Embedded Electrode Sensor for Bio-Gas Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensors for bio-gas and infrared optical materials have high manufacturing costs and complex processes due to semiconductor or thick film formation methods, leading to potential defects and reduced reliability.
Innovation Solution
A sensor with embedded electrodes, where conductive layers are stacked with a separation layer and exposed on side surfaces, allowing for adjustable electrode lengths and widths, and a simplified ceramic process to reduce costs and prevent short-circuits, with optional slots or grooves for enhanced sensing surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If semiconductor process or thick film formation process is used to manufacture sensors, then sensing functionality is achieved, but manufacturing cost increases and manufacturing process becomes complicated
Solution Approach 1:
The sensor structure is segmented into distinct functional layers: substrate, first conductive layer, separation layer, second conductive layer, and sensing material layer. This segmentation allows each layer to be optimized independently and simplifies the manufacturing process by enabling sequential deposition of functional layers rather than complex semiconductor processing
Solution Approach 2:
A separation layer is introduced as an intermediary between the first and second conductive layers. This separation layer prevents direct contact and potential short-circuits between conductive layers while allowing independent formation of each layer through sequential deposition processes, thereby simplifying manufacturing
2Productivity
If conventional sensor manufacturing methods are used, then sensors can be produced, but defects due to short-circuit or disconnection of sensing electrode occur
Solution Approach 1:
The separation layer acts as an intermediary barrier between conductive layers, preventing short-circuits. The electrode terminals are formed as intermediaries that reliably connect to conductive layers through controlled exposure and connection processes, preventing disconnection defects
Solution Approach 2:
The conductive layers are formed and positioned in advance before the sensing material layer is deposited. The separation layer is pre-positioned to prevent short-circuits. This preliminary arrangement of critical components ensures reliable electrode connections and prevents defects during subsequent manufacturing steps
3Reliability
If sensing electrode patterns are formed on substrate with coated sensing membrane, then sensing capability is achieved, but manufacturing cost increases
Solution Approach 1:
The conductive layers and separation layer are merged into a single integrated sensor structure formed through sequential deposition. This merging eliminates the need for separate electrode pattern formation and sensing membrane coating processes, reducing manufacturing steps and cost while maintaining sensing capability
Solution Approach 2:
The sensor structure transitions from planar electrode patterns on a substrate to a three-dimensional stacked architecture with conductive layers separated by the separation layer. This dimensional change allows for compact integration and simplified manufacturing through vertical stacking rather than complex planar patterning
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 solution enables cost-effective, reliable, and sensitive bio-gas and infrared optical sensors with adjustable sensitivity, reduced manufacturing complexity, and versatility in applications, including use as antennas or discharge arrestors.
Implementation Method 1
a sensing stack in which first and second conductive layers are stacked and embedded within a material, the material including a separation layer between the conductive layers
Implementation Method 2
when gas or light contacts the sensing membrane, the sensing membrane may be changed in conductivity (or resistance)
Data Source
AI summary
Disclosed is a sensor having an embedded electrode, which can be manufactured at a reduced cost and applied to many different fields. The sensor comprises: a sensing stack in which a first conductive layer and a second conductive layer are stacked and layered with a separation layer interposed therebetween; and an electrode terminal arranged at a side surface of the sensing stack and electrically connected to the first and second conductive layers. The first and second conductive layers are exposed on at least one side surface of the sensing stack except for the side surface on which the electrode terminal is arranged, to thereby form a sensing surface.