Ceramic Temperature Probe Form-Fitting Housing Design
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Solution Overview
Problem
Conventional temperature sensors with ceramic, polymer, or glass encasements face limitations in high-temperature applications and aggressive media due to delayed response times, low heat conduction, and geometric instability, making them unsuitable for standardized installation and use in extreme conditions.
Innovation Solution
A temperature sensor featuring a functional ceramic sensor element with a ceramic housing, where the sensor element has direct form-fitting contact with the housing, and the housing is made of high-purity aluminum oxide or other thermally conductive ceramics, ensuring robustness and short response times without additional potting materials, and is produced using injection molding for precise geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymer or glass encapsulation is used to protect sensor elements, then mechanical stability and corrosion protection are improved, but response time increases and geometric stability deteriorates
Solution Approach 1:
The patent removes the polymer or glass encapsulation layer that was previously used to protect the sensor element. Instead, the sensor element is directly embedded in a ceramic housing, eliminating the intermediate encapsulation layer that caused delayed response time and geometric instability while maintaining protection through the ceramic material itself
Solution Approach 2:
The patent uses a ceramic housing material that combines mechanical strength, thermal conductivity, and geometric stability in a single integrated structure. The ceramic material replaces the previous composite of sensor element + polymer/glass encapsulation, providing both protection and rapid thermal response without geometric variability
2Reliability
If additional protective layers and potting compounds are added to enable use in aggressive media, then chemical resistance is improved, but thermal conductivity deteriorates and response time increases
Solution Approach 1:
The patent eliminates potting compounds and additional protective layers that were previously added to enable use in aggressive media. The ceramic housing itself provides the necessary chemical resistance, allowing direct embedding of the sensor element without thermal-blocking intermediates
Solution Approach 2:
The ceramic housing material is selected to provide both chemical resistance for aggressive media and high thermal conductivity for rapid response. This single material replaces multiple layers (sensor element + potting compound + protective coating) that previously impeded heat transfer
3Reliability
If polymer or glass encapsulation is used to protect sensor elements, then mechanical stability is improved, but geometric stability deteriorates
Solution Approach 1:
The patent removes the polymer or glass encapsulation that caused geometric variability. The sensor element is directly embedded in the ceramic housing with precise positioning, eliminating the intermediate layer that made geometry control difficult
Solution Approach 2:
The ceramic housing provides a rigid, geometrically stable structure that maintains precise sensor head dimensions. The ceramic material's inherent stability replaces the geometric control that was difficult to achieve with polymer or glass encapsulation
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 solution provides a temperature sensor with very short response times, high mechanical and chemical robustness, and stable long-term performance, enabling standardized installation and reliable operation in high-temperature, aggressive environments.
Implementation Method 1
The ceramic housing is made of high-purity aluminum oxide or other thermally conductive ceramics, ensuring robustness and short response times
Data Source
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AI summary
The invention relates to a temperature probe (1) which comprises a functional ceramics probe element (2) and a ceramic housing (3). The probe element (2) is mounted such in the ceramic housing (3) that at least one face (20) of the probe element (2) has direct and form-fitting contact with the ceramic housing (3). The invention further relates to a method for producing a temperature probe (1).