Ion Probe Insulation Resistance via Ceramic-Organic Adhesive Composite
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Solution Overview
Problem
Ion probes used in combustion chambers face a reduction in insulation resistance due to moisture absorption by insulation powder, leading to decreased accuracy in flame detection with repeated use, as existing ceramic and organic adhesive layers fail to effectively prevent moisture ingress and heat-induced deterioration.
Innovation Solution
An ion probe configuration featuring a metal wire, metal sheath, insulation powder, and a ceramic capillary with an organic adhesive layer, where the ceramic capillary covers the metal wire projection and part of the insulation powder is covered by the adhesive layer, preventing moisture absorption and heat-induced burnout, thus maintaining insulation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a ceramic adhesive layer is used to cover the insulation powder, then heat resistance is improved, but moisture permeation occurs through the porous structure, causing insulation resistance reduction
Solution Approach 1:
The patent uses a composite structure combining ceramic adhesive layer and organic adhesive layer. The ceramic adhesive layer provides heat resistance while the organic adhesive layer provides moisture barrier properties. This composite approach allows both heat resistance and moisture prevention to be achieved simultaneously without compromising either function.
2Object-affected harmful factors
If an organic adhesive layer is used to cover the insulation powder, then moisture absorption is prevented, but burnout due to flames or deterioration due to heat occurs
Solution Approach 1:
The patent combines organic adhesive layer and ceramic adhesive layer in a composite structure. The organic adhesive layer prevents moisture absorption while the ceramic adhesive layer protects against flame burnout and heat deterioration. This composite material approach allows both moisture prevention and flame/heat resistance to coexist.
Solution Approach 2:
The ceramic adhesive layer acts as an intermediary protective barrier between the organic adhesive layer and the harsh combustion environment (flames and high temperature). It shields the organic adhesive from direct flame contact while allowing the organic layer to perform its moisture barrier function.
3Measurement precision
If insulation powder is exposed at the distal end of the metal sheath, then flame detection function is maintained, but moisture absorption reduces insulation resistance
Solution Approach 1:
The patent applies different protective treatments to different parts of the insulation powder. The distal end insulation powder is covered with adhesive layers for moisture protection, while maintaining the necessary exposure for flame detection. This local differentiation allows simultaneous achievement of flame detection accuracy and insulation resistance maintenance.
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
This configuration effectively maintains high insulation resistance between the metal wire and sheath even after repeated use, enhancing the accuracy of flame detection by preventing moisture absorption and heat-related deterioration.
Implementation Method 1
The ceramic capillary is bonded to the distal end of the metal sheath by an organic adhesive layer
Implementation Method 2
a part of the insulation powder located at the distal end of the metal sheath is covered with the organic adhesive layer. Thus, it is possible to restrain moisture from being absorbed into the insulation powder
Implementation Method 3
the organic adhesive layer is covered with the ceramic capillary. Therefore, even if the ion probe is repeatedly used, burnout of the organic adhesive layer due to flames and deterioration of the organic adhesive layer due to heat can be restrained
Data Source
AI summary
An ion probe includes a metal wire, a metal sheath covering the metal wire, insulation powder provided between the metal wire and the metal sheath, and a ceramic capillary. A portion of the metal wire projecting from a distal end of the metal sheath is passed through the ceramic capillary. The ceramic capillary is bonded to the distal end of the metal sheath by an organic adhesive layer. A part of the insulation powder located at the distal end of the metal sheath is covered with the organic adhesive layer.