Alginate Hydrogel Thin-Film Sensor for Billet Crystallizer
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Solution Overview
Problem
Existing thin-film heat flux sensors used in billet crystallizers are prone to wear and failure due to molten steel adhering and solidifying on their surfaces, and the encapsulation required to prevent this increases response time, compromising fast response capabilities.
Innovation Solution
An alginate hydrogel-based thin-film heat flux sensor with a U-shaped planar substrate is developed, featuring a first and second film thermocouple crosslinked within the alginate hydrogel, which provides wear resistance and maintains fast response without the need for an encapsulation shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a thin-film sensor is used for heat flux measurement in billet crystallizer, then the response speed is fast, but the sensor surface is prone to molten steel adhesion and solidification causing wear and failure
Solution Approach 1:
The patent uses alginate hydrogel as a composite material that combines the advantages of thin-film sensors (fast response) with protection against molten steel adhesion. The hydrogel forms a protective layer that prevents direct contact between the sensor surface and molten steel, thereby maintaining both fast response speed and sensor durability in the harsh crystallizer environment
2Reliability
If an encapsulation shell is added to protect the thin-film sensor from molten steel adhesion, then the sensor durability is improved, but the response time is greatly increased
Solution Approach 1:
The patent employs a thin alginate hydrogel film instead of a thick encapsulation shell. This thin film provides sufficient protection against molten steel adhesion while maintaining thermal responsiveness. The hydrogel film's thin structure allows heat to quickly penetrate to the sensor surface, preserving fast response time while still preventing sensor wear and failure
3Speed
If the thin-film sensor surface is exposed directly to molten steel, then the response time is fast, but the sensor is subject to wear and eventual failure
Solution Approach 1:
The alginate hydrogel film serves as an intermediary layer between the thin-film sensor and molten steel. This intermediate layer prevents direct adhesion and solidification of molten steel on the sensor surface, eliminating the harmful effects while allowing thermal energy to quickly transfer to the sensor for fast response time
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The alginate hydrogel-based sensor effectively prevents wear from solidified steel and maintains fast response times, ensuring reliable heat flux measurements in high-wear environments without the drawbacks of encapsulation.
Implementation Method 1
the alginate hydrogel-based sensor effectively prevents wear from solidified steel
Implementation Method 2
an inner surface of the alginate hydrogel substrate is provided with a first film thermocouple and a second film thermocouple
Data Source
AI summary
An alginate hydrogel-based thin-film heat flux sensor for billet crystallizer includes an alginate hydrogel substrate. The alginate hydrogel substrate is configured in a U-shaped planar structure. The U-shaped planar structure includes a first side and a second side, and the first side is longer than the second side. An inner surface of the alginate hydrogel substrate is provided with a first film thermocouple and a second film thermocouple. The first film thermocouple is in crosslinking connection with the second film thermocouple.