CAPACITIVE SENSOR
20230091344 · 2023-03-23
Inventors
Cpc classification
B32B18/00
PERFORMING OPERATIONS; TRANSPORTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A first detection electrode is provided on an insulating layer. A second detection electrode is provided away from the first detection electrode on the insulating layer, and forms a capacitance together with the first detection electrode. The protection layer covers the first detection electrode and the second detection electrode, has a thickness d satisfying 1 μm≤d≤10 μm, and is made of zirconia or alumina. The protection layer is a sintered body.
Claims
1. A capacitive sensor using a change of a capacitance, comprising: an insulating layer; a first detection electrode provided on the insulating layer; a second detection electrode provided away from the first detection electrode on the insulating layer, and forms the capacitance together with the first detection electrode; and a protection layer covering the first detection electrode and the second detection electrode, having a thickness d satisfying 1 μm≤d≤10 μm, and is made of zirconia or alumina, the protection layer being a sintered body.
2. The capacitive sensor according to claim 1, wherein the protection layer is made of zirconia.
3. The capacitive sensor according to claim 1, wherein the protection layer has a relative dielectric constant ε, and ε/d≥1 is satisfied.
4. The capacitive sensor according to claim 1, wherein a minimum interval between the first detection electrode and the second detection electrode is 100 μm or less.
5. The capacitive sensor according to claim 4, wherein the minimum interval is a dimension on at least one straight line, and a dimension of each of the first detection electrode and the second detection electrode is 100 μm or less on the at least one straight line.
6. The capacitive sensor according to claim 1, further comprising a heater for heating the protection layer.
7. The capacitive sensor according to claim 1, wherein the capacitive sensor is a liquid detection sensor.
8. The capacitive sensor according to claim 1, wherein the capacitive sensor is a liquid level sensor.
9. The capacitive sensor according to claim 1, wherein the capacitive sensor is a dew condensation sensor.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0024]
[0025]
[0026]
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Embodiments of the present invention are described based on the drawings hereinafter.
Embodiment 1
[0040] (Configuration)
[0041]
[0042] The detection system 500 includes a liquid level sensor 101 and a measuring device 200. The liquid level sensor 101 is a capacitive sensor performing detection using a change of a capacitance. The liquid level sensor 101 includes an insulating layer 10, a first detection electrode 21, a second detection electrode 22, and a protection layer 50. The liquid level sensor 101 may further include a first pad electrode 31, a second pad electrode 32, a first via electrode 41, and a second via electrode 42.
[0043] The insulating layer 10 is preferably made up of a ceramic insulating material, and is more preferably made up of the same material as the protection layer 50. A thickness of the insulating layer 10 is approximately 1 mm, for example.
[0044] The first detection electrode 21 is provided on one surface of the insulating layer 10 as illustrated in
[0045] A minimum interval between the first detection electrode 21 and the second detection electrode 22 is defined as an electrode interval S (
[0046] The protection layer 50 covers the first detection electrode 21 and the second detection electrode 22. The protection layer 50 includes a surface SF and a surface on a side opposite to the surface SF to face the first detection electrode 21 and the second detection electrode 22. The protection layer 50 has a thickness d satisfying 1 μm≤d≤10 μm, and preferably has a thickness d satisfying 1 μm≤d≤5 μm. The protection layer 50 is made of zirconia or alumina, and is preferably made of zirconia. The protection layer 50 has a relative dielectric constant ε, and ε/d≥10 is preferably satisfied. For example, ε of approximately 30 can be obtained by using zirconia, and ε of approximately 10 can be obtained by using alumina. ε/d≥1 is preferably satisfied.
[0047] The first pad electrode 31 is provided on an opposite surface of the insulating layer 10 from the one surface described above. The second pad electrode 32 is provided on the opposite surface of the insulating layer 10 from the one surface described above, away from the first pad electrode 31. The first via electrode 41 passes through the insulating layer 10, and includes one end connected to the first detection electrode 21 and the other end connected to the first pad electrode 31. The second via electrode 42 passes through the insulating layer 10, and includes one end connected to the second detection electrode 22 and the other end connected to the second pad electrode 32.
[0048] The measuring device 200 has a function of measuring a capacitance. The measuring device 200 is electrically connected to the first pad electrode 31 and the second pad electrode 32. Accordingly, the measuring device 200 can measure the capacitance formed by the first detection electrode 21 and the second detection electrode 22.
