Laser-Structured Sensor Surface for Low-Temperature Condensate Control
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Solution Overview
Problem
Pressure sensors in vehicles face measurement inaccuracies and potential destruction due to condensate freezing at low temperatures, which is exacerbated by the need for immediate post-start exhaust gas measurements, leading to increased energy consumption and reduced corrosion resistance with existing hydrophobic coatings.
Innovation Solution
A sensor device with a surface structure that reduces wettability, created using ultrashort-pulse laser radiation to produce micro and nanostructures, eliminating the need for additional coatings and maintaining material properties, thereby preventing condensate accumulation and ensuring accurate measurements at low temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hydrophobic coatings (e.g., fluorosilanes) are applied to prevent condensate adhesion, then condensate adhesion is reduced, but corrosion resistance deteriorates due to organic material degradation under temperature and aggressive media exposure
Solution Approach 1:
The patent replaces chemical coatings (fluorosilanes) with a physical surface structure (micro and nanostructures) created by ultrashort-pulse laser radiation. This structure reduces condensate adhesion through surface geometry rather than chemical hydrophobicity, eliminating the corrosion resistance problem while maintaining the anti-adhesion benefit
Solution Approach 2:
The patent changes the surface parameters (roughness, microstructure, nanostructure) through laser processing to achieve reduced wettability. By modifying the physical parameters of the surface rather than applying a chemical layer, the solution maintains material resilience and corrosion resistance while preventing condensate accumulation
2Measurement precision
If independent heating of the sensor is implemented to prevent condensate freezing, then measurement accuracy is improved, but energy consumption increases
Solution Approach 1:
The patent applies preliminary action by creating a surface structure that prevents condensate adhesion in the first place. This proactive measure eliminates the need for subsequent heating or active prevention measures, reducing energy consumption while maintaining measurement accuracy
Solution Approach 2:
The surface structure provides self-service by automatically preventing condensate accumulation through its geometric properties. The micro and nanostructures cause condensate to bead up and roll off without external intervention, eliminating the need for energy-consuming heating systems
3Reliability
If measurements are delayed until positive temperatures are reached, then sensor reliability is improved, but productivity deteriorates due to extended waiting times
Solution Approach 1:
The surface structure performs preliminary prevention of condensate adhesion, ensuring the sensor remains reliable even at low temperatures. This allows measurements to proceed immediately without waiting for temperature increases, maintaining both reliability and productivity
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 device achieves reduced icing and enhanced measurement accuracy by minimizing condensate adhesion, preserving sensor function and extending lifespan through self-cleaning properties without compromising material resilience or corrosion resistance.
Implementation Method 1
The surface structure may in particular be produced by means of laser radiation, in particular by means of pulsed laser radiation
Implementation Method 2
A sensor device with a surface structure that reduces wettability... preventing condensate accumulation
Data Source
AI summary
In an embodiment a sensor device includes a sensor element, a media supply configured to transport a medium to the sensor element and a surface, wherein the surface is configured to be exposed to the medium during operation of the sensor device, and wherein the surface comprises a surface structure configured to reduce a wettability of the surface by the medium.