Conductive Particle Sensor Layout With Suction Electrode Sensitivity
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Solution Overview
Problem
Existing particle sensors, particularly soot sensors, are complex to manufacture and require multiple laser ablation steps due to their intricate electrode structures, while maintaining sensitivity and robustness is a challenge.
Innovation Solution
A sensor design with a cuboid or cylindrical substrate featuring a resistive electrode structure, including a suction electrode and a sensor detection region, where the suction electrode attracts charged particles, increasing particle density and sensitivity, and a passivation layer to enhance manufacturability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If interdigitating electrodes are used for particle detection, then sensitivity and robustness are maintained, but manufacturing complexity increases due to multiple laser ablation steps
Solution Approach 1:
The patent extracts the complex interdigitating electrode structure and replaces it with a simplified electrode arrangement consisting of parallel electrodes with extended sides. This extraction removes the need for multiple laser ablation steps while maintaining the essential function of particle detection between electrodes.
Solution Approach 2:
The electrode structure is segmented into distinct functional zones: detection zones between parallel electrodes and extended sides that serve as suction electrodes. This segmentation allows different parts of the electrode structure to perform different functions (detection vs. particle attraction), simplifying the overall manufacturing process.
2Difficulty of detecting and measuring
If complex electrode shapes are produced by laser ablation, then detection functionality is achieved, but production time and cost increase
Solution Approach 1:
The patent changes the geometric parameters of the electrode structure from complex interdigitating patterns to simple parallel arrangements with extended sides. This parameter change maintains detection functionality while enabling simpler, faster manufacturing processes such as screen printing or sputtering instead of multiple laser ablation steps.
Solution Approach 2:
The electrode structure is designed with extended sides that预先 (in advance) attract particles into the detection zone before measurement. This preliminary action of particle attraction occurs automatically through the electric field configuration, eliminating the need for complex real-time control during detection.
3Force
If unidirectional electric field is generated by electrode arrangement, then particle attraction force increases, but electrode structure complexity increases
Solution Approach 1:
The patent introduces asymmetry by extending the sides of the parallel electrodes beyond the detection zone. This asymmetric extension creates a unidirectional electric field that attracts particles toward the detection area, increasing attraction force without requiring complex multi-electrode configurations.
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 design improves manufacturability, enhances sensitivity, and maintains robustness by attracting charged particles effectively, allowing for efficient detection of conductive particles with reduced complexity and increased sensitivity.
Implementation Method 1
a first electrode is arranged in relation to a gas flow direction in a first section of the sensor and is designed in such a way that the first electrode acts as a suction electrode
Implementation Method 2
The measurement of the electrical resistance between the electrodes is a measure of the soot particle concentration in the measured exhaust gas stream
Data Source
AI summary
A sensor for detecting conductive particles in a gas flow, comprising a substrate having two front sides, wherein a gas flow direction is from a first front side to a second front side, wherein a resistive electrode structure comprising at least two electrodes is formed on the substrate, the at least two electrodes are electrically separated, wherein in relation to the gas flow direction, a first electrode is arranged in a first section of the sensor such that the first electrode acts as a suction electrode, wherein a sensor detection region is formed in a second section of the sensor, whereby the sensor detection region is formed by portions of the first electrode and a second electrode, wherein the second electrode is formed at least partially in a third section of the sensor.