Insulated sensor mount for low or high temperature applications

Abstract

An insulated sensor mount for low or high temperature applications includes at least two nested interlocking sections including a lower section and an upper section attached to the lower section with one or more gaps between the upper section and the lower section. The upper section includes a channel for receiving a sensor probe. The sensor mount may be a prismatic component using a dovetail joint, or a threaded cylindrical component threaded together. The sensor mount may be attached to an extremely cold or extremely hot substrate. Gap thermal resistance between the upper and lower sections plus an optional optical coating may isolate the sensor probe from extreme temperature. The mating surface may be artificially roughened or polished to increase interstitial thermal resistance. The sensor probe may be screwed into the sensor mount. A total of four (or more) interlocking sections provide sufficient thermal insulation from the low temperature substrate to prevent icing on the sensor.

Description

[0001] Statement of Government Interest

[0002] The invention described herein was made in the performance of work under NASA Contract No. 80MSFC20C0052 and is subject to the provisions of Section 305 of the National Space Act of 1958 (72 Stat. 435:42 U.S.C. 2457). Background Art

[0003] Sensors are widely used in various automotive, aviation and aerospace applications, such as automotive engines, aircraft, jet engines, spacecraft and satellites, which are exposed to extremely cold and / or extremely hot environments. Specifically, sensors are installed on liquid hydrogen / oxygen fuel tanks of spacecraft and must be able to withstand low temperatures (e.g., minus 300F) and still function properly. Due to the low temperature of liquid hydrogen / oxygen fuel tanks (especially under humid conditions), sensors - such as temperature sensors, pressure sensors, optical sensors and / or flow sensors - can be covered by ice without using high-heat-resistant structural brackets to thermally insulate the sensors from the cryogenic fuel tank substrate. Once encased in ice, the sensors will fail. Summary of the invention

[0004] Disclosed herein is a thermally isolated sensor mount that is strong, compact, and has a very high degree of thermal isolation (i.e., high thermal resistance) to extremely hot or extremely cold substrates. This allows the mounted sensor to operate normally under extreme temperature conditions. The thermally isolated sensor mount includes multiple interlocking sections that work together to improve the thermal isolation of various types of sensors from extremely hot or extremely cold environments. Due to tiny surface ripples and roughness, the natural gaps between the interlocking layers increase the thermal resistance between adjacent surfaces. This is the so-called "gap thermal resistance". According to the current state of the art, various combinations of surface roughness and tightness or pressure (such as ANSI tightness level RC1-9) and external surface emissivity coatings can be determined by analysis and testing. A range of gap resistances can achieve extremely small, compact and strong mounts to protect sensors from extremely cold substrates and ice accumulation or extremely hot substrates. Different materials, number of sections, stack sizes, smoothness / roughness of interface surfaces, gap thickness, surface radiation properties of the outer surface, etc. can be used to change the thermal curve to achieve the desired sensor operating temperature. Although specific examples are provided herein, there are almost unlimited configurations. Disclosed examples include prismatic and cylindrical forms.

[0005] Prismatic type: In some examples, the sensor mount is made of multiple interlocking prismatic segments with dovetail joints that can slide together to form a prismatic (e.g., cube) assembly to which the sensor probe is attached. The natural gap between each segment increases the overall thermal resistance of the sensor mount. The series of interlocking gaps protects the sensor from ice formation due to the extreme cold of the cryogenic fuel tank.

[0006] Cylindrical type : In some examples, the sensor mount is made of interlocking threaded cylindrical sections that are screwed together to form a compact cylindrical assembly to which the sensor is attached. The natural gap between the threads increases the gap thermal resistance and improves the overall thermal resistance of the sensor mount, which protects the sensor from icing due to the extreme cold of a cryogenic fuel tank, for example.

[0007] The proposed solutions are widely used in various applications such as vehicles, aircraft, spacecraft, jet engines, furnaces, ovens, industrial operations, integrated circuits, capacitors and sensors.

[0008] In some examples, the thermally isolated sensor mounting structure includes at least two nested interlocking sections, including at least a lower section and an upper section attached to the lower section with an interlocking joint, wherein the upper section and the lower section have one or more gaps between them. The upper section includes a channel for accommodating a sensor probe. The sensor mount includes (1) a prismatic assembly of polyhedral sections that slide together using a dovetail joint; or (2) a threaded cylindrical assembly of polyhedral sections that are screwed together. The sensor mount is attached to an extremely cold or extremely hot substrate. The gap thermal resistance between the upper section and the lower section isolates the sensor probe from the extreme environment. The mating surface can be artificially roughened to increase the gap thermal resistance. The sensor probe can be screwed into the sensor mount.

[0009] In some examples, a total of four (or more) interlocking segments provide sufficient isolation from the cryogenic substrate to prevent ice accumulation on the sensor probe.

[0010] In some examples, the sensor probe is disposed in a first channel located in the upper section.

[0011] In some examples, the sensor mount includes a vertical or near-vertical entry passage disposed at least partially through the upper section; and the first passage is horizontal and intersects the vertical or near-vertical entry passage.

[0012] In some examples, the sensor probe has an integral threaded shaft; the first passage is threaded; and the integral shaft is screwed into the first horizontal passage.

[0013] In some examples, the lower section is attached to a hot or cold substrate.

[0014] In some examples, the substrate is extremely hot or extremely cold.

[0015] In some examples, the lower segment and the upper segment have a prismatic shape and a pair of dovetail joints slidingly engaging the lower segment with the upper segment.

[0016] In some examples, the lower segment and the upper segment have a cylindrical shape and are both threaded; and the upper segment is screwed into the lower segment.

[0017] In some examples, the upper segment has an upper exterior surface with an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or combinations thereof.

[0018] In some examples, the sensor mount includes a total of four interlocking prismatic segments.

[0019] In some examples, the sensor mount includes a total of four interlocking cylindrical sections.

[0020] In some examples, the mating surfaces of the interlocking joints have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof.

