Flexible ETFE Leak Sensor with Patterned Conductive Lines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing leak sensors face challenges such as high installation costs, limited flexibility, and difficulty in detecting minute leaks, especially in acidic or alkaline environments, with issues like dead points and high error rates due to humidity and external impacts.
Innovation Solution
A flexible sheet-type leak sensor device made of non-conductive fluorine-based synthetic resin with conductive lines formed using carbon black-containing ethylene tetrafluoroethylene (ETFE), allowing for a patterned and spaced conductive structure that is resistant to acidic and alkaline solutions, enabling sensitive detection and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a cable-type leak sensor is used, then leak detection accuracy is improved, but installation cost and complexity increase
Solution Approach 1:
The sensor is divided into multiple conductive lines arranged in a specific pattern on a flexible base sheet, allowing the detection area to be segmented into multiple sensing zones. This segmentation enables accurate leak detection while simplifying installation compared to a single complex cable system
Solution Approach 2:
A flexible base sheet made of non-conductive fluorine-based synthetic resin is introduced as an intermediary carrier to support the conductive lines. This mediator allows the sensor to be easily installed and conform to various surfaces without requiring complex mounting brackets or rigid structures
2Ease of operation
If a band-type leak detection sensor is used, then installation ease is improved, but detection accuracy and reliability worsen
Solution Approach 1:
The sensor combines a non-conductive fluorine-based synthetic resin base sheet with carbon black-containing conductive fluorine-based synthetic resin to create a composite structure. This composite material provides both the flexibility needed for easy installation and the electrical conductivity required for reliable leak detection, overcoming the limitations of simple band-type sensors
Solution Approach 2:
Conductive lines are selectively formed in specific patterns on the base sheet where leak detection is needed, rather than making the entire band conductive. This localized conductivity approach maintains reliability while reducing material costs and improving installation ease
3Measurement precision
If conventional leak sensors are used in acidic or alkaline environments, then general leak detection is achieved, but resistance to chemical corrosion worsens
Solution Approach 1:
Both the base sheet and conductive lines are made from fluorine-based synthetic resins, which are known for their excellent chemical resistance to acids and alkalis. This composite material structure maintains leak detection precision while providing superior corrosion resistance compared to conventional sensors using standard polymers or metals
Solution Approach 2:
The patent specifies using fluorine-based synthetic resin with specific chemical properties (high resistance to acidic and alkaline solutions) for both the base sheet and conductive material. This parameter change in material composition directly addresses the chemical corrosion resistance issue while maintaining electrical conductivity for detection
4Quantity of substance
If module-type leak sensor is used, then cost reduction is achieved, but detection flexibility and coverage area worsen
Solution Approach 1:
The sensor is segmented into multiple conductive lines forming a patterned array on a large flexible base sheet, enabling coverage of extensive areas and adaptation to various installation surfaces. This segmented design provides the flexibility and coverage of cable-type sensors while maintaining the cost-effectiveness of simpler sensor designs
Solution Approach 2:
The flexible sheet-type sensor with its patterned conductive lines can be applied to multiple surfaces and configurations, serving multiple detection locations and orientations. This universal design replaces the need for multiple fixed module-type sensors, reducing overall cost while improving detection flexibility and coverage area
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 flexible sheet-type leak sensor device provides accurate and sensitive leak detection without dead points, is resistant to acidic and alkaline solutions, and can be reused, combining the advantages of cable and band-type sensors with a simple and cost-effective structure.
Implementation Method 1
conductive lines being formed by depositing on the base sheet surface a carbon black-containing, conductive fluorine-based synthetic resin comprising ethylene tetrafluoroethylene (ETFE)
Implementation Method 2
When water comes in contact with an electric wire when an electric current flows through the electric wire, the resistance value of the electric wire will change. Based on this change in the resistance value, the band-type leak detection sensor can detect water leaks
Data Source
AI summary
A flexible sheet-type leak sensor device according to the present invention comprises: a flexible base sheet made of a non-conductive fluorine-based synthetic resin comprising ethylene tetrafluoroethylene (ETFE); conductive lines formed on a surface of the base sheet so as to have a predetermined pattern and so as not to meet or cross each other, the conductive lines being formed by depositing on the base sheet surface a carbon black-containing, conductive fluorine-based synthetic resin comprising ethylene tetrafluoroethylene (ETFE); and a conductive material composed of pure carbon black, formed at the bottom of the conductive lines.