Gas Sensor Guard Pattern Leakage Current Suppression

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Solution Overview

Problem

Conventional gas concentration measuring apparatuses face challenges in achieving high measurement accuracy due to weak sensor currents being affected by electrical noises and leakage currents, especially under adverse conditions like high temperature and high humidity, which degrade the surface resistance of circuit substrates made from insulating materials like glass epoxy resin.

Innovation Solution

A gas concentration measuring apparatus with a gas sensor and a measurement substrate featuring a signal processing circuit that includes a connection terminal with high input impedance, conductive patterns with specific impedance and potential differences, and a guard pattern to prevent leakage currents, ensuring accurate measurement of weak sensor currents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional circuit substrates made of insulating materials like glass epoxy resin are used, then the device can be manufactured with standard materials and processes, but leakage current increases under high temperature and high humidity conditions, degrading measurement accuracy

Engineering Contradiction:
ImprovemanufacturabilityVSAvoidmeasurement accuracy
Core Design Contradiction:
Ease of manufactureVSMeasurement precision

Solution Approach 1:

A guard pattern is introduced as an intermediary conductive structure between the signal input pattern and different potential patterns. This guard pattern acts as a mediator that intercepts and redirects leakage current, preventing it from reaching the signal input pattern. The guard pattern is maintained at a constant potential through connection to the signal input terminal, creating an equipotential region that eliminates the potential difference driving leakage current across the insulating substrate.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The guard pattern is electrically connected to the signal input terminal, ensuring it maintains the same potential as the signal input pattern. This creates an equipotential condition between adjacent conductive regions, eliminating the potential difference that drives leakage current through the insulating substrate. By making adjacent conductive elements equipotential, the harmful leakage current is suppressed without requiring special substrate materials.

Inventive Principle:
Principle #12Equipotentiality

2Device complexity

If the sensor current measurement circuit is simplified, then the device complexity is reduced, but the weak sensor current becomes more susceptible to electrical noises and leakage currents

Engineering Contradiction:
Improvecircuit complexityVSAvoidmeasurement accuracy
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The guard pattern serves as an intermediary protective structure that does not require complex circuitry or additional active components. It is simply a conductive pattern on the substrate that is electrically connected to the signal input terminal, providing passive protection against leakage current and electrical noise while maintaining circuit simplicity.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The input impedance of the connection terminal is set to 500 kΩ or higher, which is a specific parameter change that optimizes the circuit for measuring weak sensor currents. This high input impedance minimizes the loading effect on the sensor while the guard pattern compensates for the increased susceptibility to leakage current that would otherwise result from the high impedance configuration.

Inventive Principle:
Principle #35Parameter changes

3Measurement precision

If the surface resistance of the circuit substrate is reduced to minimize leakage current, then measurement accuracy improves, but the substrate material properties must be changed or specialized materials used

Engineering Contradiction:
Improvemeasurement accuracyVSAvoidmanufacturability
Core Design Contradiction:
Measurement precisionVSEase of manufacture

Solution Approach 1:

Rather than changing the substrate material properties, a guard pattern is introduced as an intermediary conductive element that actively manages leakage current. This approach maintains compatibility with standard glass epoxy resin substrates while achieving low leakage current through the guard pattern's current-redirection function.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The leakage current that would normally flow through the insulating substrate under high temperature and humidity conditions is intercepted and redirected by the guard pattern. The guard pattern converts the harmful leakage current path into a controlled current flow that maintains the guard pattern's equipotential condition, thereby neutralizing the harmful effect without requiring special substrate materials.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 apparatus effectively suppresses leakage currents, allowing for high-accuracy measurement of sensor currents, thereby improving the overall measurement precision of gas concentrations, especially in challenging environmental conditions.

Implementation Method 1

the surface resistance of circuit substrate decreases, thereby excessively increasing the leakage current

Methodology Applied
Scientific EffectElectrical Resistance: Electrical Resistance

Implementation Method 2

a conductive pattern portion having conductivity and formed in the measurement substrate

Methodology Applied
Scientific EffectElectrical Conductivity: Conduction (electrical)

Implementation Method 3

said connection terminal having input impedance of 500 k Ω or over; said signal input pattern having direct current impedance with respect to the connection terminal, said direct current impedance being 10 percent or less of the input impedance of the connection terminal

Methodology Applied
Scientific EffectElectrical Impedance: Electrical Resistance

Data Source

PatentUS7416650B2Gas concentration measuring apparatus
Publication Date: 2008.08.26 DENSO CORP
  • US7416650B2 patent drawing
  • US7416650B2 patent drawing
  • US7416650B2 patent drawing

AI summary

In a gas concentration measuring apparatus, a measurement substrate is provided. A conductive pattern portion is formed in the measurement substrate. The conductive pattern portion includes a signal input pattern constituting the signal processing circuit and electrically connected to the connection terminal, said signal input pattern having direct current impedance with respect to the connection terminal, said direct current impedance being 10 percent or less of the input impedance of the connection terminal; a different potential pattern having a potential difference of 2 V or over from a potential of the signal input pattern; and a guard pattern having a substantially constant potential and a potential difference of less than 0.5 V from the potential of the signal input pattern, said guard pattern being arranged on at least a portion of the measurement substrate, said at least portion of the measurement substrate being located between the signal input pattern and the different potential pattern.