[0021] In some examples, the thickness of the gap between adjacent mating surfaces is less than about 0.001 inches.

[0022] In some examples, the thermally isolated sensor mount includes at least two interlocking cylindrical sections, including: a lower section having a cylindrical shape and being threaded; an upper section having a cylindrical shape and being threaded; a first passage in the upper section, the first passage being operable to receive a sensor probe; an upper exterior surface of the upper section; and a first gap between the lower section and the upper section. The upper section is screwed into the lower section.

[0023] In some examples, the thermally isolated sensor mount includes: at least four interlocking cylindrical sections, including: a bottom section having a cylindrical shape and threads; a middle section having a cylindrical shape and threads; an upper section having a cylindrical shape and threads; a top section having a cylindrical shape and threads; a first passage in the upper section, the first passage being operable to accommodate a sensor probe; a first gap disposed between the bottom section and the middle section; a second gap disposed between the middle section and the upper section; and an upper outer surface of the top section. The middle section is screwed into the bottom section. The upper section is screwed into the middle section; and the top section is screwed into the upper section.

[0024] In some examples, a vertical or near vertical entry channel is positioned at least partially through the upper section and disposed completely through the top section.The first channel is horizontal and intersects the vertical or near vertical entry channel. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A schematic perspective view of a first example of a thermally isolated prismatic sensor mounting structure according to the present disclosure is shown.

[0026] Figure 2 A schematic perspective cross-sectional view (section AA) of a first example of a thermally isolated prismatic sensor mount with an attached sensor according to the present disclosure, mounted to a hot or cold substrate, is shown.

[0027] Figure 3 A schematic bottom cross-sectional view (Section AA) of a first example of a thermally isolated prismatic sensor mount with an attached sensor, mounted to a hot or cold substrate, according to the present disclosure is shown.

[0028] Figure 4A A schematic bottom cross-sectional view (section AA) of an example of a bottom section of a first example of a thermally isolated prismatic sensor mount according to the present disclosure is shown.

[0029] Figure 4B A schematic bottom cross-sectional view (Section AA) of an example of a mid-section of a first example of a thermally isolated prismatic sensor mount according to the present disclosure is shown.

[0030] Figure 4C A schematic bottom cross-sectional view (Section AA) of an example of an upper section of a first example of a thermally isolated prismatic sensor mount according to the present disclosure is shown.

[0031] Figure 4D A schematic bottom cross-sectional view (Section AA) of an example of a top section of a first example of a thermally isolated prismatic sensor mount according to the present disclosure is shown.

[0032] Figure 5 A schematic exploded perspective view of a first example of a thermally isolated prismatic sensor mount with an attached sensor according to the present disclosure is shown.

[0033] Figure 6 A schematic partially exploded perspective view of a first example of a thermally isolated prismatic sensor mount with an attached sensor according to the present disclosure is shown.

[0034] Figure 7 A schematic perspective view of a second example of a thermally isolated cylindrical sensor mount attached to a hot or cold substrate according to the present disclosure is shown.

[0035] Figure 8A schematic perspective cross-sectional view (section BB) of a second example of a thermally isolated cylindrical sensor mount attached to a hot or cold substrate according to the present disclosure is shown.

[0036] Fig. 9 A schematic exploded perspective view of a second example of a thermally isolated cylindrical sensor mount with an attached sensor according to the present disclosure is shown.

[0037] Fig.10 A schematic exploded cross-sectional view of a second example of a thermally isolated cylindrical sensor mount with an attached sensor according to the present disclosure is shown.

[0038] Fig.11 A schematic exploded cross-sectional view of a second example of a thermally isolated cylindrical sensor mount with an attached sensor according to the present disclosure is shown.

[0039] Fig.12 A schematic perspective view of a third example of a thermally isolated prismatic sensor mount according to the present disclosure is shown.

[0040] Fig.13 A schematic bottom cross-sectional view (Section CC) of a third example of a thermally isolated prismatic sensor mount attached to a substrate according to the present disclosure is shown, with a sensor probe attached to the sensor mount.

[0041] Fig.14 A schematic perspective view of a fourth example of a 2-stage thermally isolated cylindrical sensor mount according to the present disclosure is shown.

[0042] Fig.15 A schematic perspective cross-sectional view (section DD) of a fourth example of a thermally isolated cylindrical sensor mount attached to a hot or cold substrate according to the present disclosure is shown. DETAILED DESCRIPTION

[0043] The present disclosure may have examples in many different forms. Representative examples of the present disclosure are shown in the drawings and will be described in detail herein, but it should be understood that these examples are provided as examples of the disclosed principles and do not limit the broad aspects of the present disclosure. In this case, elements and limitations that are described in the introduction, abstract, detailed description, and summary sections but not explicitly set forth in the claims, for example, should not be incorporated into the claims individually or collectively by implication, inference, or otherwise.

[0044] For the purposes of this detailed description, unless specifically and expressly denied otherwise, then: the singular includes the plural and vice versa; "and" and "or" are both conjunctions and disconjunctions; "any" and "all" mean "any and all"; "include," "contain," "includes," "have," and the like mean "including but not limited to." In addition, approximations such as "approximately," "almost," "substantially," "generally," "about," and the like are to be understood herein to mean "at, approximately, or nearly at," or "within 0-5%," or "within an acceptable manufacturing tolerance," or any logical combination thereof. Finally, directional adjectives and adverbs such as: front, back, inside, outside, left, right, vertical, horizontal, above, below, upward, downward, front, back, left, right, and the like may be relative to the plane of the substrate to which the sensor mount is attached. The drawings are not drawn to scale but are schematic diagrams illustrating geometric relationships between elements and objects.

