Planar Ceramic Electrochemical Gas Sensor Housing
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Solution Overview
Problem
Existing housing structures for electrochemical gas sensors face challenges in miniaturization due to the use of gaskets and caulking, which complicates production control and electrode connections, and the application of pressure on conductive membranes is difficult to ensure consistent contact.
Innovation Solution
A compact electrochemical gas sensor design featuring a planar ceramic housing with a recess, an ionic conductive membrane, and electrically conductive gas diffusion membranes, where a metal lid presses the membranes against the housing to establish electrical connections without the need for caulking, ensuring reliable and consistent contact with a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a gasket and caulking structure is used to fix the MEA between metal plates, then the housing can be assembled, but the gas sensor becomes large and production control becomes difficult
Solution Approach 1:
The patent removes the gasket and caulking components from the traditional housing structure. Instead of using separate fastening elements, the invention integrates the fixing function directly into the housing body through recesses that mechanically hold the MEA and conductive membranes in place, thereby eliminating unnecessary components and reducing overall sensor size
Solution Approach 2:
The patent combines multiple functions into the housing structure itself. The housing recesses serve both as structural support and as the fixing mechanism for the MEA and membranes. Additionally, the housing integrates electrical connection paths that extend from the bottom surface to the recess bottom, merging mechanical support and electrical connectivity into a single integrated component
2Ease of manufacture
If caulking is used to fix the MEA, then the components can be held in place, but the MEA position varies and production control becomes difficult
Solution Approach 1:
The housing is divided into multiple recesses, each precisely designed to hold specific components (MEA, conductive membranes) in predetermined positions. This segmentation approach replaces the continuous pressure application of caulking with discrete, geometry-defined positioning features that ensure uniform placement
Solution Approach 2:
The recesses act as intermediary structures between the housing and the MEA/membranes. These recesses provide a geometric interface that ensures consistent positioning without requiring variable caulking pressure, thereby improving manufacturing precision through a mediating structural element
3Adaptability or versatility
If permeable electrically conductive membranes are used, then gas diffusion is enabled, but it becomes difficult to press the membranes with predetermined pressure to secure contact
Solution Approach 1:
The housing recesses are designed with specific local geometries that provide predetermined pressure distribution to the conductive membranes. The recess depth and wall angles are optimized to apply just enough pressure to ensure electrical contact while maintaining the membranes' permeability for gas diffusion, addressing different requirements at different locations
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
This design allows for the creation of compact, uniformly performing gas sensors with improved electrode connections and reduced production complexity, enabling easier installation on substrates while maintaining air-tightness and consistent gas permeability.
Implementation Method 1
said lid presses the first and second electrically conductive membranes and the MEA toward the bottom surface of the recess
Implementation Method 2
an ionic conductive membrane, a first electrode on a surface of the ionic conductive membrane, a second electrode on an opposite surface of the ionic conductive membrane
Implementation Method 3
a first electrically conductive gas diffusion membrane and a second electrically conductive gas diffusion membrane
Data Source
AI summary
An electrochemical gas sensor has a planar ceramic housing having a recess, a MEA, first and second electrically conductive gas diffusion membranes, and a metal lid fixed on the housing so as to cover the recess. The MEA is provided with an ionic conductive membrane, a first electrode on a surface of the membrane, and a second electrode on the opposite surface of the membrane. The first electrically conductive gas diffusion membrane is electrically connected to the first electrical connection. The second electrically conductive gas diffusion membrane is electrically connected to the second electrical connection. The lid presses the second electrically conductive gas diffusion membrane toward the MEA, and in the lid or in the bottom of the housing, a gas inlet is provided. The electrochemical gas sensor is easily made compact, small in the variations in the performances, and easily installed on a print circuit board.