Encapsulated Gas Sensor Cavity Design for Liquid Drainage
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Solution Overview
Problem
Existing sensor devices face issues with liquid accumulation in the cavity, leading to false humidity readings and residue contamination, which affects measurement accuracy and response time.
Innovation Solution
The sensor device features a cavity design that extends from the sensor to two non-parallel side surfaces, allowing liquids to flow out laterally, combined with a hydrophobic protective layer and a flat, cuboid encapsulation for efficient gas access, preventing residue accumulation and enhancing response time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cavity is designed as a funnel-shaped narrowing extending from the top of the encapsulation to the sensor, then access to the sensor is provided, but liquids can accumulate in the cavity causing false humidity readings and slow drying
Solution Approach 1:
The cavity is extended from a single-top access design to a multi-directional design that reaches at least two delimiting side surfaces of the encapsulation. This dimensional expansion prevents liquid accumulation by providing multiple drainage paths, eliminating the funnel-shaped narrowing that caused false readings while maintaining sensor accessibility.
2Ease of operation
If the sensor is placed in the center of the encapsulation with a funnel-shaped cavity, then the sensor is accessible, but liquid accumulation occurs leading to residues and contamination
Solution Approach 1:
The cavity design transitions from a symmetric funnel shape centered on the sensor to an asymmetric configuration that extends to multiple side surfaces. This asymmetric geometry creates natural drainage pathways that prevent liquid accumulation and residue formation, while the sensor position can be optimized independently for accessibility.
3Device complexity
If the cavity has perpendicular side walls, then the structure is simple, but liquid drainage is inefficient causing slow response time
Solution Approach 1:
The cavity side walls are designed with non-perpendicular orientations, creating sloped surfaces that facilitate liquid drainage toward the sensor area. This curved or angled geometry promotes faster liquid removal and improves response time, while maintaining manufacturing simplicity through standard encapsulation molding techniques.
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
This design ensures accurate and rapid humidity measurements by preventing liquid accumulation and residue formation, enabling quick response times and versatile applications in various environments.
Implementation Method 1
the moisture sensor has a moisture-permeable protective layer that is designed to be hydrophobic
Implementation Method 2
the liquid can flow out of the cavity quickly because of the lateral opening
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3c
AI summary
A sensor device comprising an integrated signal processing module (1), a gas-sensitive sensor (2) connected to the signal processing module, and an encapsulation (4) that at least partially encloses the signal processing module (1). Access to the sensor (2) is provided via a recess (6) in the encapsulation (4). The recess (6) extends from the sensor (2) to at least two limiting side surfaces of the encapsulation (4).