[0045] The term "sensor" and "sensor probe" are used interchangeably herein. The term "probe" refers to the substrate temperature T 基体 Low temperatures (e.g., T 基体 <-250F) and high furnace temperatures (e.g., T 基体 >600F). The term "interlocking" includes both types of joints, namely (1) a dovetail joint for prismatic sensor mounting assemblies, and (2) a threaded, screw-on joint for cylindrical sensor mounting assemblies. The phrase "low emissivity" means a thermal emissivity ≤ 0.1, while the phrase "high emissivity" means a thermal emissivity ≥ 0.9. Symbols It means "center line" and indicates the center line of a cylindrical object or a cylindrical hole.

[0046] Figure 1A schematic perspective view of a first example of a thermally insulated prismatic sensor mount 10 according to the present disclosure is shown. The sensor mount 10 includes a series of nested (i.e., stacked) interlocking prismatic segments (e.g., four interlocking segments 12, 14, 16, and 18). The dovetail joint has 3 stacking levels, each of which has a pair of dovetail joints 8, 8', etc., for a total of 6 dovetail joints. The sensor mount 10 is attached to a substrate 6 (e.g., using screws, adhesives, brazing, or other attachment methods). The substrate 6 can be extremely cold (e.g., -300F), or extremely hot (e.g., ≥600F). At the lower end of the sensor mount 10 is a first interlocking bottom segment 12, which is shaped like a capital letter "I". Next, a second middle segment 14 is disposed above the bottom segment 12 and is slidably interlocked with the bottom segment 12 using a first pair of left / right dovetail joints 8 and 8', respectively. Next, the third upper segment 16 is disposed over the middle segment 14 and slidably interlocked with the middle segment 14 using a second pair of left / right dovetail joints (not numbered). Finally, at the top, the top segment 18 is disposed over the upper segment 16 and slidably interlocked with the upper segment 16 using a third pair of left / right dovetail joints (not numbered). The four interlocking prismatic segments 12, 14, 16, and 18 slide together to form a prismatic assembly that securely houses the sensor (not shown) while providing good thermal isolation from the base 6 (which can be extremely hot or cold).

[0047] Still refer to Figure 1 , a first horizontal hole 20 is located in the upper section 16 for attaching a sensor (not shown) to the sensor mount 10. A second nearly vertical (inclined) hole 22 is located in the approximate center of the top section 18 for providing an electrical / signal path for a sensor (not shown). For respective internal details of the first hole 20 and the second hole 22, see Figure 2 . The four interlocking prismatic segments 12, 14, 16, 18 may be securely locked together using removable set screws, dowel pins, clips, etc. (not shown) or other removable locking attachment methods. Note that it may be useful to leave a rough interface gap between each interlocking segment in order to increase the gap thermal resistance and improve the thermal isolation of the sensor (not shown) from the substrate 6. The sensor mount 10 may have a prismatic shape (e.g., a rectangular or cubic shape). The upper outer surface 29 of the top prismatic segment 18 may have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof.

[0048] Figure 2A schematic perspective cross-sectional view (section AA) of a first example of a thermally insulated prismatic sensor mount 10 with an attached sensor 24 mounted to a substrate 6 according to the present disclosure is shown. The substrate 6 has an extreme cold temperature or an extreme hot temperature. The sensor 24 has an integral shaft 25 that is screwed into a horizontal hole 20 of the sensor mount 10. In some examples, the shaft 25 may be screwed into the horizontal hole 20. At the lower end of the sensor mount 10 is a first interlocking bottom section 12 having a capital letter "I" shape. Next, a second middle section 14 is disposed above the bottom section 12 and is slidably interlocked with the bottom section 12 using a first pair of left / right dovetail joints (not numbered). Next, a third upper section 16 is located above the middle section 14 and is slidably interlocked with the middle section 14 using a second pair of left / right dovetail joints (not numbered). Finally, at the top, a fourth top section 18 is disposed above the upper section 16 and slidably interlocked with the upper section 16 using a third pair of left / right dovetail joints (not numbered). The four interlocking prismatic sections 12, 14, 16, and 18 slide together via dovetail joints to form a prismatic assembly 10 that securely houses the sensor 24 while providing good thermal isolation from the substrate 6. A first gap 7 is disposed between the bottom section 12 and the middle section 14. Similarly, a second gap 7' is disposed between the middle section 14 and the upper section 16. At low temperatures, the thickness of the gaps 7, 7' may be very small (e.g., less than 0.001 inches) to prevent "cryopumping" across the gaps 7, 7' (which undesirably increases heat transfer across the gaps). The bottom surface 9 of the bottom section 12 may be artificially roughened to increase the gap thermal resistance across the joint between the bottom section 12 and the substrate 6. The upper exterior surface 29 of the top prismatic section 18 may have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof.

[0049] Still refer to Figure 2 , a first horizontal hole 20 is located in the upper section 16 for attaching a sensor 24 (having an integral shaft 25) in the sensor mount 10. A second nearly vertical (inclined) access channel 22 is located in the center of the top section 18 for providing an electrical / signal path for the sensor 24 through intersecting cylindrical channels 26 and 28. The horizontal cylindrical channel 28 is connected to the horizontal hole 20. The horizontal cylindrical channel 28 may be threaded to mate with optional threads on the sensor shaft 25. The four interlocking prismatic sections 12, 14, 16, 18 may be securely locked together with removable set screws, dowel pins, clips or other locking methods (not shown). The sensor mount 10 may be removably attached to the substrate 6 by one or more screws 4, 4', etc. or other attachment methods. It is noted that it may be useful to have a rough interface gap between each interlocking section, which increases the gap thermal resistance. This configuration may provide enhanced thermal isolation of the sensor 24 from the substrate 6 (which may be extremely hot or cold).

