Ceramic Sensor for 1800°C Environments

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing sensors fail to reliably operate for long periods in very high temperatures and harsh conditions, such as those found in propulsion and power generation systems, due to limitations in materials used in transducers and gauges.

Innovation Solution

A sensor device featuring an electrically non-conductive ceramic core with electrically conductive ceramic conductors and transducers that can withstand temperatures up to 1,800°C, including capacitive pressure sensing transducers with ceramic housings and membranes, and 4-wire Kelvin sensing circuits for temperature measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional sensors and transducers are used in very high temperature environments, then manufacturing and operation are straightforward, but they fail to operate reliably for long periods due to material limitations

Engineering Contradiction:

Improvereliability of sensor operationVSAvoidmaximum operating temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent changes the material parameters of the sensor components by using ceramic materials instead of conventional metals and polymers. The ceramic core, ceramic conductors, and ceramic transducer components are selected to withstand extremely high temperatures up to 1800°C, fundamentally altering the thermal parameter range in which the sensor can operate reliably

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite structure combining electrically non-conductive ceramic core material with electrically conductive ceramic conductor materials. This composite approach allows the sensor to simultaneously achieve electrical functionality and extreme heat resistance, as each ceramic material contributes its specific properties to the overall sensor system

Inventive Principle:

Principle #40Composite materials

2Temperature

If materials that can withstand very high temperatures are used, then temperature resistance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvetemperature resistanceVSAvoidease of manufacture

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent divides the sensor into distinct ceramic segments: a ceramic core, ceramic conductor traces on the core, and a separate ceramic transducer component. This segmentation allows each part to be manufactured and tested independently using specialized ceramic processes, then assembled together, reducing the overall manufacturing complexity compared to attempting to create a monolithic high-temperature sensor

Inventive Principle:

Principle #1Segmentation

3Temperature

If ceramic materials are used for high temperature operation, then temperature resistance is improved, but electrical conductivity may be compromised

Engineering Contradiction:

Improvetemperature resistanceVSAvoidelectrical conductivity

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent applies different material qualities to different parts of the sensor structure. The core and insulating components use electrically non-conductive ceramic materials for thermal stability, while the conductor traces and transducer elements use electrically conductive ceramic materials for electrical functionality. This local differentiation of material properties allows the sensor to achieve both heat resistance and electrical reliability simultaneously

Inventive Principle:

Principle #3Local quality

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 sensor device provides reliable and accurate measurements of temperature, pressure, fluid flow rate, and fluid level in extreme conditions, maintaining functionality and precision even at high temperatures.

Implementation Method 1

A second electrode on the membrane is movable with the membrane toward and away from the first electrode in a manner that forms a variable capacitor

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 2

the ceramic electrical conductors and the transducers can withstand temperatures as high as 1,800° C.

Methodology Applied

Scientific EffectThermal stability: Thermal Insulation

Implementation Method 3

the membrane is positioned a spaced distance apart from a first electrode and is resiliently deformable toward and away from the first electrode in response to pressure changes

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10436661B2Heat resistant sensors for very high temperature conditions

Publication Date: 2019.10.08 SPORIAN MICROSYST

AI summary

Heat resistant sensors equipped with any of a variety of transducers for measuring any of a variety of properties of fluids are constructed with components comprising materials that can withstand very high temperatures. Some embodiments of the sensors include a base comprising non-conductive ceramic material, and some embodiments of the transducers include conductive ceramic materials with resistivities that vary as a function of temperature. Some embodiments of the sensors also include electrical conductors comprising electrically conductive ceramic material or electrical conductors comprising an electrically conductive refractory metal on the base. Other embodiments of the transducers include a capacitor constructed of materials that can withstand very high temperatures.