Molded Lead Frame Gas Sensor for Compact Electrochemical Packaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing small electrochemical devices, particularly gas sensors, is challenging due to high costs and difficulty in producing compact designs.
Innovation Solution
The use of a molded lead frame housing with integrated electrodes and a chamber for electrochemical solutions, allowing for low-cost manufacturing of small electrochemical devices with efficient gas detection capabilities, utilizing conductive non-metal materials and a membrane for selective gas communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional manufacturing methods are used for electrochemical devices, then manufacturing precision and reliability can be maintained, but device size becomes large and manufacturing cost increases
Solution Approach 1:
The patent combines multiple components (housing, lead frame, electrodes, and molding compound) into a single integrated structure. The lead frame serves both as structural support and as the electrode assembly, while the molding compound simultaneously provides housing and sealing functions. This merging of functions enables compact device size while maintaining manufacturability through standard molding processes.
Solution Approach 2:
The patent implements a nested structure where the lead frame with electrodes is positioned within the molding compound housing. The electrochemical solution is contained within chambers formed by the nested arrangement of the lead frame and housing. This nesting allows multiple functional components to occupy overlapping spatial volumes, achieving compact device size without compromising manufacturing ease.
2Productivity
If device size is reduced for compact design, then productivity and cost-effectiveness improve, but manufacturing precision and electrode integration become more difficult
Solution Approach 1:
The molding process automatically performs multiple functions: it forms the housing structure, positions the lead frame, provides electrical insulation, and seals the electrochemical chambers. The process self-adjusts to accommodate minor variations in lead frame dimensions, eliminating the need for separate precision assembly steps. This self-service capability maintains manufacturing precision while enabling high-volume production of compact devices.
Solution Approach 2:
The patent utilizes the molding compound's physical parameters (viscosity, curing characteristics, and shrinkage properties) to achieve precise electrode integration. By controlling the molding parameters such as injection pressure, temperature, and curing time, the process automatically positions the lead frame electrodes with high accuracy within the compact housing, maintaining manufacturing precision while enabling compact device design.
3Volume of moving object
If compact design is implemented, then device size decreases and cost decreases, but access to electrochemical solution and gas communication become more challenging
Solution Approach 1:
The patent incorporates a membrane structure that allows gas molecules to diffuse through while preventing bulk liquid flow. This thin film approach enables the compact device to maintain effective gas access to the electrochemical solution without requiring large access ports or complex fluid pathways, thus preserving ease of operation despite reduced device size.
Solution Approach 2:
The patent utilizes porous structures in the housing or membrane that allow gas permeation while maintaining liquid containment. The porous material provides numerous micro-channels for gas diffusion to reach the electrochemical solution, enabling effective gas access in a compact configuration without compromising the ease of operation or requiring additional access mechanisms.
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
Enables the production of compact, cost-effective electrochemical devices that can detect gases by monitoring electrical property changes, with improved manufacturing efficiency and accuracy.
Implementation Method 1
The access port includes a membrane that allows gas communication between the chamber and the outside environs while preventing liquid communication between the chamber and the outside environs
Implementation Method 2
An electrochemical sensor device can observe chemical reactions by monitoring changes in electrical properties (e.g., voltage and current)
Data Source
AI summary
A gas sensor is disclosed. The gas sensor can include a housing that has an upper portion and a lower portion. The gas sensor can also include a chamber that is formed in the lower portion of the housing. The chamber can be configured to receive an electrochemical solution. The gas sensor can also include a plurality of electrodes that are formed in the upper portion of the housing. The plurality of electrodes can be molded in the upper portion of the housing and at least partially exposed to the chamber. The gas sensor can further include an access port that is formed in the upper portion. The access port can be configured to provide fluid communication between the an interior of the housing and the outside environs. The gas sensor can be a system-in-package (SiP) sensor.