Gas Sensor Separator Fluorine Coating Moisture Insulation
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Solution Overview
Problem
Moisture accumulation within the sealed sheath of gas sensors can lead to dew formation, causing a drop in insulation resistance and improper output due to water soaking into the separator, especially when the sealing filler releases humidity.
Innovation Solution
A water-impermeable coating layer is applied to the surface of the electrically insulating ceramic separator, preventing water absorption and maintaining insulation resistance, even in humid conditions, and potentially providing heat resistance for long-term performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separator made of electrically insulating ceramic is used to accommodate conduction members, then insulation between conduction members is achieved, but insulation resistance drops when moisture soaks into the separator
Solution Approach 1:
A water-impermeable coating layer is applied to the surface of the separator to act as an intermediary barrier. This coating prevents moisture from directly contacting and soaking into the ceramic separator, thereby maintaining its insulation resistance even in humid environments within the sealed sheath.
Solution Approach 2:
The separator structure becomes a composite material system combining the ceramic base material with a water-impermeable coating layer. This composite structure leverages the electrical insulation properties of ceramic while adding the moisture barrier properties of the coating, solving both insulation and moisture resistance requirements simultaneously.
2Reliability
If the sheath is sealed to protect the detection element, then protection from external environment is achieved, but moisture released by sealing filler causes dew formation inside
Solution Approach 1:
The water-impermeable coating on the separator converts the harmful effect of internal moisture into a non-problematic condition. By preventing moisture from affecting the separator's insulation properties, the coating allows the sealed structure to maintain its protective function while tolerating the presence of moisture released by the sealing filler.
3Ease of operation
If lead wires are passed through the elastic member for electrical connection, then electrical output is achieved, but insulation between conduction members may be compromised
Solution Approach 1:
The water-impermeable coating on the separator acts as an intermediary protective layer that allows lead wires to be accommodated while maintaining insulation. The coating prevents moisture from creating conductive paths between the lead wires and other conduction members, ensuring both electrical connection functionality and insulation 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 coating layer effectively prevents insulation resistance degradation and leakage currents, ensuring stable and reliable output from the gas sensor by maintaining the insulation properties of the separator over time.
Implementation Method 1
a coating layer having water impermeability is formed on at least a surface of the separator
Data Source
AI summary
A gas sensor including coating layers (64) and (69) of fluorine or a fluorine compound formed on the surface of a separator (60), including a front separator (61) and a rear separator (66), disposed inside a sheath (30). The coating layers (64) and (69) have water impermeability and water repellency. Even in the case where moisture contained in the atmosphere within a sheath (30) forms dew on the surface of the separator (60), the coating layers (64) and (69) prevent soaking of moisture into the separator (60), to thereby secure the insulation property of the separator (60). Also, the coating layers (64) and (69) having water repellency prevent a water droplet from spreading on the surface of the separator (60) with resultant formation of a film of water, to thereby prevent flow of leakage current via a film of water.