Design and Optimization of Microwave Sensor for the Non-Contact Measurement of Pure Dielectric Materials

This article presents an optimized microwave sensor for the non-contact measurement of complex permittivity and material thickness. The layout of the proposed sensor comprises the parallel combination of an interdigital capacitor (IDC) loaded at the center of the symmetrical differential bridge-type inductor fabricated on an RF-35 substrate (εr = 3.5 and tanδ = 0.0018). The bridge-type differential inductor is introduced to obtain a maximum inductance value with high quality (Q) factor and low tunable resonant frequency. The central IDC structure is configured as a spur-line structure to create a high-intensity coupled electric field (e-field) zone, which significantly interacts with the materials under test (MUTs), resulting in an increased sensitivity. The proposed sensor prototype with optimized parameters generates a resonant frequency at 1.38 GHz for measuring the complex permittivity and material thickness. The experimental results indicated that the resonant frequency of the designed sensor revealed high sensitivities of 41 MHz/mm for thickness with a linear response (r2 = 0.91567), and 53 MHz/Δεr for permittivity with a linear response (r2 = 0.98903). The maximum error ratio for measuring MUTs with a high gap of 0.3 mm between the testing sample and resonator is 6.52%. The presented performance of the proposed sensor authenticates its application in the non-contact measurement of samples based on complex permittivity and thickness.