[0050] Figure 3 A schematic bottom cross-sectional view (section AA) of a first example of a thermally insulated prismatic sensor mount 10 with an attached sensor 24 (which is mounted to a substrate 6) according to the present disclosure is shown. The substrate 6 can have an extremely cold temperature or an extremely hot temperature. The sensor 24 has an integral shaft 25, which is inserted into the horizontal hole 20 of the sensor mount 10. In some examples, the sensor 24 can be screwed into a horizontal cylindrical channel 28 (which can be threaded). At the lower end of the sensor mount 10 is a first interlocking bottom section 12, which has a capital letter "I" shape. Next, the second middle section 14 is disposed above the bottom section 12 and is slidably interlocked with the bottom section 12 using a first pair of left / right dovetail joints 8, 8'. Next, the third upper section 16 is disposed above the middle section 14 and is slidably interlocked with the middle section 14 using a second pair of left / right dovetail joints 2, 2'. Finally, at the top, the top section 18 is disposed over the upper section 16 and slidably interlocked with the upper section 16 using a third pair of left / right dovetail joints 3, 3'. The four interlocking prismatic sections 12, 14, 16 and 18 slide together via three pairs of dovetail joints to form a prismatic assembly 10 that can securely house the sensor 24 while providing good thermal isolation from the base 6.

[0051] Still refer to Figure 3 , a first gap 7 is disposed between the bottom section 12 and the middle section 14. Similarly, a second gap 7' is disposed between the middle section 14 and the upper section 16. At low temperatures, the thickness of the gaps 7, 7' may be very small (e.g., less than 0.001 inches) to prevent "cold pumping" across the gaps 7, 7' (which undesirably increases heat transfer across the gaps). The bottom surface 9 of the bottom section 12 may be artificially roughened to increase the gap thermal resistance across the joint between the bottom section 12 and the substrate 6. The upper outer surface 29 and / or the outer side surface of the top prismatic section 18 may have an optical finish selected from a black (high emissivity) coating, a high polished (low emissivity) surface, or a low emissivity coating, or a combination thereof.

[0052] Still refer to Figure 3, the first horizontal hole 20 is located on the side of the upper section 16 for mounting the sensor 24 in the sensor mount 10. The second nearly vertical (tilted) hole 22 is located in the center of the top section 18, which provides an electrical / signal path for the sensor 24 through the intersecting cylindrical channels 26 and 28. The horizontal cylindrical channel 28 can be threaded to mate with optional threads on the shaft 25 of the sensor 24. The horizontal cylindrical channel 28 is connected to the horizontal hole 20. The four interlocking sections 12, 14, 16, 18 can be firmly locked together using removable fixing screws, dowel pins, clips, or other locking methods (not shown). The cylindrical channel 26 can be drilled at an angle of 20 - 30 degrees with respect to the normal direction of the upper outer surface 29 of the top section 18. Note that having a rough interface gap between each interlocking section can be useful, which increases the gap thermal resistance. This configuration provides enhanced thermal insulation between the sensor 24 and the substrate 6 (which can be extremely hot or cold). The sensor mount 10 can be detachably attached to the substrate 6 by one or more screws 4, 4', etc. or other attachment methods. The wires 50 and 50' from the sensor shaft 25 are contained within the cylindrical channels 26 and 28 and exit through the upper hole 22.

[0053] Figure 4A Fig. shows a schematic bottom-up sectional view (section A - A) of the bottom section 12 of the first example of the thermally insulated prismatic sensor mount 10 according to the present disclosure. The bottom section 12 has the shape of a capital letter "I", which has an upper wing 13, an extended lower shoulder 15, and a pair of horizontal open grooves 17, 17' respectively for forming the first pair of left / right dovetail joints (not numbered). Thus, the bottom section 12 is referred to as a "double dovetail" section. The upper width of the bottom section 12 = A, and the lower width = B, where A < B. The bottom surface 9 of the bottom section 12 is marked.

[0054] Figure 4B Fig. shows a schematic bottom-up sectional view (section A - A) of the middle section 14 of the first example of the thermally insulated prismatic sensor mount 10 according to the present disclosure. The middle section 14 has a complex cross-sectional shape, including twenty connected outer surfaces. The lower region of the middle section 14 includes a pair of lower grooves 19 and 19', which form the first pair of left / right dovetail joints (not numbered). The upper region of the middle section 14 includes a pair of upper open grooves 17 and 17', which are used to form the second pair of left / right dovetail joints (not numbered). The middle section 14 also includes an upper wing 13 and an extended lower shoulder 15. In this example, the middle section 14 includes a total of four dovetail joints. Thus, the middle section 14 is referred to as a "quadruple dovetail" section. The upper width of the middle section 14 = A, and the lower width = B, where A < B.

[0055] Figure 4CSchematic bottom-up sectional view (section A-A) showing an example of the upper section 16 of a first example of a thermally insulating prismatic sensor mount 10 according to the present disclosure. The upper section 16 has a complex cross-sectional shape, including twenty different outer surfaces. The lower region of the upper section 16 includes a pair of lower grooves 19 and 19' with concave corners, which are used to form a second pair of left / right dovetail joints (not numbered). The upper region of the upper section 16 includes a pair of upper open grooves 17 and 17', which are used to form a third pair of left / right dovetail joints (not numbered). The upper section 16 also includes upper wings 13 and extended lower shoulders 15. In this example, the upper section 16 includes a total of four dovetail joints. Therefore, the upper section 16 is referred to as a "four-dovetail" section.

[0056] Still referring to Figure 4C , a first horizontal hole 20 is located in the side of the upper section 16 for mounting a sensor 24 (not shown in the figure) into the upper section 16. The first horizontal cylindrical hole 28 serves as a horizontal cylindrical channel, which is connected to the horizontal hole 20. A second nearly vertical (inclined) cylindrical channel 26 is located approximately in the center of the upper section 16. The intersecting cylindrical channels 26 and 28 can provide an electrical / signal path to the sensor 24 (not shown) from a nearly vertical access channel 30 (which may be threaded) in the top surface 13 of the upper section 16. The upper width of the upper section 16 = A, and the lower width = B, where A < B. It should be noted that although the specific dimensions and proportions are different, the middle section 14 is topologically the same as the upper section 16 (both have twenty outer surfaces and the same number of grooves (i.e., four grooves each).

