Multi-Layer Ceramic Thermoanalytical Sensor for 3D Heat Flow
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Solution Overview
Problem
Conventional thermoanalytical sensors produced by thin-film and thick-film technologies have limitations such as high production costs, low mechanical and chemical endurance, and limited ability to measure heat flow in three dimensions due to two-dimensional thermocouple arrangements, leading to measurement uncertainties.
Innovation Solution
A thermoanalytical sensor with multiple ceramic layers sintered together to form a monolithic unit, featuring structured ceramic elements and measurement chains that extend in both horizontal and vertical directions, allowing for three-dimensional heat flow measurement and improved sensitivity and structural flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thin-film technology is used to produce thermocouple arrangements, then production cost increases and mechanical/chemical endurance decreases, but measurement precision is maintained
Solution Approach 1:
The patent employs composite material construction by combining ceramic layers with metal thermocouple wires embedded within the ceramic matrix. This composite structure provides both the measurement precision of thermocouples and the mechanical/chemical durability of ceramic materials, resolving the contradiction between measurement accuracy and reliability.
Solution Approach 2:
The ceramic matrix acts as an intermediary medium that supports and protects the thermocouple arrangements. It provides mechanical support and chemical stability while allowing the thermocouples to function for heat flow measurement, thus maintaining measurement precision without exposing the fragile thermocouples to direct environmental stress.
2Device complexity
If two-dimensional thermocouple arrangements are used, then device complexity is reduced, but measurement precision deteriorates due to inability to measure three-dimensional heat flow
Solution Approach 1:
The patent transitions from two-dimensional thermocouple arrangements to three-dimensional configurations by embedding thermocouples within multiple stacked ceramic layers. This dimensional expansion enables measurement of heat flow in all spatial directions (horizontal and vertical), significantly improving measurement precision without proportionally increasing device complexity.
Solution Approach 2:
The sensor is segmented into multiple ceramic layers, each containing thermocouple arrangements oriented in different directions. This segmentation allows independent optimization of measurement capabilities in different spatial dimensions while maintaining manageable complexity through modular layer construction.
3Measurement precision
If multiple thick-film coating layers are formed on carrier substrate, then measurement precision improves, but production time increases and manufacturing precision deteriorates due to multiple sintering steps
Solution Approach 1:
The patent merges multiple functional layers (ceramic matrix and thermocouple arrangements) into a single integrated structure formed in one sintering process. This consolidation eliminates the need for multiple separate coating and sintering steps, dramatically improving productivity while maintaining measurement precision through the unified multi-layer ceramic-thermocouple composite structure.
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 achieves higher sensitivity and accuracy in calorimetric measurements by capturing heat flow in three dimensions, reducing thermal stress and production costs through the use of a single ceramic material and advanced structuring techniques.
Implementation Method 1
several layers which are formed by ceramic elements that have been solidly bonded to each other by undergoing a sintering process together
Implementation Method 2
at least one thermocouple arrangement which is formed in the sensor and extends along the heat flow path
Implementation Method 3
the heat flow which occurs between the temperature control device and the sample is measured
Data Source
AI summary
Thermoanalytical sensor for calorimetric measurements which cooperates with a temperature control device and comprises at least one measurement position formed on the sensor, a heat flow path established between the temperature control device and the at least one measurement position, and at least one temperature-measuring element, characterized in that the sensor has a plurality of layers which are formed substantially by ceramic elements that have been solidly bonded to each other by undergoing a sintering process together and which in their green state can be provided with a structure, wherein at least a part of the ceramic elements are structured.