Flexible-Substrate PID With Folded Electrodes for Condensation Control
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Solution Overview
Problem
Existing photoionization detectors (PIDs) are bulky and complex, leading to higher manufacturing costs and susceptibility to interference from humidity and condensation, which can cause false alarms and reduce measurement accuracy.
Innovation Solution
A low-profile PID design using a flexible substrate with electrodes folded onto separate planes and a spacer, featuring a guard electrode to minimize interference and simplify assembly, reducing component count and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional rigid substrate structures are used in PID sensors, then structural stability is maintained, but device size and complexity increase
Solution Approach 1:
The patent employs a flexible substrate instead of traditional rigid structures, allowing the sensor components to be folded into a compact configuration. The flexible substrate supports the electrode patterns and can be bent or folded to reduce the overall sensor volume while maintaining electrical connectivity and structural integrity.
Solution Approach 2:
The patent folds the flexible substrate to create a nested or layered structure where electrodes and sensing regions are arranged in multiple planes. This nesting approach allows multiple functional elements to be packed into a smaller volume while maintaining their relative positions and electrical relationships.
2Reliability
If multiple separate components are used in PID sensors, then functional performance is maintained, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent integrates multiple electrode patterns directly onto the flexible substrate, combining what would traditionally be separate components into a unified structure. The flexible substrate serves as both the structural support and the carrier for multiple electrode patterns, reducing the number of discrete parts and simplifying assembly.
Solution Approach 2:
The flexible substrate performs multiple functions simultaneously: it provides structural support, carries electrode patterns, enables compact folding, and maintains electrical connectivity. This multi-functionality reduces the need for separate components and simplifies the overall device architecture.
3Ease of manufacture
If electrodes are placed on the same plane, then manufacturing is simplified, but susceptibility to humidity and condensation interference increases
Solution Approach 1:
The patent utilizes the third dimension by folding the flexible substrate to create electrodes on different planes or levels. This vertical separation removes condensation and humidity interference between adjacent electrodes, as liquid condensate cannot bridge the gap between non-coplanar surfaces, while the electrodes remain electrically connected through the flexible substrate.
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 design achieves a smaller, less complex PID with improved measurement accuracy and reduced interference from humidity and condensation, lowering manufacturing costs and simplifying the assembly process.
Implementation Method 1
A photoionization detector (PID) can be used to detect the presence and concentration of toxic gases... A PID employs an ultraviolet (UV) lamp to emit photons that ionize target gases in the proximity of detector electrodes. Ionization occurs when a molecule absorbs the high-energy UV light, which excites the molecule and results in the temporary loss of a negatively charged electron and the formation of positively charged ion.
Implementation Method 2
An electric field is established between the plates of the electrodes by an applied voltage bias. The electric field induces ionized particles to move to one or another plate, thereby establishing an electric current between the electrodes.
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
Embodiments relate generally to systems and methods for a low profile PID typically comprising a flexible substrate; two or more electrodes containing an array of holes; a spacer with one or more holes; and two or more contacts corresponding to the electrodes. Typically, the unfolded flexible substrate defines a plane, and the electrodes are disposed on the flexible substrate such that when the flexible substrate is folded, one electrode is located on a top plane and another electrode is located on a bottom plane and the spacer is disposed between the electrodes to form an ionization chamber for use with a UV radiation source.