Planar pH Sensor Element Bonding With a Glass Intermediary Layer
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Solution Overview
Problem
Conventional methods for producing planar sensor elements face challenges in mechanical stability and adhesion issues due to wetting problems at the interface between the glass body and the substrate or carrier body, leading to production rejects and susceptibility to mechanical damage.
Innovation Solution
A method involving the formation of an electrically insulating glass layer on a base body, followed by attaching a copper or copper-based alloy substrate, and then integrating a glass body to form a sensor element with an ion-selective glass layer, controlled at specific temperatures to ensure robust bonding without slipping, thereby avoiding wetting issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a glass body is directly bonded to a substrate or carrier body, then the sensor element can be produced, but wetting problems at the interface occur leading to adhesion issues and mechanical instability
Solution Approach 1:
The patent introduces an intermediate layer between the glass body and the substrate/carrier body to eliminate direct contact and prevent wetting problems. This intermediate layer acts as a mediator that ensures proper adhesion without the harmful wetting effects that occur when glass directly bonds to certain substrates, thereby resolving the adhesion quality issue.
2Productivity
If conventional production methods are used for planar sensor elements, then production can proceed, but mechanical stability is compromised and production rejects increase
Solution Approach 1:
By introducing the intermediate layer, the patent eliminates the root cause of mechanical instability (wetting problems at the interface) while maintaining production continuity. This allows conventional production workflows to proceed without the need for complex corrective measures, thereby improving both productivity and reliability simultaneously.
3Ease of manufacture
If direct bonding of glass body to substrate is performed, then the structure can be formed, but susceptibility to mechanical damage increases
Solution Approach 1:
The intermediate layer serves as a protective buffer between the glass body and substrate, reducing stress concentration and improving the overall mechanical durability of the sensor element. This allows the structure to be formed easily while simultaneously enhancing its resistance to mechanical damage.
4Reliability
If an intermediate layer is introduced to prevent wetting problems, then adhesion quality improves, but the number of production steps increases
Solution Approach 1:
The patent optimizes the parameters of the intermediate layer (such as material composition, thickness, and bonding temperature) to enable effective adhesion while minimizing the impact on the production process. By carefully controlling these parameters, the intermediate layer can be integrated into existing production workflows with minimal additional complexity.
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 approach enables the reproducible production of mechanically stable planar sensor elements with a smooth surface, minimizing production defects and enhancing durability, particularly suitable for applications with hygiene requirements.
Implementation Method 1
forming a glass layer made of an electrically insulating glass on a surface of a base body
Implementation Method 2
controlling a temperature of the arrangement of the base body, substrate and glass body thus formed in such a way that the substrate is integrally bonded to the glass body made of the ion-selective glass and the glass layer on the surface of the base body
Data Source
AI summary
A method for manufacturing a sensor element for a potentiometric sensor includes: forming a glass layer made of an electrically insulating glass on a surface of a base body, in particular a base body made from an electrically insulating material; arranging a substrate made of copper or a copper-based alloy having a mass fraction of at least 60% copper on the glass layer; covering the substrate arranged on the glass layer with a glass body, for example a glass plate, made of an ion-selective, in particular pH-selective, glass; and subsequently controlling the temperature of the arrangement of the base body, substrate and glass body thus formed in such a way that the substrate is integrally bonded to the glass body made of the ion-selective glass and the glass layer on the surface of the base body.