Laser Structured Soot Sensor with Interlaced Conductive Structures
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Solution Overview
Problem
Existing soot sensors lack sufficient sensitivity to detect low concentrations of soot particles, require multiple sensors and connecting terminals, and are costly and complex to produce, making them inadequate for meeting stringent emission regulations and cost-effectiveness goals.
Innovation Solution
A soot sensor is produced using a method involving a contiguous metallic layer applied on an electrically insulating substrate, with interlaced conductive structures created by laser vaporization, allowing for close spacing and reduced production costs, and combined with a temperature sensor for enhanced sensitivity and installation simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional soot sensors are used, then the sensor structure is simple, but the sensitivity to detect low concentrations of soot particles is insufficient
Solution Approach 1:
The sensor surface is segmented into multiple interlaced conductive structures (heating elements and sensor elements) that are spatially separated but extend close to one another. This segmentation increases the effective surface area for soot particle adsorption and enhances the measurement signal without requiring multiple separate sensors.
Solution Approach 2:
The conductive structures are arranged in an interlaced pattern where they extend close to one another in the lateral dimension while being spatially separated. This creates a three-dimensional sensing volume that increases sensitivity to soot particle concentration without increasing the overall sensor footprint or structural complexity.
2Measurement precision
If multiple sensors are installed to detect low soot concentrations, then the detection sensitivity increases, but the number of connecting terminals and installation complexity increases
Solution Approach 1:
Multiple functional elements (heating elements and sensor elements) are merged into a single sensor unit with a unified structure. The interlaced conductive structures are integrated on one substrate, eliminating the need for multiple separate sensors and their associated connecting terminals, thus simplifying installation while maintaining high detection sensitivity.
Solution Approach 2:
The sensor structure performs multiple functions within a single device: the conductive structures serve both as heating elements for burning off soot and as sensor elements for detecting soot particle concentration. This multi-functionality reduces the number of components and simplifies the overall system.
3Measurement precision
If multiple sensors and connecting terminals are used, then detection capability improves, but production costs increase
Solution Approach 1:
The heating function and sensing function are merged into a single integrated structure, reducing the total number of components that need to be manufactured and assembled. This integration lowers production costs while maintaining or improving detection capability through the interlaced conductive structure design.
Solution Approach 2:
The conductive structures serve dual purposes as both heating elements and sensor elements, eliminating the need for separate components. This multi-functionality reduces material usage, manufacturing steps, and assembly operations, thereby reducing production costs while achieving the required detection capability.
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 achieves greater sensitivity in detecting soot particle concentrations with reduced production costs and complexity, meeting stricter emission standards while simplifying installation and reducing material usage.
Implementation Method 1
structuring the metal coating with a laser beam by vaporizing areas of the metallic layer
Implementation Method 2
The heating element is heated to a sufficiently high temperature in order to burn free the sensor
Implementation Method 3
a conductive track structure is applied on a smooth Al2O3 surface. Such a structure simplifies the adsorption of soot particles
Data Source
AI summary
A method for producing a soot sensor is provided. The method includes steps of applying a contiguous metallic layer on an electrically insulating substrate and structuring the metal coating with a laser beam by vaporizing areas of the metallic layer. At least two interlaced contiguous electrically conductive structures are produced. The electrically conductive structures are spatially separated from one another with the laser beam and are electrically insulated from one another such that the conductive structures substantially extend next to one another and close to one another in an area relative to a total length thereof. A soot sensor produced using such a method is also provided. The soot sensor has an electrically insulating substrate and at least two contiguous electrically conductive structures which are spatially separated from one another and are interlaced as structured metallic layers. An intermediate space between the conductive structures is burned free with a laser.