Multilayer Ceramic Heat Transfer Sensor for Thin-Wall Measurement

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Solution Overview

Problem

Existing heat exchange coefficient determination systems are bulky, require intrusive installation, and are limited in temperature resistance, making them unsuitable for thin walls and dynamic fluid environments, with high manufacturing costs and complexity.

Innovation Solution

A multilayer structure comprising thin ceramic layers and metal tracks, integrated into the thickness of the layers, allows for non-intrusive installation on thin walls, capable of withstanding high temperatures, and provides precise heat exchange coefficient measurements through resistive probes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional temperature measurement devices are used to determine heat exchange coefficient, then measurement capability is provided, but the devices are bulky, require intrusive installation, and are limited in temperature resistance

Engineering Contradiction:

Improveheat exchange coefficient measurementVSAvoiddevice structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The measurement device is segmented into multiple thin layers (first thin layer, second thin layer, third thin layer) with metal tracks integrated at different depths. This segmentation allows the device to be thin enough for non-intrusive installation on thin walls while maintaining measurement capability through distributed temperature sensing at multiple levels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Metal tracks are nested within the thin ceramic layers, with each metal track integrated into the thickness of a specific layer. This nesting approach allows the sensing elements to be embedded within the structure itself, eliminating the need for separate bulky sensors and enabling non-intrusive installation while preserving measurement functionality.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Measurement precision

If traditional measurement systems are installed on thin walls, then heat exchange coefficient can be measured, but the installation is intrusive and may affect the thermal properties of the wall

Engineering Contradiction:

Improveheat exchange coefficient measurementVSAvoidthermal intrusion

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The device uses thin layers with specific thermal conductivity properties matched to the wall material, minimizing thermal resistance and thermal intrusion. The metal tracks are positioned at specific depths within the layers to optimize temperature gradient measurement while maintaining local thermal properties similar to the surrounding wall structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The measurement device is constructed as a thin film structure that can be applied conformally to thin walls without requiring intrusive installation. The thin layered structure minimizes the thermal mass and thermal resistance introduced by the device, reducing its impact on the thermal behavior of the wall being measured.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If correlation models are used to determine heat exchange coefficient, then calculation can be performed, but the models are unsuitable for turbulent fluids with large temperature differences, non-condensable substances, and singularities

Engineering Contradiction:

Improvemeasurement implementationVSAvoidapplicability to various fluid conditions

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent replaces correlation-based mathematical models with a direct physical measurement approach using temperature sensing. By measuring actual temperature gradients in the wall and applying heat conduction equations, the system directly determines heat exchange coefficient without relying on empirical correlations that fail under turbulent flow, large temperature differences, or presence of non-condensable substances.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system achieves precise and cost-effective heat exchange coefficient measurements on thin walls and various supports, including those exposed to dynamic fluid flows, with improved sensitivity and reduced manufacturing time and cost.

Implementation Method 1

each track being adapted to be connected to an electrical power supply means and to a resistance measurement means so as to form a resistive probe able to measure a temperature TP1, TP2, TP3

Methodology Applied

Scientific EffectElectrical resistance temperature measurement: Electrical Resistance

Implementation Method 2

first means for calculating from temperature values TC1 and TC2 a temperature value TP of the wall and a heat flow density φ

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12529610B2System for determining a heat exchange coefficient

Publication Date: 2026.01.20 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

AI summary

A system for determining a coefficient of heat exchange between a fluid and a medium at a surface in contact with the fluid, comprising a temperature measurement device comprising: a multilayer structure comprising: four thin ceramic layers, and three metal tracks, a resistive temperature sensor attached to the multilayer structure and intended to be in contact with the fluid to measure a fluid temperature TF, the system further comprising a computer.