Measuring Resistor Protective Frame for High-Temperature Ion Migration
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Solution Overview
Problem
High-temperature temperature sensors have complex structures, leading to high production costs and sensitivity to polarity, which can result in drift and damage at temperatures above 700°C.
Innovation Solution
A simple and cost-effective design with electrodes arranged next to the resistance structure on the substrate, acting as a sacrificial cathode, which frames the resistance structure and is electrically connected to connection contacts, reducing the need to consider polarity during installation and protecting the sensor from ion migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex multi-layer structure with diffusion barrier layers is used to protect the platinum resistance layer from ion migration, then the protection against chemical attacks is improved, but the manufacturing complexity and production costs increase significantly
Solution Approach 1:
The invention extracts and eliminates the complex multi-layer diffusion barrier structure from the temperature sensor design. Instead of using multiple protective layers (silicon dioxide 200-400 nm, titanium oxide 600-1200 nm, glass layers), the patent employs a single platinum electrode arranged in a grid pattern directly on the substrate, which serves as a sacrificial cathode to protect the resistance layer through electrochemical means rather than physical barrier layers.
Solution Approach 2:
The invention introduces an intermediary protective mechanism - a platinum electrode grid that acts as a sacrificial cathode. This electrode network serves as an active protective layer that chemically intercepts metal ions through electrochemical reactions, preventing them from reaching and damaging the platinum resistance layer. The electrode grid functions as an intermediary between the harmful ion migration and the sensitive resistance layer.
2Temperature
If a sacrificial cathode is added to protect the resistance layer at high temperatures, then the temperature resistance is improved, but the device complexity and polarity sensitivity increase
Solution Approach 1:
The platinum electrode grid serves multiple functions simultaneously: it acts as the sacrificial cathode for ion protection, provides electrical connection paths, and forms a protective network across the entire sensor surface. This multi-functional design eliminates the need for separate protective layers and simplifies the overall structure while maintaining high-temperature protection capabilities up to 1100°C.
Solution Approach 2:
The grid pattern of the electrode creates equipotential zones across the sensor surface, ensuring uniform electrochemical protection throughout the measurement area. The interconnected grid structure maintains consistent potential distribution, which enhances the effectiveness of the sacrificial cathode function while simplifying connection requirements compared to point-contact designs.
3Duration of action of stationary object
If the resistance layer is applied as a thick layer in meanders to reduce ion migration effects, then the durability is improved, but the manufacturing precision requirements and production costs increase
Solution Approach 1:
The invention employs a disposable sacrificial cathode (platinum electrode grid) that is intentionally designed to be consumed or degraded preferentially to protect the main functional element (the resistance layer). The electrode grid serves as a consumable protective component that absorbs damage from ion migration, thereby extending the life of the precision resistance layer without requiring high manufacturing precision for the protective structure itself.
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 results in a compact, inexpensive temperature sensor with reduced drift and increased durability, capable of withstanding temperatures from 750°C to 1200°C, and is insensitive to power connection polarity, facilitating easier installation and mass production.
Implementation Method 1
metallic ions can migrate to the resistance layer and damage or even destroy it
Implementation Method 2
at least one electrode, which is electrically connected to the respective connection contact, is arranged next to the resistance structure on both connection contacts
Data Source
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AI summary
A high temperature sensor includes a substrate, at least two terminal contacts and at least one resistive structure, wherein the terminal contacts and the at least one resistive structure are disposed on a first side of the substrate, and at least one of the resistive structures is electrically contacted by the terminal contacts, wherein at least one electrode is disposed on each of the two terminal contacts next to the resistive structure on the first side of the substrate. The electrodes are electrically connected to the terminal contacts, respectively, or at least one electrode is disposed on at least one terminal contact next to the resistive structure on the first side of the substrate, wherein the electrode is designed in one piece with the resistive structure. The invention also relates to a high temperature sensor and a method for producing such a sensor.