Sensor Manufacturing Using Spontaneous Transition Layer
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Solution Overview
Problem
Existing gas sensors using metal oxide nanoparticles face challenges in maintaining gas response while stabilizing nanoparticles on device electrodes, as high-temperature heat used to remove bonding agents can lead to contamination and unexpected characteristics.
Innovation Solution
A method of manufacturing a sensor involving the formation of a sensor layer by coating nanoparticle layers with cobalt oxide, forming a spontaneous transition layer with cobalt hydroxide using deionized water, and annealing at temperatures between 300° C to 700° C to enhance adhesive force and gas response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high-temperature heat is applied to remove bonding agent, then bonding agent is removed, but nanoparticle contamination occurs and unexpected characteristics arise
Solution Approach 1:
The patent extracts and removes the organic bonding agent (alpha-terpineol) from the nanoparticle mixture through solvent extraction using a non-aqueous solvent, separating the bonding agent from the metal oxide nanoparticles without requiring high-temperature heat treatment that would cause contamination
Solution Approach 2:
The patent introduces a non-aqueous solvent as an intermediary substance to dissolve and remove the organic bonding agent, acting as a mediator between the nanoparticle layer and the bonding agent removal process, avoiding direct high-temperature thermal processing
2Stability of the object's composition
If nanoparticles are immobilized using organic bonding agent, then nanoparticles are fixed on electrode, but gas response is compromised
Solution Approach 1:
The patent removes the organic bonding agent from the nanoparticle composition through solvent extraction, eliminating the substance that compromises gas response while maintaining nanoparticle fixation through alternative means
Solution Approach 2:
The patent uses a soluble organic compound as a temporary bonding agent that can be easily removed by solvent extraction, allowing the nanoparticles to be fixed during processing and then released to maintain their gas sensing capability
3Ease of manufacture
If high-temperature heat is applied to process sensor layer, then sensor layer is formed, but space between sensor materials and device is affected
Solution Approach 1:
The patent replaces high-temperature thermal processing with a chemical solvent extraction method to remove bonding agents, substituting thermal mechanics with chemical processes to achieve sensor layer formation without affecting the spacing between sensor materials and device components
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 method results in a sensor layer with improved adhesive force and gas response, achieving stability and performance comparable to or exceeding that of typical sensor layers, with a response of 0.6 to 0.7 and long-term stability of 0.5 to 0.6.
Implementation Method 1
providing deionized water on the nanoparticle layer to form a spontaneous transition layer which includes cobalt hydroxide
Implementation Method 2
annealing the spontaneous transition layer at a temperature of 300° C. to 700° C. to form the sensor layer
Data Source
AI summary
Disclosed is a sensor and a method of manufacturing the same. The method includes forming a plurality of electrodes on a substrate and forming a sensor layer on the substrate between the plurality of electrodes. The forming of the sensor layer includes coating a nanoparticle layer, providing deionized water on the nanoparticle layer to form a spontaneous transition layer, and annealing the spontaneous transition layer to form the sensor layer.