Ceramic-Coil Heat Sensor Cable for Void-Free Eutectic Salt Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat sensor cables for aircraft bleed air ducts suffer from voids and debris accumulation due to ceramic bead fractures, leading to incomplete filling of eutectic salt and delayed detection of overheat conditions.
Innovation Solution
A heat sensor cable design featuring a ceramic coil and eutectic salt between inner and outer conductors, where the ceramic coil provides a non-porous structure to allow consistent eutectic salt distribution, eliminating voids and ensuring complete filling, and a metal sheath like Inconel for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ceramic beads are used as insulation between conductor and outer sheath, then the cable can be coiled and stored, but the ceramic beads may fracture and cause voids in eutectic salt distribution
Solution Approach 1:
The patent removes the ceramic beads from the system entirely and replaces them with a ceramic coating applied directly to the conductor. This extraction eliminates the source of fracture and void formation while maintaining the necessary insulation function between the conductor and outer sheath.
Solution Approach 2:
The patent employs a porous ceramic coating on the conductor that allows complete impregnation with eutectic salt. The porous structure ensures no voids remain while the ceramic material provides the necessary electrical insulation and mechanical protection during coiling operations.
2Device complexity
If ceramic beads are used for insulation, then the cable structure is established, but voids in eutectic salt distribution cause delayed detection of overheat conditions
Solution Approach 1:
By removing ceramic beads and replacing them with a continuous ceramic coating, the patent eliminates voids in the eutectic salt distribution. This ensures complete thermal contact between the salt and conductor, enabling immediate detection of overheat conditions without delay.
Solution Approach 2:
The patent creates a composite structure with a ceramic-coated conductor core and eutectic salt surrounding it. This composite design ensures complete impregnation of the porous ceramic with salt, eliminating voids and ensuring rapid thermal response for overheat detection.
3Strength
If ceramic beads are used, then insulation is provided, but fracture and accumulation cause log jams and improper filling
Solution Approach 1:
The patent eliminates ceramic beads that cause log jams during the filling process. The ceramic coating is applied to the conductor before filling, so no loose ceramic particles exist to accumulate and block the eutectic salt flow during manufacturing.
Solution Approach 2:
The ceramic coating is applied to the conductor in advance before the eutectic salt filling process. This preliminary action ensures the conductor is properly insulated and the surface is ready to receive complete impregnation with salt, eliminating filling problems associated with bead-based systems.
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 design ensures rapid detection of overheat conditions by preventing voids and debris accumulation, allowing for timely response to duct leaks or ruptures, enhancing the reliability of aircraft safety systems.
Implementation Method 1
an eutectic salt that is disbursed between the conductor and the outer sheath
Implementation Method 2
a coil that is non-conductive... wherein the coil surrounds the conductor from the conductor first end to the conductor second end
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Disclosed is a heat sensor cable having: a conductor defining a conductor first end and a conductor body extending by a first longitudinal span from the conductor first end to a conductor second end; a coil that is non-conductive and includes a coil first end and a coil body extending by a second longitudinal span from the coil first end to a coil second end, wherein the coil surrounds the conductor from the conductor first end to the conductor second end; an outer sheath that is conductive and includes an outer sheath first end and an outer sheath body extending by a third longitudinal span from the outer sheath first end to an outer sheath second end, wherein the outer sheath surrounds the coil from the conductor first end to the conductor second end; and an eutectic salt that is disbursed between the conductor and the outer sheath.