High-Flux Sensor for Corrosion Monitoring via Stacked Electrodes
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Solution Overview
Problem
Current atmospheric corrosion evaluation methods are unable to continuously monitor environmental corrosivity in real time and traditional sensors are difficult to manufacture, leading to inconsistencies and short service lives, especially in challenging environments.
Innovation Solution
A high-flux sensor comprising stacked metal sheets with an insulating layer and a working hole, where the metal sheets are standard electrodes with a potential difference of at least 50 mV, and a low-resistivity wire connection, allowing for simple manufacturing and long-term monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional atmospheric corrosion sensors are used for monitoring, then corrosion rate data can be obtained, but the sensors are difficult to manufacture, causing large errors and poor consistency
Solution Approach 1:
The sensor is divided into multiple metal sheets with different electrode potentials stacked together, where each sheet serves a specific function in the electrochemical corrosion monitoring system. This segmentation simplifies the manufacturing of individual components while maintaining overall measurement precision through the collective arrangement of multiple standardized sheets.
Solution Approach 2:
The invention changes the material parameters by selecting metal sheets with specific electrode potential differences (≥50mV), transforming the sensor from a complex single-component device into a multi-material assembly with standardized parameters that are easier to manufacture consistently across production batches.
2Reliability
If traditional sensors are deployed in harsh environments, then corrosion monitoring is performed, but the service life is limited to not more than 2 years
Solution Approach 1:
The sensor employs a composite structure combining multiple metal sheets with different corrosion resistances and electrochemical properties, along with insulating layers and sealing components. This composite design enhances overall reliability and service life in harsh environments while maintaining adaptability through the synergistic interaction of different materials.
Solution Approach 2:
The sensor design incorporates protective measures in advance, including insulating layers between metal sheets, sealing structures, and corrosion-resistant material selections, to cushion against the harsh environmental conditions before they cause damage, thereby extending service life while maintaining environmental adaptability.
3Measurement precision
If long-term field sheet corrosion tests are conducted to evaluate environmental corrosivity, then average corrosion rate can be obtained, but real-time continuous monitoring of corrosivity change cannot be achieved
Solution Approach 1:
The invention replaces the mechanical field exposure method with an electrochemical sensing system that uses electrical current measurement to detect corrosion activity. This substitution enables real-time continuous monitoring while maintaining measurement precision through electrochemical principles, eliminating the time delay inherent in physical sheet exposure methods.
Solution Approach 2:
The sensor enables continuous electrochemical measurement of corrosion rates through constant electrical monitoring, eliminating the intermittent nature of field sheet tests. This continuous action provides real-time corrosivity data while maintaining accuracy through sustained electrochemical reactions between the metal sheets and the environment.
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 sensor provides high stability, consistency, and extended service life, enabling continuous real-time monitoring of environmental corrosivity with improved accuracy and reliability, suitable for harsh environments.
Implementation Method 1
a first metal sheet and a second metal sheet, the first metal sheet and the second metal sheet being stacked; an insulating layer provided between the first metal sheet and the second metal sheet... the first metal sheet and the second metal sheet are standard electrodes, and a difference between electrode potentials between the first metal sheet and the second metal sheet is not less than 50 mV
Data Source
AI summary
The present disclosure provides a high-flux sensor suitable for corrosion big data monitoring and a method of manufacturing the same. The sensor includes a first metal sheet, a second metal sheet and an insulating sheet therebetween. The two metal sheets are laminated. The metal sheets and the insulating sheet form a test piece group. A through hole is drilled in the test piece group.