Interdigital Electrode Sensor for Thawing Detection
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Solution Overview
Problem
Existing sensor devices for detecting thawing require a separate condensation core layer, which complicates their construction and increases production costs, while also limiting detection speed and sensitivity.
Innovation Solution
The resistance layer is structured to form interdigital electrodes and simultaneously creates a moisture-sensitive hydrophilic surface through laser processing, eliminating the need for a separate condensation core layer and allowing for rapid detection by oxidizing material on the electrode surface, thus acting as both the sensor and condensation core layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate condensation core layer is used, then the sensor device has reliable condensation formation, but the construction becomes complex and production costs increase
Solution Approach 1:
The patent combines the resistance layer and condensation core layer into a single integrated layer. The resistance layer is structured to form interdigital electrodes while simultaneously creating a moisture-sensitive hydrophilic surface that acts as the condensation core, eliminating the need for a separate condensation core layer and reducing structural complexity
Solution Approach 2:
The resistance layer performs multiple functions: it provides electrical resistance for sensing, forms interdigital electrodes for signal detection, and creates a hydrophilic surface for condensation formation. This multi-functional design eliminates the need for separate dedicated layers for each function
2Reliability
If multiple layers including condensation core layer are used, then condensation detection is reliable, but detection speed is limited
Solution Approach 1:
By merging the resistance layer and condensation core layer into one integrated structure, the sensor eliminates the time delay associated with signal transmission through multiple layers. The direct contact between the condensation formation site and the sensing elements enables faster detection response
3Reliability
If multiple layers including condensation core layer are used, then condensation detection is reliable, but production costs increase
Solution Approach 1:
The integration of the resistance layer and condensation core layer into a single layer reduces the number of manufacturing steps, materials required, and assembly operations. This simplification directly reduces production costs while maintaining the reliability of condensation detection through the hydrophilic surface structure
4Reliability
If interdigital electrodes are coated with moisture-insensitive insulating layer, then electrical insulation is improved, but condensation core functionality is reduced
Solution Approach 1:
The resistance layer is structured to create locally differentiated zones: the interdigital electrode regions provide electrical conduction paths, while the spaces between electrodes create hydrophilic surfaces for condensation formation. This local differentiation allows simultaneous electrical insulation and condensation core functionality without requiring separate coating layers
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 approach results in a corrosion-stable, low-cost sensor device with enhanced sensitivity for relative humidity above 90% and significantly reduced detection times, eliminating the need for additional protective layers and enabling faster measurement of thawing events.
Implementation Method 1
heating, melting and evaporating parts of the substrate and resistance layer by means of laser radiation
Implementation Method 2
The resistance layer which is formed by a structuring process to produce two electrodes interdigitally engaging in one another also forms the sensitive layer in the sensor device according to the invention
Implementation Method 3
The resistance and substrate evaporated in this process is precipitated onto the interdigital electrodes and acts as a condensation core layer on the surface
Implementation Method 4
The local evaporation of the resistance and substrate results, in ambient atmosphere, in oxidation of the material precipitating as terms on the surface of the interdigital electrodes
Data Source
AI summary
A sensor device is provided for detecting thawing on surfaces with interdigital electrodes formed in a resistance layer which is formed on a substrate. In order to develop the sensor device further so that the measuring speed of the sensor device is further increased, the disclosure proposes that the interdigital electrodes and recesses between the interdigital electrodes have a moisture-sensitive hydrophilic surface through condensation cores applied to it.