Sulfidation Detection Sensor Protective Film Layout for Electrode Stability
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Solution Overview
Problem
Existing sulfidation detection sensors face issues with detachment of external electrodes due to inclined surfaces of protective films, which compromises their sensitivity and reliability in detecting sulfidation in electronic components exposed to sulfide gas.
Innovation Solution
A method of manufacturing sulfidation detection sensors involving the use of insoluble and soluble protective films, where the surface height of the soluble film is set lower than the insoluble films, preventing plating material adherence to the soluble film and thus avoiding angular shapes that could lead to electrode detachment, while maintaining high sensitivity by exposing the sulfidation detection portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sulfidation detection body is exposed without being covered with a protective film, then the sensitivity to sulfidation is improved, but the external electrodes become pointed in angular shapes which causes easy detachment
Solution Approach 1:
The protective film is divided into two functional segments: a first protective film made of insoluble material that covers the end portions of the sulfidation detection body to support electrode formation, and a second protective film made of soluble material that covers the center portion and is removed to expose the detection body for high sensitivity detection
Solution Approach 2:
Different regions of the protective film have different properties: the first protective film at the ends maintains structural integrity for electrode bonding, while the second protective film at the center is designed to be removed to enable direct exposure of the sulfidation detection body for maximum sensitivity
2Ease of manufacture
If a protective film is formed by printing of resin paste, then the manufacturing process is simplified, but the end portions of the protective film have inclined surfaces causing plating materials to form in close contact and create angular shapes
Solution Approach 1:
The first protective film is formed in advance at the end portions before external electrode formation, creating a flat surface that prevents angular shape formation during subsequent plating processes
Solution Approach 2:
The first protective film acts as an intermediary structure between the substrate and the external electrodes, providing a flat bonding surface that ensures proper electrode formation and prevents detachment
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 ensures high sensitivity in detecting sulfidation while preventing external electrode detachment, allowing for stable operation and accurate detection of sulfidation levels in electronic components.
Implementation Method 1
the protective film 103 is removed by using a solvent or the like
Implementation Method 2
by performing electrolytic plating with respect to each of the chip substrates
Data Source
AI summary
After a sulfidation detection conductor (2) is formed on a front surface of a large-sized substrate (10A), a pair of first protective films (3) made of an insoluble material is formed, respectively, on predetermined positions of the sulfidation detection conductor (2), and a second protective film (7) made of a soluble material is formed so as to cover the sulfidation detection conductor (2) positioned between the pair of first protective films (3), and thereafter, end face electrodes (5) are formed, respectively, on divided faces of each strip-shaped substrate (10B) obtained by primarily dividing the large-sized substrate (10A). Then, after external electrodes (6) are formed by performing electrolytic plating with respect to each chip substrate (10C) obtained by secondarily dividing each strip-shaped substrate (10B), a sulfidation detection portion (2a) is exposed to the outside by removing the second protective film (7), whereby a sulfidation detection sensor (10) can be obtained.