Polyimide Thermocouple Bundle Assembly for Multi-Point Sensing
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Solution Overview
Problem
Conventional thermocouple cables suffer from limited temperature sensing points, insulation degradation due to moisture, and frequent connection failures in high-temperature environments, making them unsuitable for thermal recovery schemes.
Innovation Solution
A thermocouple cable design featuring polyimide-insulated wires, bundled within a tubing and secured by a high-strength support cable, with junctions protected by dual-layer heat shrink sleeves, and optionally filled with a high-temperature matrix, to enhance durability and prevent twisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermocouple cables are used in high-temperature environments, then temperature measurement capability is provided, but insulation degradation occurs due to moisture accumulation and connection failures increase
Solution Approach 1:
The patent changes the insulation material parameter from conventional polymer insulation to polyimide insulation, which maintains its insulating properties at high temperatures and is not hygroscopic, thereby preventing moisture accumulation and connection failures
Solution Approach 2:
The patent uses a composite structure combining polyimide-insulated wires with a support cable framework, creating a more reliable thermocouple cable system that can withstand high-temperature environments without insulation degradation
2Measurement precision
If mineral insulated thermocouple conductors are used, then temperature measurement is provided, but the number of discrete temperature sensing points is limited
Solution Approach 1:
The patent segments the thermocouple cable into multiple discrete thermocouple junctions along the cable length, each capable of independent temperature measurement, thereby providing multiple temperature sensing points while maintaining a unified cable structure
Solution Approach 2:
The patent transitions from a single-point temperature measurement to multi-point measurement by distributing thermocouple junctions along the length of the cable, adding the spatial dimension of measurement capability
3Measurement precision
If long thermocouple cables with multiple junctions are installed using conventional methods, then temperature measurement at multiple points is achieved, but connection failures increase due to wire twisting and insulation damage
Solution Approach 1:
The patent implements preliminary action by pre-organizing and pre-insulating the wires with polyimide insulation before assembly, and by establishing a support cable framework in advance to prevent wire twisting and insulation damage during installation
Solution Approach 2:
The patent provides beforehand cushioning through the use of polyimide insulation that protects wires from mechanical damage, and through the support cable structure that cushions and stabilizes the thermocouple junctions during handling and installation
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 design provides reliable, high-temperature resistance and minimizes connection failures, enabling accurate temperature measurement at multiple points along the cable.
Implementation Method 1
each thermocouple conductor is a polyimide-insulated wire
Implementation Method 2
when two different electrically conductive materials are joined together at one end, and the temperature of the joined end is different than that of the open end, a millivoltage differential is produced
Data Source
AI summary
A thermocouple cable is formed from a tubing and a plurality of polyimide insulated thermocouple conductors bundled within the tubing, wherein each thermocouple conductor forms a junction with a shared thermocouple conductor to form a thermocouple junction, and each thermocouple junction is attached to a support cable in a thermocouple bundle. The cable is formed by pulling the thermocouple bundle into the tubing.