Composite Temperature Sensor Using Ceramic Filler
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Solution Overview
Problem
Conventional temperature sensors are complex and costly to produce, making them inefficient for widespread use in temperature measurement applications.
Innovation Solution
A composite material comprising a ceramic filler with a positive or negative temperature coefficient of electrical resistance embedded in a formable matrix, allowing for the creation of a simple, inexpensive temperature sensor with good thermal conductivity and deformability, which can be processed into various forms including films and surface-mountable elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional temperature sensors are used for surface temperature measurement, then temperature measurement function is achieved, but the structure becomes complicated and production becomes laborious and costly
Solution Approach 1:
The patent uses a composite material consisting of a polymer matrix combined with ceramic filler particles (such as barium titanate, lead zirconate titanate, or nickel oxide) to create a temperature-sensitive composite. This composite exhibits temperature-dependent electrical resistance characteristics while maintaining structural simplicity and ease of manufacturing, eliminating the need for complex conventional sensor structures
Solution Approach 2:
The patent exploits the temperature-dependent electrical resistance parameter of the ceramic filler particles within the polymer matrix. As temperature changes, the electrical resistance of the composite material changes predictably, enabling temperature measurement functionality through simple resistance measurement without requiring complex sensor mechanisms
2Reliability
If conventional temperature sensors are used, then temperature measurement is achieved, but production becomes costly and time-consuming
Solution Approach 1:
The patent utilizes the inherent temperature-dependent electrical resistance parameter of ceramic filler materials embedded in a polymer matrix. This natural parameter change with temperature allows for simple, low-cost temperature sensing without requiring complex manufacturing processes or expensive materials, enabling high-volume production
Solution Approach 2:
The composite material approach allows for the creation of inexpensive temperature sensors that can be mass-produced using simple mixing and molding processes. The sensors are cost-effective enough for widespread use in applications where conventional sensors would be prohibitively expensive
3Reliability
If ceramic filler particles are added to polymer matrix, then temperature-dependent resistance characteristic is achieved, but the material may lose deformability
Solution Approach 1:
The patent distributes ceramic filler particles locally within the polymer matrix at controlled concentrations and size distributions. This local distribution maintains the deformability of the polymer matrix while creating sufficient particle interactions to produce measurable temperature-dependent resistance changes. The filler particles are dispersed rather than concentrated in one location
Solution Approach 2:
The patent optimizes the concentration, size, and type of ceramic filler particles to achieve the desired balance between temperature sensitivity and deformability. By controlling these parameters, the composite maintains enough flexibility for manufacturing and application while exhibiting sufficient electrical resistance changes with temperature for accurate measurement
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 composite material enables the production of cost-effective, flexible, and formable temperature sensors with reliable temperature-dependent resistance characteristics, facilitating efficient temperature measurement and radiation detection without the need for additional carriers or envelopes.
Implementation Method 1
The ceramic filler has a positive or negative temperature coefficient of electrical resistance. The composite material has a resistance-temperature characteristic determined by the ceramic filler.
Implementation Method 2
The particles may form continuous current paths in the matrix. A filling level of the particles of 50% to 95% in the matrix can ensure continuous current paths of the ceramic particles for current flow.
Implementation Method 3
The composite material may also have a good thermal conductivity.
Data Source
AI summary
A composite material 1 for temperature measurement is specified, as is a temperature sensor 10 formed from the composite material 1. Additionally specified are processes for producing the composite material 1 and for producing the temperature sensor 10.