Integrated Die-Form Gas Sensor with Wavelength Control
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Solution Overview
Problem
Conventional gas sensors face challenges in accurately detecting gas concentrations at parts-per-million (ppm) levels due to limitations in optical path length, leading to inadequate sensitivity and specificity for multiple gas types, especially in compact designs for mobile and consumer devices.
Innovation Solution
A fully integrated gas concentration sensor is developed, featuring a package substrate with a gas-permeable mesh, an integrated die-form light source, and an integrated die-form infrared detector, along with control circuitry that manages spectral wavelengths to enhance sensitivity and specificity for ppm-level detection, configured as a micro-optics package with a form factor of about 4 mm×4 mm×2 mm or smaller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional gas sensors are used, then device complexity is reduced, but measurement precision deteriorates due to insufficient optical path length
Solution Approach 1:
The patent combines the light source, gas detection chamber, and detector into a single integrated sensor unit. The light source is positioned inside the detection chamber with the detector on the opposite side, creating an optical path through the gas sample. This integration allows the sensor to achieve sufficient optical path length for ppm-level detection while maintaining a compact form factor that reduces overall device complexity.
Solution Approach 2:
The patent transitions from conventional surface-mounted gas sensors to a three-dimensional integrated structure where the light source, gas path, and detector are arranged in spatial layers. This dimensional reorganization enables extended optical path length within a compact footprint, improving measurement precision without proportionally increasing device complexity.
2Measurement precision
If optical path length is extended to improve sensitivity, then measurement precision improves, but device size increases
Solution Approach 1:
By merging the light source, gas detection chamber, and detector into a single integrated unit with the light source positioned inside the chamber and detector on the opposite side, the patent achieves sufficient optical path length for ppm-level detection while maintaining a compact form factor of approximately 4 mm × 4 mm × 2 mm.
Solution Approach 2:
The patent employs a thin-film substrate structure that supports the light source and detector while allowing gas permeation. This thin-film approach enables extended optical paths through multiple reflections or folded geometries without proportionally increasing the overall sensor volume, thus maintaining sensitivity while controlling form factor.
3Adaptability or versatility
If multiple gas types are detected simultaneously, then adaptability improves, but device complexity increases due to spectral control requirements
Solution Approach 1:
The patent employs a broadband light source and detector system that can detect multiple gas types by varying spectral wavelengths. The control circuitry manages the light source to emit different wavelengths that correspond to specific gas absorption spectra, enabling a single sensor to detect multiple gases without requiring separate specialized sensors for each gas type.
Solution Approach 2:
The patent changes the spectral wavelength parameter of the light source to selectively detect different gases. By modulating the wavelength according to the absorption characteristics of target gases, the sensor achieves multi-gas detection capability. The control circuitry adjusts this parameter dynamically, enabling adaptability to different gas types while managing complexity through software or control algorithm optimization.
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 solution enables accurate detection of various gases at ppm levels while maintaining a compact design, effectively addressing the limitations of conventional sensors by controlling spectral wavelengths and optimizing the optical path for improved sensitivity and specificity.
Implementation Method 1
measuring changes in electrical properties of the sensor... optical... based sensors
Data Source
AI summary
A gas concentration sensor is includes an integrated die-form electromagnetic radiation source and an integrated die-form infrared detector. In one or more implementations, the gas concentration sensor includes a package substrate defining at least one aperture, a gas permeable mesh coupled to the package substrate and covering at least a portion of the at least one aperture, a die-form electromagnetic radiation source positioned in an interior region of the package substrate, a die-form detector positioned in the interior region of the package substrate, and control circuitry operably coupled to the die-form detector and configured to detect and calibrate one or more signal outputs from the die-form detector to determine a gas concentration within the interior region of the package substrate. The gas concentration sensor can be configured for specific detection of various gases through control of the spectral wavelengths emitted by the electromagnetic radiation source(s) and/or detected by the detector(s).