Printed Impedance Sensor With Coated Electrode for Corrosion Resistance
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Solution Overview
Problem
Existing sensors for measuring salinity and sugar content in edible oil and fat are bulky, costly, and prone to corrosion and durability issues due to manufacturing methods like vacuum deposition, necessitating a compact, reliable, and cost-effective alternative.
Innovation Solution
A sensor manufactured using a printing method with a conductive layer composed of Graphite and carbon black, integrated with a substrate like PET, and a coating electrode to enhance conductivity and durability, eliminating the need for a separate power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum deposition method is used to form sensing electrode, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent changes the manufacturing method from vacuum deposition to printing method, altering the process parameters and conditions. This substitution maintains sufficient manufacturing precision for the sensing electrode while significantly reducing process complexity and equipment requirements
Solution Approach 2:
The patent adopts a printing method that uses consumable ink or paste materials containing conductive particles and binder, replacing expensive and complex vacuum deposition equipment. This approach reduces manufacturing cost and device complexity while achieving acceptable precision
2Manufacturing precision
If vacuum deposition method is used to form sensing electrode, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing method from vacuum deposition to printing method, altering the process parameters and conditions. This substitution maintains sufficient manufacturing precision for the sensing electrode while significantly reducing process complexity and equipment requirements
Solution Approach 2:
The patent adopts a printing method that uses consumable ink or paste materials containing conductive particles and binder, replacing expensive and complex vacuum deposition equipment. This approach reduces manufacturing cost and device complexity while achieving acceptable precision
3Ease of manufacture
If printing method is used to manufacture sensor, then manufacturing cost is reduced, but reliability deteriorates due to corrosion
Solution Approach 1:
The patent uses a composite material composition for the sensing electrode, combining conductive particles (silver, carbon, or conductive polymer) with a binder. This composite structure provides both electrical conductivity and corrosion resistance, improving reliability while maintaining the low-cost printing manufacturing advantage
Solution Approach 2:
The patent specifies controlled ratios of conductive particles to binder (conductive particles: 70-95 wt%, binder: 5-30 wt%) to optimize both conductivity and corrosion resistance, ensuring reliable sensor performance
4Adaptability or versatility
If terminal type sensor is used, then measurement function is integrated, but volume and weight increase
Solution Approach 1:
The patent extracts the power supply function from the sensor itself, making the sensor passive and eliminating the need for internal batteries or power sources. The sensor only performs measurement and transmits results to external devices, significantly reducing weight and volume while maintaining functional integration
Solution Approach 2:
The patent leverages the smartphone or external device to perform multiple functions (power supply, data processing, display), allowing the sensor to be minimalistic while the external device provides universal functionality
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 sensor achieves compact size, reduced manufacturing costs, and improved reliability by using electronic printing, ensuring precise impedance measurements without deformation or corrosion.
Implementation Method 1
senses an impedance change of a target material to measure salinity and a sugar content
Data Source
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AI summary
Provided is a sensor comprising a non-conductive substrate; and a conductive layer electronically printed on one side of the substrate, wherein the conductive layer comprises: an antenna pattern for transmitting and receiving a radio signal with an external device; a sensing electrode connected to the antenna pattern via a circular wiring for sensing an impedance change due to contact with a sensing target material; and a coating electrode stacked on the sensing electrode for removing an occurrence of noise of the impedance change. Accordingly, the present invention solves the problem of a sensor, in the form of a terminal, not being compact and the problem of high manufacturing costs and low manufacturing quality of a sensor manufactured using a deposition method in order to replace such sensor with a sensor manufactured by a printing method, and solves a corrosion problem of a sensing electrode, a durability problem, etc. that may occur in the sensor of the printing method.