Sensor Assembly Thermal Shunt for Gas Turbine Heat Management

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Solution Overview

Problem

Sensor assemblies in high-temperature environments, such as gas turbine engines, face issues with ceramic insulators fracturing and sensor leads experiencing embrittlement due to heat, leading to reliability challenges and the need for customized connectors.

Innovation Solution

The use of additive manufacturing to create a sensor assembly with a thermal shunt portion that limits heat to the sensor connector, employing a metallic particulate structure with a high thermal resistance path and a standardized connector, eliminating the need for ceramic insulation and custom connectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a ceramic insulator and threaded stud assembly is used to provide electrical isolation and connectivity in high-temperature environments, then electrical isolation and connectivity are achieved, but the ceramic insulator is prone to fracture and sensor leads are subject to embrittlement

Engineering Contradiction:

ImprovereliabilityVSAvoidheat

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the ceramic insulator and threaded stud assembly from the sensor assembly, replacing them with a thermal shunt that conducts heat away from the sensor leads and connector. This extraction eliminates the harmful effects of heat on the electrical components while maintaining structural integrity without fragile ceramic parts.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The thermal shunt acts as an intermediary element between the high-temperature environment and the sensor leads/connector. It mediates the thermal interaction by conducting heat away from sensitive components, protecting them from embrittlement and fracture while allowing the sensor to function in high-temperature environments.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If a customized connector with ceramic insulator is used for high-temperature sensor locations, then electrical isolation is provided, but the device complexity increases and manufacturing becomes more difficult

Engineering Contradiction:

ImproveadaptabilityVSAvoidcomplexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The thermal shunt performs multiple functions: it provides thermal management by conducting heat away from sensor leads, serves as a structural mounting element, and eliminates the need for separate ceramic insulators and threaded studs. This multi-functionality reduces device complexity while maintaining adaptability to high-temperature environments.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the thermal management function and structural support function into a single thermal shunt component, replacing the previously separate ceramic insulator and threaded stud assembly. This consolidation simplifies the overall device structure and reduces the number of parts required.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If sensor leads are exposed to high temperature environments, then sensing capability is maintained, but the sensor leads experience embrittlement

Engineering Contradiction:

ImprovetemperatureVSAvoidstrength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent converts the harmful effect of heat into a beneficial thermal conduction path. The thermal shunt deliberately conducts heat away from the sensor leads, using the heat flow itself to protect the leads from embrittlement. The high-temperature environment is thus transformed from a harmful condition into a controlled thermal management opportunity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution reduces the temperature of the sensor assembly's housing portion, prevents embrittlement of measurement leads, and allows the use of standardized connectors, enhancing reliability and simplifying construction by avoiding ceramic structures and custom terminal studs.

Implementation Method 1

a thermal shunt portion extending from the mounting portion... to limit temperature of a sensor connector fixed to the housing portion

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

fusing a metallic particulate using an additive manufacturing technique to define a mounting portion

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS11692909B2Sensor assemblies and methods of making sensor assemblies

Publication Date: 2023.07.04 ROSEMOUNT AEROSPACE INC

AI summary

A sensor assembly includes a mounting portion arranged to support a sensing device, a thermal shunt portion extending from the mounting portion, and a housing portion. The housing portion extends from the thermal shunt portion and is arranged on a side of the thermal shunt portion opposite the mounting portion to limit temperature of a sensor connector fixed to the housing portion of the sensor assembly. Gas turbine engines having sensor assemblies and methods of making sensor assemblies are also described.