Layered Liquid Leak Sensor Using PTFE-CNT Sintered Structure
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Solution Overview
Problem
Conventional capacitance leakage sensors are prone to corrosion and peeling when exposed to chemical solutions, have a cumbersome manufacturing process, and are expensive due to the use of metal conductive lines, which limits their repeated use and accuracy.
Innovation Solution
A liquid leak sensor is fabricated by alternately stacking nonconductive and conductive layers made of PTFE and carbon nanotubes, compressed, sintered, and then processed to a specific thickness using a skiving method, creating a robust and cost-effective detection device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive lines are formed using carbon material by printing, then vulnerability to chemical solutions is reduced, but a protection film is easily peeled off due to steps between the base film and conductive lines
Solution Approach 1:
The patent employs a thin film structure where the conductive layer is formed directly on the base film surface. This thin film approach minimizes step height differences, allowing the protection film to conform smoothly to the surface topology and preventing peeling while maintaining chemical resistance.
Solution Approach 2:
The patent applies different material properties to different layers: the base film provides chemical resistance, the conductive carbon layer provides conductivity with minimal step height, and the protection film provides environmental protection. This local optimization of material properties at each layer resolves the adhesion issue while maintaining chemical resistance.
2Reliability
If conventional plating methods are used to form conductive lines, then excellent conductivity is achieved, but the manufacturing process becomes very cumbersome and the price increases
Solution Approach 1:
The patent replaces the complex mechanical plating process (etching, nickel-copper plating, gold plating) with a simpler carbon material deposition method. This substitution eliminates multiple manufacturing steps while achieving the required conductivity, significantly simplifying the manufacturing process and reducing costs.
Solution Approach 2:
The patent replaces expensive metal materials requiring complex plating processes with carbon material that can be applied through simpler methods. This material substitution directly reduces both manufacturing complexity and cost while maintaining the necessary electrical conductivity for sensor function.
3Measurement precision
If metal conductive lines are used in capacitance leakage sensors, then detection capability is achieved, but the sensor requires frequent maintenance due to corrosion and signal errors
Solution Approach 1:
The patent uses a composite structure of base film and carbon conductive layer that maintains stable electrical properties over time. This composite design prevents the corrosion and signal degradation issues of metal materials, ensuring consistent detection capability throughout the sensor's service life without frequent maintenance.
Solution Approach 2:
The patent replaces metal conductive lines with carbon material that exhibits greater long-term stability in chemical environments. This substitution extends the sensor's service life by eliminating corrosion-related failures and signal errors, reducing maintenance frequency while preserving detection precision.
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 provides a durable, cost-effective liquid leak sensor with enhanced chemical resistance and stability, allowing for accurate detection without frequent signal errors and peeling issues, while simplifying the manufacturing process.
Implementation Method 1
a fifth process of sintering the molded compressed article
Implementation Method 2
a fourth process of shaping a single compressed article by applying pressure to the stacked nonconductive mold article and conductive mold article up and down using presses
Data Source
AI summary
The present disclosure relates to a method of fabricating a liquid leak sensor and, more particularly, to a method of fabricating a liquid leak sensor, which is cheap and can be easily fabricated by consecutively disposing a nonconductive layer and a conductive layer and compressing the layers. The method may include shaping a nonconductive mold article having a flat top surface and bottom surface using nonconductive powder, shaping a conductive mold article having a flat top surface and bottom surface using a conductive raw material, alternately stacking the nonconductive mold article and the conductive mold article on a die up and down, shaping a single compressed article by applying pressure to the stacked nonconductive mold article and conductive mold article up and down using presses, sintering the molded compressed article, and performing skiving processing on a side of the sintered compressed article to a given thickness.