Printed Gas Sensor Solid Gel Electrolyte Design
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Solution Overview
Problem
Existing electrochemical gas sensors are costly, large, and have limited performance due to issues with electrolyte stability, temperature sensitivity, and maintenance requirements, making them unsuitable for widespread, cost-effective applications in detecting toxic gases like carbon monoxide.
Innovation Solution
A printed gas sensor design featuring a porous substrate, porous electrodes, and a solid or gel electrolyte layer encapsulated within an encapsulation layer, allowing for compact, low-cost, and high-performance detection of gases by utilizing alternative polymer components and a capillary channel for electrolyte filling and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid electrolyte is used in conventional sensors, then ionic conductivity is achieved, but the sensor requires frequent maintenance due to evaporation and leakage
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 leakage issues while maintaining ionic conductivity, thereby improving reliability and reducing maintenance frequency without sacrificing electrical performance
Solution Approach 2:
The solid or gel electrolyte enables the sensor to be designed as a disposable, low-cost device. The simplified construction without large reservoirs and reduced maintenance needs make the sensor economically viable for single-use or limited-life applications, aligning with the principle of using simpler, shorter-lived components
2Reliability
If large electrolyte reservoirs are used, then electrolyte stability is maintained, but the sensor size increases making integration difficult
Solution Approach 1:
The patent employs thin film structures for the solid or gel electrolyte layer, replacing bulky liquid reservoirs. This thin-film approach maintains sufficient electrolyte for operation while dramatically reducing sensor volume, enabling integration into compact devices and portable applications
Solution Approach 2:
Changing the electrolyte from liquid to solid/gel form fundamentally alters the volume requirements. Solid and gel electrolytes can be deposited as thin films that provide stable ionic conduction without requiring large containment volumes, thus resolving the contradiction between stability and size
3Reliability
If NAFION layers are used for coating electrodes, then liquid proton conduction is achieved, but the sensor cannot operate at temperatures of 0°C and below due to freezing
Solution Approach 1:
The patent changes the electrolyte from liquid to solid or gel state, which eliminates the freezing point limitation. Solid and gel electrolytes maintain their structural integrity and ionic conductivity at sub-zero temperatures without freezing, thereby extending the operating temperature range while preserving proton conduction capability
Solution Approach 2:
The invention extracts the water component from the electrolyte system (using non-aqueous electrolytes or anhydrous gel systems), thereby removing the freezing point constraint entirely. This allows the sensor to operate in cold environments where water-based electrolytes would freeze
4Productivity
If liquid electrolyte sensors are manufactured, then high volume production is possible, but manufacturing costs remain high
Solution Approach 1:
The patent changes the electrolyte formulation to solid or gel types that can be applied using low-cost printing techniques such as screen printing, inkjet printing, or dip-coating. These methods are suitable for high-volume production and reduce material waste, thereby lowering manufacturing costs while maintaining scalability
Solution Approach 2:
The solid/gel electrolyte enables a disposable sensor design that eliminates expensive components like large reservoirs, complex sealing mechanisms, and maintenance systems. The simplified construction reduces per-unit manufacturing cost, making high-volume production economically viable for single-use applications
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 creation of compact, cost-effective gas sensors with improved performance and longevity, capable of detecting a range of gases, including carbon monoxide, with enhanced stability and reduced maintenance needs, suitable for various applications from home monitoring to industrial use.
Implementation Method 1
a porous substrate; an electrode layer, wherein the electrode layer comprises two or more porous electrodes that are formed on one side of said porous substrate
Implementation Method 2
a solid, liquid, gel or similarly functional electrolyte layer, wherein the electrolyte layer is in electrolytic contact with the electrode layer
Implementation Method 3
an encapsulation layer, wherein the encapsulation layer encapsulates the electrode layer and part or all of its substrate and electrolyte layer, thereby forming an integrated structure
Data Source
AI summary
A printed gas sensor is disclosed. The sensor may include a partially porous substrate, an electrode layer, an electrolyte layer, and an encapsulation layer. The electrode layer comprises one or more electrodes that are formed on one side of the porous substrate. The electrolyte layer is in electrolytic contact with the one or more electrodes. The encapsulation layer encapsulates the electrode layer and electrolyte layer thereby forming an integrated structure with the partially porous substrate.