Polymeric Sleeve Electrochemical Sensor for Harsh Environments

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing electrochemical sensors face issues with durability and contamination in harsh environments due to glass breakage and limited space for reference electrolytes, which affects their longevity and maintenance in industrial and laboratory settings.

Innovation Solution

An electrochemical sensor design featuring a polymeric sleeve for electrical insulation within a protective outer shaft, allowing increased space for the reference electrolyte and enhanced robustness, along with a support structure and materials like PEEK and titanium for high chemical resistance, and an optional temperature sensor for environmental adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a glass sensing electrode is used in harsh environments, then measurement precision is maintained, but the electrode is prone to breakage and contamination

Engineering Contradiction:

Improvesensor durabilityVSAvoidglass breakage and contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent combines glass sensing electrode with polymeric protective shaft and sleeve to create a composite structure. The glass membrane maintains measurement precision while the polymeric outer shaft and sleeve provide mechanical protection against breakage and chemical resistance in harsh environments, eliminating the vulnerability of pure glass construction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polymeric sleeve acts as an intermediary protective layer between the glass sensing electrode and the harsh external environment. This intermediate polymeric barrier prevents direct exposure of the glass electrode to damaging conditions while allowing the electrode to function, thus protecting against breakage and contamination.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If a polymeric shaft is used to protect the sensing electrode, then robustness is enhanced, but the space for reference electrolyte is limited

Engineering Contradiction:

Improvesensor robustnessVSAvoidreference electrolyte space

Core Design Contradiction:

StrengthVSVolume of stationary object

Solution Approach 1:

The protective shaft is segmented into an outer polymeric shaft and an inner sensing electrode assembly. This segmentation allows the polymeric shaft to provide external protection while the inner assembly maintains the reference electrolyte chamber with sufficient volume, separating the protective function from the electrolyte housing function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensing electrode assembly including the reference electrolyte chamber is nested within the polymeric protective shaft. This nested configuration allows the compact reference electrolyte space to be efficiently arranged within the protective structure, maximizing the use of available volume while maintaining both protection and electrolyte capacity.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Adaptability or versatility

If standard 12 mm diameter glass membrane sensors are used, then compatibility with existing housings is achieved, but the sensors remain vulnerable to breakage

Engineering Contradiction:

Improvehousing compatibilityVSAvoidsensor durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent maintains the standard 12 mm diameter glass membrane sensing electrode to ensure compatibility with existing housings, while adding a polymeric protective shaft and sleeve that provides enhanced mechanical strength and chemical resistance. This composite approach preserves housing compatibility while dramatically improving durability against breakage in harsh environments.

Inventive Principle:

Principle #40Composite materials

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 design provides increased durability and longevity of the sensor, reduced maintenance frequency, and improved safety by preventing glass breakage and contamination, while maintaining compatibility with standard mounting configurations.

Implementation Method 1

The liquid junction is known to establish an electrolytic connection between the reference electrode and the measurement medium

Methodology Applied

Scientific EffectElectrolytic connection: Conduction (electrical)

Implementation Method 2

the sensor sleeve is a polymeric sleeve, which is electrically isolating and is disposed within the protective outer shaft

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS11686702B2Electrochemical sensor

Publication Date: 2023.06.27 METTLER TOLEDO GMBH

AI summary

An electrochemical sensor for potentiometric measurements in a measurement medium has a sensor head (201) at an end of a longitudinal sensor body (203). A sensing electrode (210) and a reference electrode (220) are disposed within the longitudinal sensor body. A liquid junction (223) is established between the reference electrode and the sensing electrode. The sensor is characterized by a protective outer shaft (250) into which a polymeric tube-like structure (230) is disposed, electrically isolating the protective outer shaft from a reference electrolyte.