductivity of the media, the system achieves accurate surface evaluation while the media can be formulated to be non-contaminating or easily removable, reducing surface damage and contamination
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 non-destructive evaluation of coating uniformity, composition, and component integrity, identifying foreign materials, and determining the need for maintenance or repair, using smart technology for data analysis and visualization.
Implementation Method 1
a conductive media disposed in the first cavity, the second cavity being configured to receive the conductive media from the first cavity
Implementation Method 2
The first container is fluidly coupled to the second container
Data Source
AI summary
The present disclosure provides a sensor system including one or more sensors having a first container fluidly coupled to a second container, the second container being configured to receive a conductive media from the first container. A first movable element is slidingly engaged with the first container to cause the second container to receive the conductive media from the first container. A first electrode is positioned in the first cavity and electrically coupled to the conductive media. In some examples, a second electrode is electrically coupled to the first electrode and the conductive media. The sensor deposits the conductive media on a working electrode to form an electrochemical cell and obtain one or more material properties of the working electrode. In some examples, the sensor system includes an array of sensors which deposit the conducive media in multiple locations on a working electrode to generate a material property map.