Unibody Impedance Sensor via Additive Manufacturing
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Solution Overview
Problem
Existing impedance sensors for monitoring fluids in industrial machinery require complex assembly of multiple pieces, which is costly and limits their structural integrity and sensitivity for broad applications.
Innovation Solution
A unibody impedance sensor is formed using additive manufacturing techniques, integrating mechanical and electrical support components, allowing for complex shapes and non-conventional designs that reduce assembly costs and enhance sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate electrodes are used in traditional impedance sensors, then the sensor can be manufactured using conventional methods, but the assembly becomes complex and costly with reduced structural integrity
Solution Approach 1:
The patent merges multiple separate electrodes into a single unibody structure where multiple sensing elements are integrated into one piece. This eliminates the need for complex assembly of multiple components while maintaining the functional requirements of multiple electrodes, directly resolving the contradiction between structural integrity and assembly complexity.
2Ease of manufacture
If multiple separate electrodes are assembled in complex configurations, then the sensor can be manufactured separately, but the sourcing and assembly costs increase significantly
Solution Approach 1:
The patent combines multiple electrodes into a single unibody component that can be manufactured as one piece using additive manufacturing. This eliminates the need for separate sourcing and assembly of multiple electrodes, reducing costs while simplifying the manufacturing process.
Solution Approach 2:
The patent employs additive manufacturing technology to create complex geometries that would be difficult or impossible to achieve with traditional manufacturing methods. This parameter change in manufacturing approach enables the unibody design with multiple sensing elements to be produced efficiently.
3Measurement precision
If traditional impedance sensors are used, then the assembly can be manufactured with conventional techniques, but the flow characteristics across larger surfaces are suboptimal
Solution Approach 1:
The patent integrates multiple sensing elements into a unibody configuration that optimizes flow characteristics across larger surface areas. This merged structure allows for better fluid distribution and contact with sensing elements, improving impedance measurement accuracy while eliminating complex multi-component configurations.
Data Source
AI summary
A sensor having a sensor head including a unibody construction, a first electrode, and at least one second electrode is provided. The first electrode can include a first pair of sensing elements coupled to each over via at least one bridge element extending from a first sensing element to a second sensing element. The at least one second electrode can include a second pair of sensing elements interleaved with the first pair of sensing elements. The second pair of sensing elements can be coupled to each other via at least one second bridge element extending from a third sensing element to a fourth sensing element. A method of manufacturing the sensor is also provided.