[0057] Figure 4D Schematic bottom-up sectional view (section A-A) showing an example of the top section 18 of a first example of a thermally insulating prismatic sensor mount 10 according to the present disclosure. The top section 18 has the shape of a lateral capital letter "C", and has a pair of horizontal grooves 19, 19' with concave corners, which are respectively used to form a third pair of left / right dovetail joints (not numbered). Therefore, the top section 18 is referred to as a "double-dovetail" section. The top section 18 has a nearly vertical inclined access through-hole 22 (which may be a threaded hole), which is aligned with the hole 30 in the upper section 16 for providing an electrical / signal path to the intersecting cylindrical channels 26 and 28. The top section 18 has an upper width = A. The upper outer surface 29 and / or the outer side surface of the top prismatic section 18 may have an optical finish selected from a black (high emissivity) coating, a highly polished (low emissivity) surface, or a low emissivity coating or a combination thereof.

[0058] Figure 5A schematic exploded perspective view of a first example of a thermally insulated prismatic sensor mount 10 with a mounted sensor 24 according to the present disclosure is shown. The sensor mount 10 includes four interlocking prismatic segments 12, 14, 16, and 18 having dovetail joints (not numbered) that slide together to form a seamless prismatic assembly (e.g., a cube). Segment 16 has a near vertical angled entry channel 30 and a horizontal sensor horizontal hole 20 for accommodating the sensor 24. Segment 18 has an upper near vertical angled entry channel 22 (which may be threaded) aligned with the hole 30 (which may also be threaded). The sensor 24 has an integral shaft 25 that can be inserted into the horizontal hole 20 of the sensor mount 10. In some examples, the shaft 25 is threaded and it can be screwed into the threaded horizontal hole 20. The upper outer surface 29 and / or the outer side surface of the top prismatic segment 18 can have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof.

[0059] Figure 6 A schematic partially exploded perspective view of a first example of a thermally insulated prismatic sensor mount 10 with a mounted sensor probe 24 according to the present disclosure is shown. In this view, the individual interlocking prismatic segments 12, 14, 16, and 18 are partially assembled by sliding the segments together using a plurality of dovetail joints. The sensor mount 10 includes four interlocking prismatic segments 12, 14, 16, and 18 that slide together to form a seamless prismatic shape (e.g., a cube). Segment 16 has a nearly vertical angled entry channel 30 and a horizontal sensor horizontal hole 20 for accommodating the sensor 24. Segment 18 has an upper nearly vertical angled entry channel 22 (which may be a threaded hole) aligned with the hole 30 (which may be threaded). The sensor 24 has an integral shaft 25 that can be inserted into the horizontal hole 20 of the sensor mount 10. In some examples, the shaft 25 is threaded and it can be screwed into the threaded horizontal hole 20. The upper outer surface 29 and / or the outer side surfaces of the top prismatic segment 18 may have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof.

[0060] In some examples, the total number of interlocking prismatic segments of the prismatic sensor mount may be different than four. For example, depending on how much thermal isolation is desired, the number of interlocking prismatic segments may be 2, 3, 4, 5, 6, 7, or 8 segments.

[0061] Figure 7A schematic perspective view of a second example of an insulated cylindrical sensor mount 32 removably attached to a substrate 6 according to the present disclosure is shown. The substrate 6 may have an extremely cold temperature or an extremely hot temperature. The cylindrical sensor mount 32 may be made of four threaded cylindrical sections 34, 36, 38, and 40, each section having threaded segments that screw into each other. The natural gaps between the threads increase the interfacial gap thermal resistance, which increases the total amount of thermal insulation. A vertical entry hole 42 is provided on the top of the top section 40, and a horizontal sensor horizontal hole 20 (which may be threaded) is provided on one side of the cylindrical section 38. The bottom surface 9 of the bottom section 34 may be artificially roughened to increase the gap thermal resistance across the joint between the bottom section 34 and the substrate 6. The upper outer surface 29 and / or the outer sidewall of the top cylindrical section 40 may have an optical finish selected from a black (high emissivity) coating, a high polished (low emissivity) surface, or a low emissivity coating, or a combination thereof.

[0062] Figure 8 A schematic perspective cross-sectional view (section BB) of a second example of a thermally insulated cylindrical sensor mount 32 attached to a substrate 6 according to the present disclosure is shown. The substrate 6 may have an extremely cold temperature or an extremely hot temperature. The cylindrical sensor mount 32 includes a bottom cylindrical section 34, which is removably attached to the substrate 6 by, for example, one or more screws 4, 4', etc. or other attachment methods. Then, the middle cylindrical section 36 is screwed into the bottom cylindrical section 34. Then, the upper cylindrical section 38 is screwed into the middle cylindrical section 36. Finally, the top cylindrical section 40 is screwed onto the upper cylindrical section 38. The sensor 24 has an integral shaft 25 (which may be threaded) that is mounted through a horizontal hole 20 into a cylindrical passage 45 (which may be threaded) of the upper cylindrical section 38. Wires / signals 50 and 50' are threaded through intersecting cylindrical passages 43 and 45 and exit through vertical entry passage 42 in top cylindrical section 40. A first gap 7 is provided between bottom section 12 and middle section 14. Similarly, a second gap 7' is provided between middle section 14 and upper section 16. At low temperatures, the thickness of gaps 7, 7' may be very small (e.g., less than 0.001 inches) to prevent "cryopumping" across gaps 7, 7' (which undesirably increases heat transfer across the gap). The bottom surface 9 of bottom section 34 may be artificially roughened to increase the gap thermal resistance across the joint between bottom section 34 and substrate 6. The upper outer surface 29 of top cylindrical section 40 may have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof. Such a nested threaded cylindrical assembly 32 may produce a sturdy and compact thermally isolated sensor mount 32.