[0049] A plurality of processes described hereinafter are performed in a liquid detection method using the liquid level sensor 101. Performed firstly is a process of detecting the capacitance of the liquid level sensor 101. Performed next is a process of detecting the liquid LQ, specifically a process of detecting the liquid level PL of the liquid LQ based on the capacitance detected by the process of detecting the capacitance.
[0050]
[0051] A configuration that the liquid LQ and the first detection electrode 21 face each other via the protection layer 50 forms a capacitance C1 with reference to
C=C1×C2/(C1+C2).
[0052] As illustrated in
C=C1/2.
[0053] A measurement value of the capacitance C is substantially proportional to the liquid level PL as illustrated in
[0054] Herein, the capacitance C is approximated by a capacitance formed via the protection layer 50, thus is substantially proportional to a product of a relative dielectric constant and a thickness of the protection layer 50, that is ε/d. A magnitude of the capacitance C is preferably large to some extent to detect a rate of change of the capacitance C with a high degree of accuracy. Thus, ε/d is preferably large to some extent, and specifically, ε/d≥1 is preferably satisfied.
[0055] (Manufacturing Method)
[0056]
[0057] Prepared with reference to
[0058] The green sheet 50G as the protection layer 50 is pressure-bonded to the laminated body described above as illustrated by an arrow (
[0059] Next, the laminated body to which the green sheet 50G has been pressure-bonded as described above is sintered. The liquid level sensor 101 is thereby obtained.
EXAMPLE
[0060] Table 1 described hereinafter indicates an experimental result of examples A1 to A4 of the liquid level sensor 101 and comparative examples B1 and B2 thereof.
TABLE-US-00001 TABLE 1 EXAMPLE EXAMPLE EXAMPLE EXAMPLE COMPARATIVE COMPARATIVE A1 A2 A3 A4 EXAMPLE B1 EXAMPLE B2 PROTECTION MATERIAL ZIRCONIA ALUMINA GLASS ZIRCONIA LAYER RELATIVE DIELECTRIC 30 10 4 30 CONSTANT ε THICKNESS d (μm) 5 1 10 3 5 20 ε/d 6.0 30 3.0 3.3 0.8 1.5 DETECTION MATERIAL PLATINUM TUNGSTEN PLATINUM ELECTRODE SENSITIVITY LIQUID ELECTRICAL 15 120 7.0 8.0 3.5 5.0 (pF/mm) CONDUCTIVITY = 1 mS/cm LIQUID ELECTRICAL 3.0 24 1.5 2.0 0.7 1.0 CONDUCTIVITY = 0.01 mS/cm
[0061] The bottom of Table 1 described above indicates sensitivity when a liquid level of each of a liquid having an electrical conductivity of 1 mS/cm and a liquid having an electrical conductivity of 0.01 mS/cm was measured by each of these liquid level sensors. As shown by this result, higher sensitivity was obtained in the cases of examples A1 to A3, in which the protection layer 50 was made of zirconia and had the thickness d of 10 μm or less, than the case of comparative example B1, in which the protection layer 50 was made of glass and the case of comparative example B2, in which the protection layer 50 had the thickness d of 20 μm, larger than 10 μm. Higher sensitivity was obtained also in the case of example A4, in which the protection layer 50 was made of alumina and had the thickness d of 10 μm or less, specifically 3 μm, than the cases of comparative example B1 and comparative example B2.
[0062] In the above experiment, the first detection electrode 21 and the second detection electrode 22 were a pair of line patterns each having a width of 100 μm, and these line patterns were separated by a space having a width of 100 μm. In other words, a dimension of L=S=100 μm was adopted in
[0063] Table 2 described hereinafter indicates an experimental result of further examples A5 to A8 having the protection layer 50 similar to that of example A1 together with the experimental result of example A1.
TABLE-US-00002 TABLE 2 EXAMPLE EXAMPLE EXAMPLE EXAMPLE EXAMPLE A1 A5 A6 A7 A8 PROTECTION MATERIAL ZIRCONIA LAYER RELATIVE DIELECTRIC 30 CONSTANT ε THICKNESS d (μm) 5 ε/d 6 DETECTION MATERIAL PLATINUM ELECTRODE ELECTRODE WIDTH L (μm) 100 20 50 50 150 ELECTRODE INTERVAL S (μm) 100 20 30 50 150 SENSITIVITY LIQUID ELECTRICAL 15 15 15 15 12 (pF/mm) CONDUCTIVITY = 1 mS/cm LIQUID ELECTRICAL 3.0 5.0 4.0 3.5 2.0 CONDUCTIVITY = 0.01 mS/cm
[0064] Examples A1 to A7 having the electrode interval S of 100 μm or less had higher sensitivity than example A8 having the electrode interval S of 150 μm. Examples A1 to A7 having the electrode width L of 100 μm or less had higher sensitivity than example A8 having the electrode width L of 150 μm.
