Electrochemical Gas Sensor Packaging With Leak-Blocking Membrane
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Solution Overview
Problem
Existing electrochemical gas sensor devices face challenges in manufacturing small, cost-effective units with efficient gas detection capabilities.
Innovation Solution
The proposed gas sensor design includes a housing with a molded lead frame, conductive non-metal materials filled with carbon fiber for electrodes, and a membrane in the access port to allow gas communication while preventing liquid leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional electrochemical gas sensor devices are manufactured, then gas detection capability is achieved, but device size and manufacturing cost are reduced
Solution Approach 1:
The patent combines multiple components into an integrated housing structure that accommodates the electrochemical cell, electrodes, and fluid management features in a single compact unit. The housing integrates the access port, fill port, and sealing mechanisms, eliminating the need for separate assemblies and reducing overall device size while simplifying manufacturing processes.
Solution Approach 2:
The patent employs thin-film membranes at the access port that allow gas permeation while blocking liquid electrolyte. These thin films reduce the vertical height of the device and enable compact packaging of the electrochemical cell, directly addressing the size reduction goal while maintaining functional performance.
2Volume of moving object
If compact design is implemented, then device size is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent divides the housing into distinct functional zones: an access port region with membrane integration, a fill port region for electrolyte loading, and a main chamber for the electrochemical cell. This segmentation allows each zone to be optimized independently and assembled through standardized processes, reducing manufacturing complexity despite the compact overall design.
Solution Approach 2:
The patent introduces intermediate sealing structures and integrated manifolds that mediate between different functional components. These intermediaries simplify the connection interfaces and fluid pathways, making the compact design manufacturable through conventional processes rather than requiring complex custom tooling.
3Reliability
If membrane is added to access port, then gas communication is enabled, but liquid leakage prevention is achieved
Solution Approach 1:
The patent utilizes porous or microporous membrane materials at the access port that selectively permit gas molecules to pass through while blocking larger liquid electrolyte molecules. This selective permeability achieves reliable liquid leakage prevention while maintaining gas detection functionality, without requiring complex mechanical sealing systems.
Solution Approach 2:
The access port membrane is integrated as a composite structure combining gas-permeable material with liquid-blocking properties. This composite approach achieves both gas communication and liquid leakage prevention in a single component, avoiding the need for separate gas channels and liquid seals that would increase structural 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
This design enables the manufacturing of compact, low-cost electrochemical gas sensors with improved gas detection capabilities, effectively addressing the challenges of small size and cost-effectiveness.
Implementation Method 1
The access port includes a membrane that allows gas communication between the chamber and the outside environs while preventing liquid communication between the chamber and the outside environs
Implementation Method 2
An electrochemical sensor device can observe chemical reactions by monitoring changes in electrical properties (e.g., voltage and current). The electrochemical sensor device can be a gas sensor device for detecting gases.
Data Source
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Figure 2A
AI summary
A gas sensor is disclosed. The gas sensor can include a housing that has an upper portion and a lower portion. The gas sensor can also include a chamber that is formed in the lower portion of the housing. The chamber can be configured to receive an electrochemical solution. The gas sensor can also include a plurality of electrodes that are formed in the upper portion of the housing. The plurality of electrodes can be molded in the upper portion of the housing and at least partially exposed to the chamber. The gas sensor can further include an access port that is formed in the upper portion. The access port can be configured to provide fluid communication between the an interior of the housing and the outside environs. The gas sensor can be a system-in-package (SiP) sensor.