Multilayer Substrate Heat Flow Sensor for Precision Measurement
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Solution Overview
Problem
Existing heat flow distribution measurement methods using separate heat flow sensors suffer from performance differences and inaccuracies, making it difficult to measure heat flow distribution with high precision, while thermographic methods convert surface temperature distributions to heat flow distributions with limited precision.
Innovation Solution
A heat flow distribution measurement device featuring a multilayer substrate with integrated heat flow sensor portions formed from electrically independent thermoelectric conversion elements, where the thermoelectric conversion elements are manufactured using the same process, reducing performance differences and enhancing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple separate heat flow sensors are used to measure heat flow distribution, then the measurement coverage is improved, but the measurement precision deteriorates due to performance differences between individual sensors
Solution Approach 1:
Multiple heat flow sensor elements are integrated into a single multilayer substrate structure, forming one unified sensor module. This merging approach ensures all sensor elements share identical manufacturing conditions and structural characteristics, eliminating performance variations between separate sensors while maintaining comprehensive measurement coverage through the array of sensor elements within the integrated module.
Solution Approach 2:
The sensor module is segmented into multiple independent sensor elements arranged in a matrix pattern on the multilayer substrate. Each element can independently measure heat flow at its specific location, providing spatial distribution information. The segmentation enables comprehensive coverage while the integrated manufacturing process ensures uniform performance across all segments.
2Device complexity
If thermographic device is used to measure heat flow distribution by converting surface temperature distribution, then the measurement process is simplified, but the measurement precision deteriorates due to indirect measurement and complex analysis requirements
Solution Approach 1:
The patent replaces indirect optical measurement (thermography) with direct thermal-electrical conversion using thermoelectric elements. Instead of measuring temperature distribution and performing complex analysis to infer heat flow, the thermoelectric elements directly convert heat flow into electrical signals through the Seebeck effect, providing accurate heat flow measurement without complex computational processing.
Solution Approach 2:
The patent introduces thermoelectric conversion elements as intermediary components that directly transduce heat flow into electrical measurements. These elements serve as a precise mediator between the thermal field and electrical measurement system, eliminating the need for complex thermal analysis and inference required by direct thermographic methods.
3Ease of manufacture
If multiple separate heat flow sensors are manufactured independently, then the manufacturing flexibility is improved, but the manufacturing precision deteriorates due to performance variations between batches
Solution Approach 1:
Multiple sensor elements are manufactured together as an integrated assembly on a single multilayer substrate using concurrent manufacturing processes. This approach ensures all elements experience identical manufacturing conditions, materials, and processing parameters, guaranteeing uniform performance characteristics across all sensor elements while maintaining manufacturing efficiency through batch production.
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 device allows for precise measurement of heat flow distribution by minimizing performance variations among thermoelectric conversion elements and providing a direct electrical output from the heat flow through the multilayer substrate, improving measurement accuracy compared to separate sensors.
Implementation Method 1
each of the plurality of heat flow sensor portions (10) is formed of an electrically independent thermoelectric conversion element... each of the thermoelectric conversion elements produces an electric output in accordance with a heat flow passing through the inside of the multilayer substrate
Data Source
AI summary
A heat flow distribution measurement device includes a sensor module having one multilayer substrate and a plurality of heat flow sensor portions arranged inside of the multilayer substrate. The multilayer substrate has one surface and another surface opposite to the one surface and includes a plurality of stacked insulating layers each formed of a thermoplastic resin. The heat flow sensor portions are each formed of thermoelectric conversion elements and are thermoelectrically independent. An arithmetic portion arithmetically determines a heat flow distribution based on an electromotive force generated in each of the heat flow sensor portions. The thermoelectric conversion elements are formed in the multilayer substrate and therefore manufactured by the same manufacturing process for manufacturing the multilayer substrate. This can minimize the performance difference between the individual thermoelectric conversion elements and allow the heat flow distribution to be measured with high precision.