[0065] (Outline of Effect)
[0066] According to the present embodiment, firstly, the protection layer 50 covering the first detection electrode 21 and the second detection electrode 22 is made of zirconia or alumina. Accordingly, corrosion resistance and chemical resistance of the liquid level sensor 101 are increased.
[0067] Secondly, the thickness d of the protection layer 50 satisfies 1 μm≤d≤10 μm. Accordingly, significant reduction in sensitivity of the liquid level sensor 101 caused by the provision of the protection layer 50 is prevented while ensuring the corrosion resistance and the chemical resistance described above.
[0068] As described above, detection can be performed with a high degree of sensitivity while ensuring the corrosion resistance and the chemical resistance. Specifically, the liquid level can be detected with a high degree of sensitivity.
[0069] The protection layer 50 is preferably made of zirconia. Accordingly, the relative dielectric constant ε of the protection layer 50 takes a high value of approximately 30. Accordingly, reduction in sensitivity of the liquid level sensor 101 caused by the provision of the protection layer 50 is prevented more sufficiently.
[0070] ε/d≥1 is preferably satisfied. Accordingly, a capacitance per unit area formed via the protection layer 50 is increased. Accordingly, the sensitivity of the liquid level sensor 101 can be easily ensured sufficiently.
[0071] When the electrode interval S is 100 μm or less, higher sensitivity can be obtained. When the electrode interval S is 20 μm or more, a desired electrode interval can be formed by multilayer ceramic technology relatively easily.
[0072] When the electrode width L is 100 μm or less, higher sensitivity can be obtained. When the electrode width L is 20 μm or more, a desired electrode width can be formed by multilayer ceramic technology relatively easily.
[0073] Both the insulating layer 10 and the protection layer 50 are preferably made up of a ceramic insulating material, and is more preferably made up of the same material. Suppressed accordingly is a difference in a shrinkage ratio in a sintering process for manufacturing the liquid level sensor 101. Thus, the protection layer 50 with no pin hole can be obtained even when the thickness d thereof is relatively small. Accordingly, the thickness d can be reduced while sufficiently obtaining the effect of increasing the corrosion resistance and the chemical resistance by the protection layer 50.
[0074] A portion which is to be the protection layer 50 is preferably formed by pressure-bonding the green sheet 50G (
[0075] The first detection electrode 21 and the second detection electrode 22 are preferably made of metal having a high melting point, and is made of platinum, tungsten, or cobalt, for example. Accordingly, volatilization and melting of the electrodes in a sintering process for manufacturing the liquid level sensor 101 can be prevented.
Embodiment 2
[0076]
[0077] In the detection system 500 (
[0078] A minimum interval between the first detection electrode 21 and the second detection electrode 22 is defined as an electrode interval S (
[0079] The dew condensation sensor 102 preferably includes a heater 60 for heating the protection layer 50. Heat generation is obtained by flowing current in the heater 60. The protection layer 50 is thereby heated; thus a liquid adhering to the surface SF can be removed by evaporation. Thus, when a large amount of liquid adheres to the surface SF due to cleaning or long-term use, for example, the liquid is removed using the heater 60; thus a state where further occurrence of dew condensation can be detected can be rapidly obtained.
[0080] The heater 60 is preferably embedded inside the dew condensation sensor 102, and is more preferably embedded inside the insulating layer 10. In such a case, the dew condensation sensor 102 may include a pad electrode 71, a pad electrode 72, a via electrode 81, and a via electrode 82 to enable an electrical connection to the heater 60. One end of the via electrode 81 (an upper end in
[0081] The heater 60 described above and the configuration related thereto may be applied to the other capacitive sensor such as the liquid level sensor 101 (embodiment 1), for example.
[0082] The configuration other than that described above is almost the same as the configuration of the liquid level sensor 101 (embodiment 1); thus the same sign is assigned to the same or corresponding element, and the description thereof is not repeated.
[0083] Table 3 described hereinafter indicates an experimental result of example D1 of the dew condensation sensor 102 described above and comparative example E1 thereof.
