Stretchable Electrode Liquid Level Sensor for Non-Flat Surfaces
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Solution Overview
Problem
Conventional non-contact capacitive liquid level sensors are limited to flat surfaces due to their rigid construction, making them ineffective for use on non-flat surfaces such as round containers, and they require direct contact with the liquid, which can lead to corrosion and damage from vapors or foam.
Innovation Solution
A stretchable electrode layer with a Young's modulus of less than 100 megapascals, allowing the sensor to conform to non-flat surfaces and operate non-contactly, using electroactive polymers and a layered design that includes a first and second stretchable receiver electrode and a transmitter electrode, enabling wireless data transmission for remote monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional non-contact capacitive liquid level sensors are used, then they can operate without direct contact with liquid, but they are limited to flat surfaces due to rigid construction
Solution Approach 1:
The sensor employs a flexible printed circuit board (FPC) as the substrate for mounting electrodes, replacing rigid circuit boards. This flexible substrate can be bent and conform to non-flat surfaces such as cylindrical containers, enabling the sensor to adapt to various surface geometries while maintaining its non-contact capacitive sensing functionality
Solution Approach 2:
The sensor design incorporates a flexible, bendable structure that can dynamically adapt to different surface shapes during installation. The FPC substrate allows the sensor to be physically deformed into different configurations to match the target surface geometry, transforming a static rigid structure into a dynamically adaptable one
2Reliability
If contact sensors are used, then liquid level can be measured, but the sensor comes into contact with liquid causing corrosion and damage
Solution Approach 1:
The sensor uses capacitive coupling through the container wall as an intermediary medium to sense liquid level without direct contact. The electric field penetrates the container wall to detect changes in dielectric constant caused by liquid presence, allowing measurement while maintaining physical isolation from corrosive liquid environments
Solution Approach 2:
The invention replaces mechanical contact-based sensing with non-contact capacitive sensing. Instead of physical electrodes touching the liquid, the system uses electric field interaction through the container wall to detect liquid level, eliminating mechanical wear and chemical corrosion issues
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 can effectively measure liquid levels on non-flat surfaces without direct contact, preventing corrosion and damage, and allows for remote monitoring, reducing manual checks and enabling automated refilling processes.
Implementation Method 1
measuring a capacitance between a transmitter electrode and a receiver electrode
Implementation Method 2
A stretchable transmitter electrode can be configured to generate an electric field, and a stretchable receiver electrode can be configured to detect the electric field
Data Source
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AI summary
An example liquid level sensor is described. The liquid level sensor includes a first layer, a stretchable electrode layer provided on the first layer, and a second layer provided on the stretchable electrode layer. The stretchable electrode layer includes a first stretchable receiver electrode and a stretchable transmitter electrode. The liquid level sensor can include an electrical connector for coupling the liquid level sensor to a computing device. The computing device can be configured to determine a liquid level within the container and wirelessly transmit data indicative of the liquid level.