Printed Gas Sensor Using Gel Electrolyte for Extended Lifetime
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electrochemical gas sensors are costly, large, and have short lifespans due to liquid electrolyte evaporation and corrosion, limiting their use in high-volume, low-cost applications for detecting toxic gases like carbon monoxide, and they often require heating, which increases power consumption and reduces sensitivity.
Innovation Solution
A printed gas sensor design featuring a porous substrate, multiple porous electrodes, a solid, liquid, or gel electrolyte layer, and an encapsulation layer that forms an integrated structure, allowing for efficient gas permeation and reaction while minimizing size and power requirements, and extending sensor lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid electrolyte is used in prior art gas sensors, then the sensor can achieve electrochemical detection function, but the sensor lifetime is limited to 6-12 months due to rapid drying and evaporation
Solution Approach 1:
The patent changes the physical state of the electrolyte from liquid to solid or gel form. This parameter change eliminates evaporation and drying issues, extending sensor lifetime beyond the 6-12 month limitation of liquid electrolyte systems while maintaining electrochemical detection functionality.
Solution Approach 2:
The patent employs composite material structures, particularly in the electrolyte formulation combining solid or gel phases with appropriate ionic conductive materials. This composite approach maintains the necessary electrochemical properties while preventing the evaporation and degradation associated with pure liquid electrolytes.
2Measurement precision
If heating is applied to the sensing element to achieve fast response time and high sensitivity, then detection performance improves, but power consumption increases
Solution Approach 1:
The patent changes the operating temperature parameter from elevated heated temperatures to room temperature operation. This is achieved through optimized solid/gel electrolyte materials and electrode designs that enable fast response and high sensitivity without requiring external heating, thus eliminating the power consumption penalty.
Solution Approach 2:
The patent replaces the thermal heating mechanism with alternative approaches to achieve fast response and high sensitivity, such as optimized electrochemical interfaces, catalytic materials, and electrolyte formulations that enable rapid gas diffusion and electron transfer at room temperature, eliminating the need for thermal energy input.
3Measurement precision
If conventional electrochemical cell design is used, then detection accuracy is achieved, but manufacturing cost exceeds $25 each and can reach several hundred dollars
Solution Approach 1:
The patent employs porous electrode structures and porous substrate materials that enable cost-effective manufacturing through simplified fabrication processes. The porous architecture provides sufficient surface area for detection accuracy while allowing cheaper material usage and easier assembly compared to conventional dense electrode designs.
Solution Approach 2:
The patent merges multiple components into an integrated structure where the solid/gel electrolyte layer is formed directly on the porous substrate with electrodes, eliminating the need for separate assembly steps and reducing manufacturing complexity. This integration simplifies production and reduces costs while maintaining detection accuracy.
4Reliability
If large electrolyte or water reservoirs are used to prevent drying, then sensor lifetime improves, but device size increases making integration difficult
Solution Approach 1:
The patent changes the electrolyte from liquid to solid or gel phase, which fundamentally alters the volume requirements. Solid and gel electrolytes do not evaporate and can be used in much thinner, more compact layers, eliminating the need for large reservoirs while maintaining sufficient electrolyte supply and extending sensor lifetime.
Solution Approach 2:
The patent employs thin film structures for the solid/gel electrolyte layer that provide sufficient functionality in a compact form factor. These thin films eliminate the need for bulky liquid reservoirs while maintaining the necessary electrolyte quantity for extended operation, enabling small-form-factor integration.
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 solution enables the production of cost-effective, high-performance gas detectors that can be used in various applications, including home carbon monoxide monitoring and large-area toxic gas monitoring, with improved sensitivity and extended lifespan without the need for external heating, thus enhancing safety and reducing manufacturing costs.
Implementation Method 1
a substrate that is at least partially gas porous or gas permeable
Implementation Method 2
an electrolyte layer, wherein the electrolyte layer is in electrolytic contact with the electrode layer
Data Source
AI summary
A printed gas sensor is disclosed. The sensor may include a porous substrate, an electrode layer, a liquid or gel electrolyte layer, and an encapsulation layer. The electrode layer comprises two or more electrodes that are formed on one side of the porous substrate. The liquid or gel electrolyte layer is in electrolytic contact with the two or more electrodes. The encapsulation layer encapsulates the electrode layer and electrolyte layer thereby forming an integrated structure with the porous substrate.