TABLE-US-00003 TABLE 3 EXAMPLE COMPARATIVE D1 EXAMPLE E1 PROTECTION MATERIAL ZIRCONIA LAYER RELATIVE 30 DIELECTRIC CONSTANT ε THICKNESS d (μm) 5 20 ε/d 6.0 1.5 MEASUREMENT INITIAL STATE 0 0 VALUE 2 SECONDS AFTER 5 0 CHANGE (pF) STARTING VAPOR BLOWING 2 SECONDS AFTER 0 0 STOPPING VAPOR BLOWING
[0084] The bottom of Table 3 described above indicates a change in the capacitance on blowing vapor to each of these dew condensation sensors from a vapor generation source located 50 mm away from the dew condensation sensors. As shown by this result, in the case of example D1, in which the thickness d of the protection layer 50 is 5 the generation of the dew condensation caused by blowing the vapor and disappearance of the dew condensation caused by stopping the blowing of the vapor could be detected as the change in the capacitance. In the meanwhile, in the case of comparative example E1, in which the thickness d of the protection layer 50 is 20 μm, the change in the capacitance caused by blowing the vapor could not be detected.
[0085] Table 4 described hereinafter indicates an experimental result of further examples D2 to D4 and comparative example E2, having the protection layer 50 similar to that of example D1, together with the experimental result of example D1.
TABLE-US-00004 TABLE 4 EXAMPLE EXAMPLE EXAMPLE EXAMPLE COMPARATIVE D1 D2 D3 D4 EXAMPLE E2 PROTECTION MATERIAL ZIRCONIA LAYER RELATIVE 30 DIELECTRIC CONSTANT ε THICKNESS d (μm) 5 ε/d 6 DETECTION ELECTRODE WIDTH L 100 50 50 20 150 ELECTRODE (μm) ELECTRODE 100 50 30 20 150 INTERVAL S (μm) MEASUREMENT 2 SECONDS AFTER 0.1 0.2 0.4 0.6 0 VALUE CHANGE STARTING BLOWING (pF/mm.sup.2) DESCRIBED ABOVE
[0086] In Table 4 describe above, the measurement value change (pF/mm.sup.2) is a change amount of the capacitance per unit area of an effective portion EF (
[0087] The measurement value change caused by the dew condensation could be detected in examples D1 to D4, each having the electrode interval S of 100 μm or less. In the meanwhile, the measurement value change caused by the dew condensation could not be detected in comparative example E2 having the electrode interval S of 150 μm. The reason is considered that a size of a liquid drop generated by the dew condensation is smaller than 150 μm; thus in comparative example E2, the liquid drop was not located across both the first detection electrode 21 and the second detection electrode 22 in a plan view (
[0088] When the electrode width L is assumed to be excessive while the electrode interval S is kept in each of examples D1 to D4, the measurement value change is considered to be small.
[0089] According to the present embodiment, the dew condensation can be detected with a high degree of sensitivity while ensuring corrosion resistance and chemical resistance. The configuration of the protection layer 50 in the embodiment shown by Table 3 described above is an example; thus the configuration of the protection layer 50 described in embodiment 1 may be adopted in place thereof. A favorable configuration of the protection layer 50 in the case of the present embodiment is also almost similar to that in the case of embodiment 1.
[0090] When the electrode interval S is 100 μm or less, the dew condensation can be detected more reliably. When the electrode interval S is 20 μm or more, a desired electrode interval can be formed by multilayer ceramic technology relatively easily.
[0091] When the electrode width L is 100 μm or less, reduction in the measurement value change caused by the excessive electrode width L is prevented. When the electrode width L is 20 μm or more, a desired electrode width can be formed by multilayer ceramic technology relatively easily.
[0092] As described above, when a minute dimension of 100 μm or less is used in relation to the first detection electrode 21 and the second detection electrode 22, it tends to be particularly difficult to prevent the protection layer 50 from significantly inhibiting the detection of the dew condensation while ensuring corrosion resistance and chemical resistance by the protection layer 50. However, according to the present embodiment, such a configuration can be achieved.
[0093] When the heater 60 is provided, the liquid adhering to the surface SF of the protection layer 50 can be removed by heating. Accordingly, sensitivity for newly detecting the liquid can be rapidly ensured.
[0094] Describe above in detail is the use application for detecting the liquid level and the dew condensation as the use application of the capacitive sensor; however, the capacitive sensor may be adopted to the other use application. The embodiments described above and a modification example may be freely combined with each other. Although the present invention is described in detail, the foregoing description is in all aspects illustrative and does not restrict the invention. It is therefore understood that numerous modifications and variations can be devised without departing from the scope of the invention.