Ruggedized Organic-Liquid Sensor With Protective Primer for Wet Detection
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Solution Overview
Problem
Existing sensors for detecting organic liquids are prone to corrosion and damage when exposed to water, affecting their performance in wet and dry conditions and various temperatures.
Innovation Solution
A sensor design featuring a circuit board with a sensor film deposited in a horseshoe pattern, treated to enhance adhesion and protected by a non-conductive primer, and incorporating a mildewcide to prevent corrosion and fungus, allowing for quick detection of organic liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor uses exposed conductive metals for electrical coupling, then the electrical conductivity is improved, but the corrosion resistance deteriorates
Solution Approach 1:
A non-conductive primer layer is introduced as an intermediary between the conductive sensor film and the environment. This primer layer protects the conductive metals from water exposure while maintaining electrical functionality through the sensor film's conductive particles, resolving the contradiction between conductivity and corrosion resistance
Solution Approach 2:
The sensor employs a composite structure combining conductive particles embedded in a non-conductive polymer matrix, topped with a non-conductive primer layer. This composite approach enables both electrical conductivity (through particles) and corrosion protection (through the polymer and primer layers) simultaneously
2Measurement precision
If the sensor film uses conductive particles for detection, then the detection capability is improved, but the susceptibility to fungus and mildew increases
Solution Approach 1:
The sensor film combines conductive particles with a non-conductive polymer matrix that resists mildew and fungus. This composite material maintains detection capability through the conductive particles while the polymer base prevents biological degradation, resolving the contradiction between detection precision and susceptibility to organic degradation
3Adaptability or versatility
If the sensor is exposed to water for detection purposes, then the detection range is improved, but the durability deteriorates
Solution Approach 1:
The non-conductive primer layer acts as a protective intermediary that allows the sensor to operate in wet environments while preventing water from reaching and damaging the conductive components, thus maintaining both detection capability in wet conditions and long-term durability
Solution Approach 2:
The sensor utilizes thin film structures with hydrophobic or water-resistant properties that allow water contact for detection while protecting the underlying conductive structure, enabling operation in wet conditions without compromising durability
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 provides enhanced corrosion resistance and durability, enabling accurate detection of organic liquids in wet and dry conditions across a range of temperatures while minimizing exposure to conductive metals and preventing mildew growth.
Implementation Method 1
The sensors can be configured to detect potential hydrocarbons and/or oils by changing a value of an electrical property, such as a resistance of the sensor, in the presence of the hydrocarbons and/or oil
Data Source
AI summary
An organic liquid sensor configured to output a signal corresponding to the presence of one or more organic liquids is provided. The sensor includes a circuit board, a sensor film deposited on the circuit board, the sensor film including a first length, a second length, and a bridge portion, the first length and the second length being electrically separated by a gap and the bridge portion being electrically coupled to the first length and the second length. The circuit board is configured to detect a resistance of the sensor film.