Electrochemical Gas Sensor Substrate Sealing via Electrode Contact Surfaces
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Solution Overview
Problem
Existing electrochemical gas sensors face challenges in sealing the housing to prevent electrolyte leakage, particularly at points where lead wires are routed through, which compromises signal derivation and integrity.
Innovation Solution
A method involving a substrate with through-openings that are closed by electrode material to create electrically contactable contact surfaces, forming a liquid-tight interface, eliminating the need for lead wires and preventing electrolyte leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead wires are routed through the housing to provide measurement signals, then electrical connection is achieved, but electrolyte leakage and sealing reliability deteriorate
Solution Approach 1:
The patent removes lead wires from the housing structure entirely. Instead of routing wires through the housing wall, the electrode substrate itself serves as the electrical connection element, with contact surfaces formed directly on the substrate that can be connected to external circuitry without penetrating the housing seal.
Solution Approach 2:
The electrode substrate performs multiple functions: it provides the electrochemical sensing function, serves as the electrical connection element for signal derivation, and acts as part of the sealing structure. This eliminates the need for separate lead wires and maintains housing integrity.
2Measurement precision
If lead wires are used for signal derivation, then electrical connection is achieved, but signal derivation quality deteriorates due to electrolyte creep
Solution Approach 1:
The patent extracts the signal derivation function from the lead wire system and relocates it to the electrode substrate contact surfaces. This removes the interface between lead wires and electrolyte that causes creep, eliminating the source of signal degradation.
Solution Approach 2:
The electrode substrate contact surfaces serve as an intermediary between the electrochemical cell interior and external measurement circuitry. This intermediary provides electrical connection without creating a pathway for electrolyte to reach external components, thus preventing creep-related signal degradation.
3Ease of manufacture
If through-openings are left open in the substrate, then manufacturing is simplified, but electrolyte leakage increases
Solution Approach 1:
The patent performs preliminary action by forming contact surfaces on the electrode substrate during the manufacturing process itself, before final assembly. The through-openings are closed with electrode material during substrate fabrication, creating sealed contact surfaces that maintain both manufacturing simplicity and sealing integrity.
Data Source
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Figure 3~4
AI summary
The present invention relates to a method for producing an electrochemical gas sensor and an electrochemical gas sensor obtainable by this method. The method comprises the steps of: providing a substrate, wherein the substrate has a number of through-openings formed in the normal direction of the substrate; applying electrode material to an upper side of the substrate and/or to an underside of the substrate; connecting the electrode material and the substrate such that the number of through-openings is closed by the electrode material in order to obtain a number of electrically contactable contact surfaces on the underside of the substrate, opposite the upper side.