[0063] Fig. 9A schematic exploded perspective view of a second example of a thermally insulated cylindrical sensor mount 32 with an attached sensor 24 according to the present disclosure is shown. First, the middle cylindrical section 36 is screwed into the bottom cylindrical section 34. Then, the upper cylindrical section 38 is screwed into the middle cylindrical section 36. Finally, the top cylindrical section 40 is screwed into the upper cylindrical section 38. The sensor 24 (which may be threaded) is mounted in the upper cylindrical section 38 through the horizontal hole 20. A vertical entry channel 42 (which may be threaded) is approximately centered in the top cylindrical section 40 and is aligned with a vertical entry channel 48 (which may be threaded) that is approximately centered in the upper cylindrical section 38. The sensor 24 has an integral shaft 25 that is inserted into the horizontal hole 20 of the sensor mount 32. In some examples, the shaft 25 is threaded and it can be screwed into the threaded horizontal hole 20. The upper outer surface 29 of the top cylindrical section 40 may have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof. This nested threaded cylindrical assembly 32 may produce a strong, compact, thermally isolated bracket 32 ​​.

[0064] Fig.10 A schematic exploded view (section BB) of a second example of a thermally insulated cylindrical sensor mount 32 with an attached sensor 24 according to the present disclosure is shown. First, the middle cylindrical section 36 is screwed into the bottom cylindrical section 34. Then, the upper cylindrical section 38 is screwed into the middle cylindrical section 36. Finally, the top cylindrical section 40 is screwed into the upper cylindrical section 38. The sensor 24 (which may be threaded) is mounted into the upper cylindrical section 38 through the horizontal hole 20. First, a vertical entry channel 42 (which may be threaded) is centered in the top cylindrical section 40 and is aligned with a second vertical entry channel 48 (which may be threaded) centered in the upper cylindrical section 38. Cylindrical channels 45 and 43 (which may be threaded) provide a path for electrical / signal wires (not shown) connected to the sensor shaft 25. The wires exit the top of the sensor mount 32 via the vertically aligned entry channels 48 and 42. The cylindrical sections 34, 36 and 40 each have a deep concave cavity 46 into which each mating cylinder is screwed. The sensor 24 has an integral shaft 25 that can be inserted into the horizontal hole 20 of the sensor mount 10. In some examples, the shaft 25 is threaded and can be screwed into the horizontal hole 20. The upper outer surface 29 of the top cylindrical section 40 can have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof. This nested threaded cylindrical assembly 32 can produce a strong and compact thermally isolated bracket 32.

[0065] Fig.11A schematic exploded cross-sectional view (section BB) of a second example of a thermally insulated cylindrical sensor mount 32 with an attached sensor 24 according to the present disclosure is shown. First, the middle cylindrical section 36 is screwed into the bottom cylindrical section 34. Then, the upper cylindrical section 38 is screwed into the middle cylindrical section 36. Finally, the top cylindrical section 40 is screwed into the upper cylindrical section 38. The sensor 24 (which may be threaded) is mounted into the upper cylindrical section 38 through the horizontal hole 20. First, a vertical entry channel 42 (which may be threaded) is centered in the top cylindrical section 40 and aligned with a second vertical entry channel 48 (which may be threaded) centered in the upper cylindrical section 38. Intersecting cylindrical channels 45 and 43 (which may be threaded) provide passage for electrical / signal wires (not shown) (which are connected to the sensor shaft 25). These signal wires exit the top of the sensor mount 32 via the vertically aligned entry channels 48 and 42. The cylindrical sections 34, 36 and 40 each have a deep concave cavity 46 into which each mating cylinder is screwed. The sensor 24 has an integral shaft 25 that can be inserted into the horizontal hole 20 of the sensor mount 32. In some examples, the shaft 25 is threaded and it can be screwed into the first threaded cylindrical passage 45. The upper outer surface 29 of the top cylindrical section 40 can have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof. This nested threaded cylindrical assembly 32 can produce a strong and compact thermally isolated mount 32.

[0066] Fig.12A schematic perspective view of a third example of a thermally insulated prismatic sensor mount 60 attached to a substrate 6 according to the present disclosure is shown. The substrate 6 may have an extremely cold temperature or an extremely hot temperature. The sensor mount 60 includes a pair of nested interlocking prismatic segments (i.e., two segments) that are slidably joined together by a pair of left / right dovetail joints 8 and 8'. The sensor mount 60 is attached to the substrate 6 by, for example, screws, adhesives, brazing, or other attachment methods (not shown). A first interlocking lower segment 62 having a capital letter "I" shape is located at the lower portion of the sensor mount 60. A second upper segment 64 is disposed above the bottom segment 62 and is slidably interlocked with the bottom segment using a pair of left / right dovetail joints 8 and 8'. A horizontal hole 66 is disposed on the side of the upper segment 64, which is used to accommodate a sensor probe 24 (not shown). A nearly vertical inclined entry channel 68 is disposed in an approximately central position of the upper segment 64. The two interlocking prismatic sections 62 and 64 slide together via a pair of left / right dovetail joints to form a prismatic assembly 60 that securely houses the sensor 24 while providing good thermal isolation from the substrate 6. The sensor 24 has an integral shaft 25 that can be inserted into the horizontal hole 20 of the sensor mount 60. In some examples, the shaft 25 is threaded, and it can be screwed into the side of the upper section 64 (which can be threaded). A first gap 7 is provided between the lower section 62 and the upper section 64. At low temperatures, the thickness of the gap 7 can be very small (e.g., less than 0.001 inches) to prevent "cryopumping" across the gap 7 (which undesirably increases heat transfer across the gap). The bottom surface 9 of the lower section 62 can be artificially roughened to increase the gap thermal resistance across the joint between the bottom section 62 and the substrate 6. The upper outer surface 29 and / or the outer side of the upper section 64 may have an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof. This nested threaded prismatic assembly 60 may produce a strong and compact thermally isolating mount 60.

