Fluid Sensor PCB Layout With Plastic Electrodes for Precise Mixing
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Solution Overview
Problem
Existing sensor systems for monitoring fluid mixing in automated analyzers are either too large, expensive, or have metal electrodes that interact with process liquids, influencing analysis results, and lack a cost-effective solution for simultaneous level, conductivity, and temperature monitoring.
Innovation Solution
A sensor system featuring vertically arranged level sensors and horizontally arranged conductivity sensors with conductive plastic electrodes, a temperature sensor, and an embedded electronic circuit board in a hot melt compound within an injection molded housing, ensuring reliable and cost-effective monitoring without metal interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If metallic electrodes are used in conductivity sensors, then measurement capability is improved, but interaction with process liquids occurs which influences analysis results
Solution Approach 1:
The patent employs disposable test cups made of plastic with integrated conductivity sensors that have a limited service life. These single-use components eliminate metal interaction issues by using non-metallic sensing elements that are discarded after one use, preventing contamination and interaction with process liquids while maintaining measurement capability.
Solution Approach 2:
The patent replaces traditional metallic electrode-based conductivity sensing with an alternative sensing mechanism using plastic test cups with integrated non-metallic sensors. This substitution eliminates the harmful mechanical/chemical interaction between metal electrodes and process liquids while preserving the electrical conductivity measurement function through different sensing technology.
2Reliability
If precise conductivity sensors from process technology are used, then measurement reliability is improved, but device size and weight increase
Solution Approach 1:
The patent divides the sensing system into segmented, modular plastic test cups that can be individually disposed of. Each cup contains integrated sensing elements, allowing the system to achieve reliable measurements through multiple units rather than relying on a single large, heavy sensor device. This segmentation enables use of lighter materials while maintaining overall system reliability.
Solution Approach 2:
The patent changes the material parameter from metal to plastic for the test cup construction, fundamentally altering the weight and interaction characteristics. This parameter change allows the system to achieve the same measurement reliability through multiple lightweight disposable units rather than a single heavy durable sensor, directly addressing the weight-reliability contradiction.
3Adaptability or versatility
If multiple sensors are integrated in a device, then monitoring capability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple sensing functions (level detection, conductivity measurement, temperature sensing) into a single integrated plastic test cup assembly. By combining these functions in one disposable unit rather than requiring separate devices, the system improves monitoring capability while actually reducing overall complexity through integration and standardization of a single multi-functional component.
Solution Approach 2:
The patent creates a universal plastic test cup design that performs multiple functions: level detection, conductivity measurement, and temperature sensing. This multi-functional approach allows a single standardized component to replace multiple specialized devices, improving versatility while simplifying the system through functional integration rather than adding complexity.
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 system provides effective, low-cost monitoring of fluid levels, conductivity, and temperature, preventing metal interactions and ensuring precise measurements while being suitable for large-scale manufacturing.
Implementation Method 1
These sensors usually measure the conductivity of the liquid by means of metallic electrodes that are immersed in the liquid
Implementation Method 2
there are also inductive sensors. With these, an electrical voltage is coupled into the liquid by means of a coil and the resulting current flow in the liquid is measured with a second coil
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a sensor system, particularly for monitoring the mixing of at least two fluids and a method for monitoring the mixture of at least two liquids. The present invention provides a sensor system for fluids, comprising at least two level sensor which are arranged vertically one upon the other on and connected to an electronic circuit board, four electrodes of four conductivity sensors which are arranged horizontally next to each other at the bottom of and connected to the electronic circuit board; and a temperature sensor which is connected to the electronic circuit board; a connector for connecting the electronic circuit board to a controller; wherein the electronic circuit board is embedded in a hot melt compound which is surrounded by an injection molded housing.