Constant Potential Electrolysis Gas Sensor Corrosion Protection
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Solution Overview
Problem
The existing constant potential electrolytic gas sensors face challenges in manufacturing due to difficulties in applying a protective agent to prevent corrosion at the connection points of lead wires and terminals, which can lead to errors in measured electrolytic current.
Innovation Solution
The proposed constant potential electrolytic gas sensor features a case body with a holding structure that can hold a predetermined amount of protective agent, ensuring it covers the connection points of external electrodes. This design simplifies the application of the protective agent and facilitates easier wiring of lead wires, enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection point where lead wire connects to terminal is immersed into electrolyte, then corrosion occurs at the connection point, but applying protective agent becomes difficult to control and manufacture is complicated
Solution Approach 1:
The patent applies protective agent to the connection point before inserting the electrode holder into the sensor case. This preliminary action ensures the protective agent is already in place before subsequent assembly steps, preventing corrosion while simplifying the manufacturing process by establishing the protection layer early in the assembly sequence
Solution Approach 2:
The patent introduces a resin layer as an intermediary substance between the lead wire connection point and the electrolyte. This resin layer acts as a mediator that physically separates the connection point from the corrosive electrolyte environment, providing reliable corrosion protection while maintaining manufacturing simplicity
2Reliability
If protective agent is applied to connection point below electrode holder, then corrosion protection is achieved, but wiring and protective agent application becomes extremely difficult and complicated
Solution Approach 1:
The patent performs protective agent application and lead wire bending before inserting the electrode holder. This preliminary action transforms a difficult post-assembly operation into a simple pre-assembly step, significantly improving manufacturing ease while ensuring reliable corrosion protection at the connection point
3Reliability
If lead wire is bent to connect to electrode surface after electrode holder insertion, then electrical connection is achieved, but manufacturing automation is hindered
Solution Approach 1:
The patent bends the lead wire and connects it to the electrode surface before inserting the electrode holder into the sensor case. This preliminary action converts a complex post-assembly wiring operation into a simple pre-assembly step that can be easily automated, improving both manufacturing automation capability and electrical connection reliability
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 effectively prevents corrosion at the connection points, reducing measurement errors and simplifying the manufacturing process, thereby enabling easier automation of manufacturing steps.
Implementation Method 1
it is necessary to apply a protective agent for protecting from corrosion caused by the electrolyte to the connection point where the lead wire is connected to the terminal
Implementation Method 2
detect an electrolytic current generated between the reactive electrode and the counter electrode due to an electrochemical reaction of a gas to be detected
Data Source
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AI summary
A constant potential electrolytic gas sensor 1 of the present invention comprises a case with a case body 21, an electrode structure 3 comprising electrodes 31, 32, 33 provided in the case body 21, lead wires 41, 42, 43 connected to the surfaces of the electrodes 31, 32, 33, and external electrodes 51, 52, 53 that extend from the outside of the case to the inside of the case, are provided in the case body 21, and are connected to the lead wires 41, 42, 43, wherein the electrodes 51, 52, 53 are arranged so that a connection point CP of the external electrode 51, 52, 53 to which the lead wire 41, 42, 43 is connected is located at a height corresponding to the electrode structure 3, and wherein the case body 21 has a holding structure 8 that can hold a predetermined amount of protective agent so as to cover the connection point CP, with respect to each of the external electrodes 51, 52, 53.