Leak Detection Electrode Layout for Small Leaks and Humidity
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Solution Overview
Problem
Existing liquid leakage detection sensors face issues such as failure to detect small leaks due to incomplete wetting of the water-absorbing layer, false alarms from high humidity, and high material costs due to complete coverage of the electrode layers.
Innovation Solution
A detection unit design featuring staggered electrode layers with insulating layers and conductive portions, allowing liquid to flow through holes to connect electrodes without a water-absorbing layer, reducing material usage and avoiding false alarms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water-absorbing layer is used to connect electrode layers, then liquid leakage can be detected, but the sensor gives false alarms when air humidity is high
Solution Approach 1:
The patent removes the water-absorbing layer from the sensor structure entirely. Instead of relying on a water-absorbing material that can be activated by either liquid leakage or high humidity, the invention uses a through-hole structure where liquid must directly connect the first and second electrode layers. This extraction of the problematic water-absorbing component eliminates the false alarm issue while preserving liquid leakage detection capability.
Solution Approach 2:
The patent introduces a through-hole as an intermediary structure between the electrode layers. This through-hole acts as a direct conduit that requires actual liquid leakage to bridge the gap between electrodes, rather than relying on a water-absorbing material that can be passively activated by humidity. The through-hole serves as a mediator that distinguishes between liquid leakage (which fills the hole) and high humidity (which does not).
2Reliability
If the water-absorbing layer is completely covered by electrode layers, then detection reliability is improved, but material cost increases
Solution Approach 1:
The patent extracts the water-absorbing layer from the structure, which eliminates the need for complete electrode coverage. Without the water-absorbing layer to bridge gaps, the electrode layers can be positioned to overlap with the through-hole boundaries rather than fully covering the entire surface, reducing material consumption while maintaining detection reliability through the direct liquid connection mechanism.
Solution Approach 2:
The patent applies partial coverage of the electrode layers over the through-hole boundaries rather than complete coverage. The first and second electrode layers are positioned to at least partially cover the boundaries of the through-hole, which is sufficient for reliable detection when liquid bridges the gap. This partial action approach reduces material usage compared to requiring full coverage of the entire electrode surface.
3Reliability
If less liquid leaks, then the water-absorbing layer may not be completely wetted, but the sensor fails to detect the leak
Solution Approach 1:
The patent removes the water-absorbing layer that requires complete wetting for detection. Instead, it uses a through-hole structure where even small amounts of liquid can bridge the gap between electrode layers. This extraction of the water-absorbing component eliminates the detection threshold problem, allowing the sensor to detect smaller leaks that would not provide sufficient wetting to activate a water-absorbing layer.
Solution Approach 2:
The through-hole serves as an intermediary structure that lowers the detection threshold for liquid leakage. Rather than requiring the water-absorbing layer to be completely wetted (which needs a certain volume of liquid), the through-hole only requires liquid to bridge its opening, making the sensor sensitive to smaller leak volumes while maintaining reliable detection.
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 effectively detects liquid leaks without material wastage and false alarms, ensuring accurate detection and cost reduction.
Implementation Method 1
liquid dripping onto the second electrode layer flows through the first through hole to contact the first electrode layer
Data Source
AI summary
A detection unit includes a first detection module including a first electrode layer, a first insulating layer and a second electrode layer stacked in sequence. The first insulating layer defines a first through hole, the first electrode layer at least partially covers the first through hole, and the second electrode layer and the first electrode layer are staggered. When liquid drips onto the second electrode layer and flow into the first through hole, the first electrode layer and the second electrode layer are electrically connected by the liquid. Thus, a controller can detect the liquid leakage. The first detection module has a sheet-like structure, and the size of the first detection module is adjustable according to actual conditions to achieve a wide coverage and adapt to more application scenarios, thereby solving the problem of a high requirement for matching between a conventional liquid leakage detection sensor and a detected scenario.