Monolithic High-Temperature Sensor Structure for Thermal Stress Resistance
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Solution Overview
Problem
Existing sensors for high-temperature, high-vibration environments, such as those in gas turbines, are prone to failure due to stresses caused by differing thermal coefficients of expansion and thermal transfer rates among components, leading to reduced durability and shorter expected time to failure.
Innovation Solution
A method of additive manufacturing that deposits alternating layers of electrically insulating and conductive materials to form a monolithic structure, where the insulating material shields the conductive components from the external environment, using techniques like laser or electron beam sintering to fuse the materials, thereby reducing thermal stresses and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete parts are used to manufacture sensors for high-temperature environments, then the sensor can be assembled from separate components, but the durability is reduced due to stresses from differing thermal coefficients of expansion
Solution Approach 1:
The patent merges the coil, insulator, and housing into a single monolithic structure formed by additive manufacturing. This eliminates the discrete interfaces between components that cause thermal stress, while still allowing the sensor to be manufactured in a controlled process. The conductive and insulating materials are deposited in alternating layers and fused together to create an integrated structure.
Solution Approach 2:
The patent uses composite materials consisting of alternating layers of electrically conductive material (for the coil) and electrically insulating material (for the insulator and housing). These composite layers are deposited sequentially and fused together, creating a structure that combines the functional properties of different materials while maintaining thermal compatibility through the additive manufacturing process.
2Adaptability or versatility
If discrete components are assembled to form the sensor, then manufacturing flexibility is improved, but thermal stresses cause earlier failure
Solution Approach 1:
The patent combines multiple discrete components (coil, insulator, housing) into a single monolithic structure through additive manufacturing. This eliminates the interfaces between discrete parts where thermal stresses concentrate, thereby extending the operational life of the sensor in high-temperature environments while maintaining manufacturing flexibility through the layer-by-layer deposition process.
Solution Approach 2:
The patent changes the manufacturing parameter from discrete assembly to additive manufacturing, fundamentally altering how the sensor is created. This parameter change allows the formation of a monolithic structure with controlled material distribution, eliminating thermal stress interfaces while maintaining the ability to manufacture different sensor configurations.
3Ease of manufacture
If conventional manufacturing methods are used, then the sensor can be produced with separate components, but the sensor is prone to damage from thermal and vibrational environment
Solution Approach 1:
The patent merges separate components into a monolithic structure that inherently resists thermal and vibrational damage by eliminating interfaces. The additive manufacturing process creates a continuous structure where the coil and insulator are fused together, preventing the separation and damage that occurs in conventionally assembled sensors under thermal and vibrational stress.
Solution Approach 2:
The patent employs composite materials deposited in alternating layers to create a structure that is inherently resistant to thermal and vibrational damage. The combination of conductive and insulating materials in a fused monolithic structure provides both mechanical strength and functional properties, eliminating the weakness of discrete component interfaces.
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 method results in sensors with improved durability and extended time to failure, capable of withstanding extreme thermal and vibrational conditions by eliminating stresses from thermal expansion differences and providing a protective shield for the conductive components.
Implementation Method 1
The step of fusing the materials comprises sintering or melting the materials, the sintering or melting the or each material using at least one of: a laser; and an electron beam.
Implementation Method 2
The step of fusing the materials comprises sintering or melting the materials, the sintering or melting the or each material using at least one of: a laser; and an electron beam.
Implementation Method 3
The step of fusing the materials comprises sintering or melting the materials
Data Source
Figure 1
Figure 2a~3b
Figure 4a~4b
AI summary
The present invention relates to a method of manufacturing a sensor for a high-temperature environment. The method comprises the steps of: depositing an electrically insulating material (108) to form at least one portion of a layer (112); depositing an electrically conductive material (110) to form at least one further portion of the layer (112); depositing successive layers (112), each layer being formed of the electrically insulating material (108) and/or the electrically conductive material (110), wherein the electrically conductive material (110) in each layer is deposited on at least a portion of the electrically conductive material (110) in the previous layer so as to form at least one electrically continuous portion extending through the layers; and fusing the materials. The invention further relates to a sensor for a high-temperature environment comprising: at least one electrically conductive portion; and at least one electrically insulating portion, encapsulating the or each electrically conductive portion. The or each electrically conductive portion and the or each electrically insulating portion are fused to form a monolithic body.