Ion Sensor Inclined Opening Prevents Air Bubble Pores
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Solution Overview
Problem
Existing ion sensors face yield reduction due to air bubbles forming in the coated solution, leading to pores in the responsive portion, which contaminate samples and affect measurement results.
Innovation Solution
The ion sensor design features a sensor main body with inclined openings that prevent air bubbles from forming pores, using a metal pin to coat the solution and evaporate the solvent, ensuring a smooth surface and preventing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the solution is coated by repetitively coating and thoroughly drying, then the responsive portion is formed compactly, but air bubbles form pores in the responsive portion
Solution Approach 1:
The patent applies preliminary action by coating the responsive material solution onto the sensor substrate in a controlled manner before drying, ensuring that air bubbles are prevented from forming in the first place. The coating process is designed to lay down a uniform layer that allows air to escape during drying, preventing pore formation in the responsive portion.
Solution Approach 2:
The patent changes parameters of the coating solution, including its viscosity, composition, and application method, to optimize the drying process. By adjusting these parameters, the solution can be coated and dried without trapping air bubbles, thereby forming a pore-free responsive portion that maintains measurement accuracy.
2Productivity
If air bubbles form pores in the responsive portion, then the yield of ion sensors decreases, but sample contamination occurs affecting measurement results
Solution Approach 1:
The patent converts the potential harm of air bubble formation into a benefit by designing a coating and drying process that utilizes controlled evaporation. The process allows air to escape in a controlled manner during drying, transforming what would be a harmful defect into a manageable process parameter, thereby preventing pore formation and ensuring both high yield and accurate measurements.
3Reliability
If the responsive portion surface is not smooth, then pores remain to contaminate samples, but achieving smooth surface increases manufacturing complexity
Solution Approach 1:
The patent applies self-service by designing a coating solution and drying process that automatically produces a smooth surface without requiring additional post-processing steps. The controlled drying process allows air bubbles to escape naturally during evaporation, and the responsive material self-organizes into a uniform, pore-free layer, eliminating the need for complex additional manufacturing steps.
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 design enhances the yield and quality of ion sensors by preventing sample contamination and increasing measurement accuracy, while also allowing for easier manufacturing and reduced parts costs.
Implementation Method 1
coating the inserted pin and a wall surface of an opening connected to the channel with a solution prepared by dissolving, in a solvent, a responsive material which selectively responds to a specific ion... after the solvent in the coated solution has evaporated
Data Source
AI summary
An ion sensor includes a sensor main body having a channel for a sample and an opening connected to the channel, a responsive portion which is filled in the opening and selectively responds to a specific ion, an electrode which has a ring shape, is set such that a central axis of the ring is substantially perpendicular to a central axis of the channel, and senses the response, and an output terminal which is formed out of one metal plate out of which the electrode is formed, has a pin shape, and is held by the sensor main body such that an axis extends along a direction substantially perpendicular to the central axis of the channel and the central axis of the ring.