Flow through thermal conductivity sensor

Objectives:
- Improve the overall robustness.

- Improve production repeatability and reliability.

- Automation compatible.

I led the development of an innovative flow-through thermal conductivity (TC) sensor with automated thermal management to enhance measurement robustness and enable automation compatibility. The project focused on improving sensor reliability, refining the fabrication process for repeatability, and redesigning the device for seamless integration into automated systems.

The resulting sensor achieved rapid characterization of a wide range of organic chemicals within five minutes with less than 5% measurement error. Key design improvements included redesigned flow channels and heater architecture to enhance accuracy and robustness, improved chemical compatibility through sensor redesign, and the integration of a resistive heater with standard Yor-Lok fittings for universal system compatibility. A 3D-printed polypropylene heater support further increased mechanical stability and overall sensor durability.

Original patent: https://patents.google.com/patent/US20250198957A1/en
Original publication: https://www.nature.com/articles/s41467-025-65553-x

Top collaborators: Andrija Stepanovic, Haoming Ye, Roozbeh Alishahian, Mohammad Zargartalebi, David Sinton