[0067] Fig.13A schematic bottom cross-sectional view (section CC) of a third example of a thermally insulated prismatic sensor mount 60 attached to a substrate 6 according to the present disclosure, wherein a sensor probe 24 is attached to the sensor mount 60. The substrate 6 may have an extremely cold temperature or an extremely hot temperature. The sensor 24 (which may be threaded) is attached to the sensor mount 60 through the horizontal hole 20. In some examples, the sensor 24 may be screwed into the upper section 64 through the horizontal hole 20. At the lower end of the sensor mount 60 is a first interlocking prismatic lower section 62 having a capital letter "I" shape. The second upper section 64 is disposed above the lower section 62 and is slidably interlocked with the lower section 62 using a pair of left / right dovetail joints 8 and 8'. The two interlocking prismatic sections 62 and 64 are slid together using the dovetail joints 8, 8' to form a prismatic (e.g., cube) assembly 60 that securely accommodates the sensor 24 while providing enhanced thermal isolation from the substrate 6. Therefore, the sensor mount 60 of this example is referred to as a "double dovetail" mount. The sensor 24 has an integral shaft 25 that is inserted into the horizontal hole 66 of the sensor mount 60. In some examples, the sensor probe shaft 25 is threaded and can be screwed into the threaded upper section 64 via the horizontal hole 20. The bottom surface 9 of the lower section 62 can be artificially roughened to increase the gap thermal resistance across the joint between the bottom section 62 and the substrate 6. The upper outer surface 29 and / or the outer side of the upper section 64 can have an optical finish selected from a black (high emissivity) coating, a high polished (low emissivity) surface, or a low emissivity coating, or a combination thereof. This nested interlocking assembly produces a sturdy and compact thermally insulated mount 60.

[0068] Still refer to Fig.13 , a first horizontal hole 20 is located in the side of the upper section 64, wherein the horizontal hole 20 is used to mount the sensor 24 in the sensor mount 60. A second nearly vertical inclined hole 68 is located in the approximate center of the upper section 64 for providing an electrical / signal path to the sensor shaft 25 through intersecting cylindrical passages 70 and 72. The horizontal first passage 70 may be threaded to mate with an optional thread on the sensor shaft 25. The horizontal first passage 70 is connected to the horizontal hole 20. The two interlocking sections 62 and 64 may be locked together with set screws, dowel pins or other locking methods (not shown). The nearly vertical inclined cylindrical passage 72 may be drilled at an angle of 20-30 degrees to the upper outer surface 29 of the upper section 64. It is noted that it may be useful to leave a rough interface gap between each interlocking prismatic section, which may increase the gap thermal resistance. This nested interlocking assembly provides good thermal isolation of the sensor 24 from the substrate 6 (which may be extremely hot or cold). The sensor mount 60 is removably attached to the base 6 by one or more screws 4, 4' etc. (or other attachment methods).

[0069] Fig.14A schematic perspective view of a fourth example of an insulated cylindrical sensor mount 80 according to the present disclosure is shown. The cylindrical sensor mount 80 includes a threaded lower cylindrical section 82, which is attached to the base 6. A threaded upper cylindrical section 84 is screwed into the lower cylindrical section 82. A gap 7 (not shown) is provided between the lower cylindrical section 82 and the upper cylindrical section 84. An access channel 86 is provided in the upper outer surface 29 of the upper cylindrical section 84. A horizontal hole 20 is provided on the side of the upper cylindrical section 84 for inserting a sensor probe (not shown). The upper outer surface 29 and / or the outer sidewall of the upper cylindrical section 84 may have an optical finish selected from a black (high emissivity) coating, a high polished (low emissivity) surface, or a low emissivity coating, or a combination thereof.

[0070] Fig.15 A schematic perspective sectional view (section DD) of a fourth example of a thermally insulated cylindrical sensor mount 80 according to the present disclosure attached to a base body 6 is shown. The cylindrical sensor mount 80 has two stages and comprises a threaded lower cylindrical section 82 and a also threaded upper cylindrical section 84. The upper cylindrical section 84 is screwed into the lower cylindrical section 84, wherein a gap 7 is provided between the upper cylindrical section 84 and the lower cylindrical section 82.

[0071] Still refer to Fig.15 , the upper cylindrical section 84 also includes a horizontal first channel 85, which is connected to the side horizontal hole 20 that can be operated to accommodate the sensor probe 24. The sensor probe 24 has a distal shaft 25 that can be threaded. The horizontal first channel 85 can also be threaded. In this case, the sensor probe shaft 25 can be screwed into the threaded horizontal first channel 85. The cylindrical sensor mount 80 has a second vertical cylindrical channel 83 that intersects the horizontal first channel 85. At low temperatures, the thickness of the gap 7 can be very small (e.g., less than 0.001 inches) to prevent "cold pumping" across the gap 7 (under low temperature conditions, cold pumping undesirably increases heat transfer across the gap 7). The bottom surface 9 of the lower section 82 can be artificially roughened to increase the gap thermal resistance across the joint between the lower section 82 and the substrate 6. The lower cylindrical section 84 can be attached to the substrate 6 with screws 4, 4', etc. or other attachment methods (e.g., including adhesives). The upper outer surface 29 and / or the outer sidewall of the upper cylindrical section 84 may have an optical finish selected from a black (high emissivity) coating (for extremely hot substrates), a highly polished (low emissivity) surface, or a low emissivity coating (i.e., for low temperature substrates), or a combination thereof. This nested threaded cylindrical assembly may produce a strong, compact, thermally isolated mount 80.

[0072] In some examples, the total number of threaded nested cylindrical segments of the cylindrical sensor mount may be different than four. For example, the number of threaded cylindrical segments may be 2, 3, 4, 5, 6, 7, or 8 segments, depending on how much thermal isolation is desired.

[0073] In some examples, the outer sidewalls and / or top exterior surface of the sensor mount may have an optical finish, such as a black (high emissivity) coating, a high polish surface, or a low emissivity coating, or a combination thereof.

