Planar Electrochemical Gas Sensor Design
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Solution Overview
Problem
Traditional electrochemical gas sensors face issues with complex fabrication processes, susceptibility to environmental changes causing electrode breakage and leakage, and incompatibility with modern thin-film electronic devices due to their cylindrical design.
Innovation Solution
A plate-body thin-film electrochemical gas sensor design featuring transversely arranged electrodes, a membrane material immersed in an electrolyte, and a signal connector nested in the sensor housing, simplifying production and reducing environmental influence, with a fabrication method involving die pressing and electrolyte injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cylindrical stacked structure is used for the sensor, then the traditional design compatibility is maintained, but the fabrication process becomes complex and time-consuming with numerous manual assembly steps
Solution Approach 1:
The patent transforms the traditional cylindrical stacked structure into a planar configuration by arranging sensing electrode, reference electrode, and auxiliary electrode in a two-dimensional plane. This dimensional change eliminates the need for complex stacking and manual assembly, enabling simplified fabrication processes while maintaining sensor functionality.
Solution Approach 2:
The patent integrates multiple electrode components and functional layers into a single planar structure where sensing electrode, reference electrode, auxiliary electrode, membrane material, and electrolyte are arranged in a two-dimensional configuration. This merging of previously separate stacked components into a unified planar design reduces fabrication complexity and eliminates numerous assembly steps.
2Reliability
If a cylindrical stacked structure is used for the sensor, then the traditional design is maintained, but the stress structure becomes complicated and susceptible to environmental changes causing electrode breakage and leakage
Solution Approach 1:
By transitioning from a three-dimensional cylindrical stacked structure to a two-dimensional planar configuration, the patent reduces structural complexity and minimizes stress concentration points. The planar arrangement distributes mechanical stress more evenly across the sensor components, reducing susceptibility to electrode breakage and leakage under environmental variations in temperature, humidity, and pressure.
3Adaptability or versatility
If a high stacked cylinder design is used for the sensor, then the traditional structure is maintained, but the matching degree with modern thin-film electronic devices is poor
Solution Approach 1:
The patent adopts a planar geometry that aligns with the two-dimensional nature of modern thin-film electronic devices. This dimensional transformation enables better integration and matching with flat-panel displays, flexible electronics, and other contemporary thin-film technologies, replacing the incompatible cylindrical form factor.
4Productivity
If manual assembly is used for the stacked structure, then the traditional fabrication method is maintained, but time and energy are wasted
Solution Approach 1:
By integrating multiple electrode components and functional layers into a single planar structure, the patent enables all components to be fabricated simultaneously using printing or deposition techniques rather than requiring sequential manual assembly. This merging approach dramatically reduces production time and increases manufacturing efficiency.
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated printing or deposition processes. The planar structure allows electrodes and functional layers to be deposited directly onto substrates using printing techniques, eliminating the need for time-consuming manual stacking and assembly operations.
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 new design enhances production efficiency, reduces issues like electrode breakage and leakage, and improves compatibility with modern gas detection instruments by being more flattened and less affected by temperature, humidity, and pressure changes.
Implementation Method 1
a membrane material (5), and a sensor housing (6)... The membrane material (5)... is immersed in the electrolyte (4) to play a role in maintaining electrolyte and increasing the wettability of the sensing electrode (1), the reference electrode (2) and the auxiliary electrode (3)
Implementation Method 2
The electrolyte (4) includes, but is not limited to, acid, base, salt and other solutions capable of releasing ions and or protons
Implementation Method 3
gas molecules diffused in from the air inlet (7)
Data Source
AI summary
Provided are an electrochemical gas sensor and a fabrication method therefor. A sensing electrode, a reference electrode and an auxiliary electrode in a planar arrangement are arranged on an upper layer in a sensor housing, and an electrolyte and a membrane material are arranged on a lower layer in the sensor housing. An upper part of the sensor housing is provided with a vent, and a lower part of the sensor housing is provided with a connector for connecting three electrodes and connected to an external circuit. Compared with the traditional cylindrical stacked electrochemical gas sensor, the fabrication method for a plate-body thin-film type sensor is simple, is less affected by the change of ambient pressure, temperature and humidity, and is beneficial to the flattening and miniaturization of electronic instruments and apparatus for gas analysis.