Sensor Module with Carbon Contact Plates for Chemical Resistance
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Solution Overview
Problem
Existing sensor modules for measuring electrical variables in solid-state environments, such as soil, face challenges in maintaining good electrical contactability, chemical resistance, and mechanical stability, especially when exposed to aggressive environments and mechanical loads.
Innovation Solution
The sensor module incorporates a sensor element arranged between inner and outer contact plates made of electrically conductive carbon material, with a meander-shaped sensor wire and a non-corroding coating, housed in a gas- and liquid-tight carbon contact plate, and secured with a conductive filling compound and non-conductive plastic bonding, ensuring mechanical and chemical protection while maintaining low contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor element is made from non-corroding material with protective coating, then chemical resistance is improved, but electrical conductivity may deteriorate
Solution Approach 1:
The sensor element combines a non-corroding base material (such as gold or other chemically resistant materials) with conductive properties. The contact plates are made of carbon material which provides both electrical conductivity and chemical resistance. This composite approach ensures that the sensor element maintains low contact resistance while being protected against chemical corrosion in aggressive environments.
2Reliability
If the sensor element is placed between two contact plates made of carbon material, then chemical resistance and mechanical protection are improved, but device complexity increases
Solution Approach 1:
The sensor element is integrated between the inner and outer contact plates in a compact sandwich structure. The carbon material contact plates serve multiple functions: providing electrical conductivity, chemical resistance, and mechanical protection for the sensor element. This merging of functions into the contact plates simplifies the overall structure compared to having separate protective housings and contact mechanisms.
Solution Approach 2:
The contact plates made of carbon material perform multiple functions simultaneously: they provide electrical contact, protect the sensor element from chemical corrosion, and offer mechanical support. This multi-functionality reduces the need for additional separate components, thereby simplifying the device structure while improving reliability.
3Reliability
If the contact plates are made gas- and liquid-tight through hot pressing and carbonization, then chemical resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The carbon material undergoes thermal processing parameters changes including hot pressing at elevated temperatures and carbonization to transform the material structure. This process creates a dense, gas- and liquid-tight structure with enhanced chemical resistance. The parameter changes in temperature and pressure during manufacturing achieve the desired material properties.
4Stability of the object's composition
If the sensor element is embedded in the contact plate during formation, then mechanical stability is improved, but positioning precision requirements increase
Solution Approach 1:
The sensor element is positioned and embedded in the contact plate during the formation process itself, before the contact plate is fully carbonized and hardened. This preliminary action allows for easier positioning and adjustment of the sensor element while the material is still in a more workable state, reducing the precision requirements compared to attempting to embed it after full carbonization.
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
This configuration provides secure, reliable electrical contact and enhanced chemical resistance, allowing the sensor module to function effectively in chemically aggressive environments and withstand mechanical stress, while also offering improved mechanical stability and reduced contact resistance.
Implementation Method 1
an inner and an outer contact plate made of an electrically conductive carbon material
Implementation Method 2
which is produced as a gas- and liquid-tight plate in a hot pressing process from a carbon material
Implementation Method 3
which is carbonized after the molding process
Implementation Method 4
The sensor element can preferably be formed from non-corroding material or material provided with a non-corroding coating
Data Source
Figure 1~3
Figure 4~7
AI summary
The invention relates to a sensor module (10) for measuring an electrical variable, comprising at least one electrode (12, 13), which is arranged in a housing (58) made of an electrically insulating material and which can be connected to an electrical measuring device by means of a connecting cable, wherein the electrode has a sensor element, which is arranged between an inner and an outer contact plate (26, 27) made of a carbon material and which is connected to the connecting cable, wherein an outer contact plate (27) of the electrode is arranged in an outer surface of the housing.