[0074] In some examples, the various segments that make up the prismatic sensor mount 10 or 60 or the cylindrical sensor mount 32 or 80 may be made of steel, porous steel, or other low thermal conductivity materials such as ceramics, carbon fiber composites, or polymer materials, or combinations thereof. The various segments may be manufactured by using electrical discharge machining (EDM) of wire, lathe turning, 3-D printing, or other well-known manufacturing techniques.

[0075] In some examples, the outer dimensions of the interlocking segments can be the same or different. For example, for a prismatic sensor mount, the width and length of the prismatic segments can be different from each other. In another example, for a cylindrical mount, the diameter of the cylindrical segments can be different from each other.

[0076] It should be noted that the prismatic sensor mounting member 60 (eg Fig.12 and Fig.13 ) and a prismatic sensor mounting member 10 (as shown Figure 3 ) are similar, except that Fig.12 and Fig.13 The middle section 14 and the top section 18 are removed (from the sensor mount 10 ). Fig.14 and Fig.15 The same relationship exists.

Claims

1. A heat-insulating sensor mounting member (60), comprising: At least two nested interlocking sections (62, 64) comprising: Lower section (62); an upper section (64) disposed above the lower section (62) and attached to the lower section (62) by an interlocking joint (8, 8'); an upper outer surface (29) disposed on the upper section (64), and The upper section and the lower section define a gap (7) therebetween.

2. The thermally isolated sensor mount (60) of claim 1, wherein the upper section (64) includes a first passage (70) operable to receive a sensor probe (24).

3. The thermally isolated sensor mount of claim 2, further comprising: a vertical or nearly vertical access passage (72) disposed at least partially through the upper section (64); and The first channel (70) is horizontal and intersects the vertical or nearly vertical entry channel (72).

4. The thermally isolated sensor mount (60) of claim 2, further comprising a sensor probe (24) disposed in the first passage (70).

5. The thermally isolated sensor mounting member (60) according to claim 4, wherein the sensor probe (24) has an integral threaded shaft (25); wherein the first passage (70) is threaded; and The integral shaft (25) is screwed into the threaded first passage (70).

6. The thermally isolated sensor mounting member (60) according to claim 1, wherein the lower section (62) and the upper section (64) have a prismatic shape; and The sensor mount (24) includes a pair of dovetail joints (8, 8') slidingly joining the lower section (62) to the upper section (64).

7. The thermally isolated sensor mounting member (80) according to claim 1, wherein the lower section (82) has a cylindrical shape and is threaded; wherein the upper section (84) has a cylindrical shape and is threaded; The upper section (84) is screwed into the lower section (82).

8. The thermally isolated sensor mount (60) of claim 1, wherein the upper exterior surface (29) includes an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof.

9. The thermally isolated sensor mount (10) of claim 1, wherein the thermally isolated sensor mount (10) comprises four interlocking prismatic sections (12, 14, 16, 18).

10. The thermally isolated sensor mount (32) of claim 1, wherein the thermally isolated sensor mount (32) comprises four interlocking cylindrical sections (34, 36, 38, 40).

11. The thermally isolated sensor mount (60) of claim 1, wherein the gap (7) has a thickness of less than about 0.001 inches.

12. A heat-insulated sensor mounting member (80), comprising: At least two interlocking cylindrical sections (82, 84) comprising: a lower section (82) having a cylindrical shape and being threaded; an upper section (84) having a cylindrical shape and being threaded; a first passage (85) disposed in the upper section (84), the first passage being operable to receive a sensor probe (24); an upper outer surface (29) of the upper section (84); and wherein the lower section (82) and the upper section (84) define a gap (7) disposed therebetween; and The upper section (84) is screwed into the lower section (82).

13. The thermally isolated sensor mount (80) of claim 12, wherein the upper exterior surface (29) includes an optical finish selected from a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof.

14. The thermally isolated sensor mount (80) of claim 12, further comprising a sensor probe (24) disposed in the first passageway.

15. A thermally isolated sensor mounting member (32), comprising: At least four interlocking cylindrical sections (34, 36, 38, 40) comprising: a bottom section (34) having a cylindrical shape and being threaded; a middle section (36) having a cylindrical shape and being threaded; an upper section (38) having a cylindrical shape and being threaded; a top section (40) having a cylindrical shape and being threaded; a first passage (45) in the upper section (38), the first passage being operable to receive a sensor probe (24); wherein the bottom section (34) and the middle section (36) define a first gap (7) disposed therein; wherein the middle section (36) and the upper section (38) define a second gap (7') disposed therebetween; and an upper outer surface (29) of the top section (40); wherein the middle section (36) is screwed into the bottom section (34); wherein the upper section (38) is screwed into the middle section (36); and The top section (40) is screwed into the upper section (38).

16. A thermally isolated sensor mount (32) as claimed in claim 15, wherein the upper outer surface of the top section includes an optical finish selected from the group consisting of a black (high emissivity) coating, a high polish (low emissivity) surface, or a low emissivity coating, or a combination thereof.

17. The thermally isolated sensor mount (32) of claim 15, further comprising a sensor probe (24) disposed in the first passage (45).

18. The thermally isolated sensor mount (32) according to claim 15, wherein the thickness of the first gap (7) is less than about 0.001 inches; and Wherein the thickness of the second gap (7') is less than about 0.001 inches.

19. The thermally isolated sensor mount (32) of claim 15, further comprising: a vertical or nearly vertical access passage (43) disposed at least partially through the upper section (38) and disposed completely through the top section (40); and The first channel (45) is horizontal and intersects the vertical or nearly vertical entry channel (43).

20. The thermally isolated sensor mount (32) of claim 19, further comprising: a sensor probe (24) disposed in the first channel (45); wherein the sensor probe (24) has an integral threaded shaft (25); wherein the first passage (45) is threaded; and The integral shaft (25) is screwed into the first threaded passage (45).

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