Gel Electrolyte Sensor Assembly for Any-Orientation Use
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Solution Overview
Problem
Existing sensors for process and bioprocess industries require frequent replacement of membranes and electrolytes, limiting their orientation flexibility and complicating assembly, especially when vertical or angled orientations are necessary to prevent electrolyte flow.
Innovation Solution
A sensor device with a pre-disposed gel electrolyte between a reinforced membrane and sensor shaft, allowing assembly in any orientation due to the non-flowing properties of the gel, which maintains its position and simplifies handling and shipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a liquid electrolyte is used, then ionic conductivity is maintained, but the electrolyte flows away when the sensor is not in vertical or angled orientation
Solution Approach 1:
The electrolyte is transformed from liquid to gel state by changing its physical parameters (viscosity, flow properties). This parameter change allows the electrolyte to maintain its position in any orientation while preserving ionic conductivity, thus resolving the contradiction between orientation flexibility and measurement reliability
Solution Approach 2:
The patent uses a composite gel electrolyte that combines the ionic conductivity properties of liquid electrolytes with the structural stability of gel matrices. This composite material enables the electrolyte to remain in place without flowing away while maintaining electrical function, solving both requirements simultaneously
2Reliability
If the membrane and electrolyte are replaced frequently, then measurement reliability is maintained, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges the membrane and electrolyte into a single integrated gel electrolyte component that is pre-applied to the membrane. This combination eliminates the need for separate electrolyte filling and membrane replacement operations, reducing assembly complexity while maintaining measurement reliability through the durable gel structure
Solution Approach 2:
The electrolyte is pre-applied to the membrane in a gel state before final assembly, rather than being filled separately during installation. This preliminary action simplifies the assembly process and reduces the frequency of maintenance operations required
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
Enables sensors to be assembled in any orientation without losing electrolyte, improving handling, assembly ease, and extending sensor lifetime by using a gel electrolyte that maintains shape and sensitivity.
Implementation Method 1
A sensor device with a pre-disposed gel electrolyte between a reinforced membrane and sensor shaft, allowing assembly in any orientation due to the non-flowing properties of the gel
Implementation Method 2
a pre-disposed gel electrolyte... which maintains its position and simplifies handling and shipping
Data Source
AI summary
A sensor for measuring a species in a process medium includes a reinforced membrane, a sensor shaft, and an electrolyte provided between the reinforced membrane and the sensor shaft. The sensor shaft includes electrodes. A device for such a sensor also includes a pre-disposed gel electrolyte. Systems and methods related to the same are also disclosed.