Thermographic Coating for Accurate Heating Surface Measurement

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Solution Overview

Problem

Existing methods for measuring thermal homogeneity of heated metal surfaces, such as electric heating plates, face challenges with intrusive contact measurements and inaccurate non-contact methods due to low emissivity of metals, leading to unreliable and non-repeatable temperature readings.

Innovation Solution

Applying a homogeneous layer of a coating material with high emissivity, such as kaolin, to the surface to enhance infrared thermography measurements, ensuring uniform emissivity and masking surface imperfections, allowing for reliable and repeatable non-contact temperature mapping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If contact measurement methods using thermocouples or RTDs are used, then temperature measurement is achieved, but measurement accuracy deteriorates due to local temperature modification and heat pumping effects

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidlocal temperature modification

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a coating layer as an intermediary substance between the infrared camera and the metal surface. This coating has high emissivity and allows the infrared camera to accurately measure the temperature of the underlying metal surface without direct contact, thus avoiding the heat pumping effect and local temperature modification caused by contact methods while maintaining measurement accuracy

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical contact measurement system (thermocouples or RTDs physically touching the surface) with a non-contact optical measurement system (infrared camera). This substitution eliminates the mechanical interaction that causes heat transfer and temperature disturbance at the measurement point, thereby improving measurement accuracy without affecting the object's thermal state

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-affected harmful factors

If pyrometer measurement method is used, then non-contact temperature measurement is achieved, but measurement completeness deteriorates due to single point measurement requiring multiple successive measurements

Engineering Contradiction:

Improvenon-intrusive measurementVSAvoidtime for multiple successive measurements

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The patent transitions from one-dimensional point measurement (pyrometer measuring single points sequentially) to two-dimensional area measurement (infrared camera capturing entire surface simultaneously). This dimensional change allows complete temperature field mapping in a single measurement, eliminating the time required for multiple successive point measurements while maintaining non-contact measurement advantages

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Object-affected harmful factors

If infrared thermography is used on metal surfaces, then non-contact temperature field mapping is achieved, but measurement accuracy deteriorates due to low emissivity of metal surfaces

Engineering Contradiction:

Improvenon-contact measurementVSAvoidtemperature measurement accuracy

Core Design Contradiction:

Object-affected harmful factorsVSMeasurement precision

Solution Approach 1:

The patent modifies the local property (emissivity) of the metal surface by applying a coating layer with high emissivity. This local quality change is confined to the measurement surface, allowing the infrared camera to accurately detect thermal radiation from the coated area while the underlying metal structure maintains its original thermal properties and functionality

Inventive Principle:

Principle #3Local quality

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

Enables instantaneous, accurate, and repeatable thermal homogeneity measurements of heating surfaces by compensating for low metal emissivity, reducing measurement errors, and maintaining surface integrity.

Implementation Method 1

the coating material having a detectable emissivity in the spectral range of the thermal measurement apparatus

Methodology Applied

Scientific EffectEmissivity: Thermal Radiation

Implementation Method 2

Pyrometers and thermal imaging cameras work on the same principle: they detect infrared radiation and convert it into a temperature measurement

Methodology Applied

Scientific EffectInfrared detection: Infrared Radiation

Data Source

PatentUS12540859B2Method for measuring by thermography a heating surface, in particular an electric heating plate

Publication Date: 2026.02.03 THERMOCOAX SAS

AI summary

A method for measuring by thermography a heating surface such as a metal surface, a ceramic surface in particular an electric heating plate includes a homogeneous layer with constant thickness of a coating material is deposited onto the surface to be measured, the surface is heated to a determined temperature; and a thermal image of the surface coated with the layer of coating material, heated, is captured using a thermal measurement apparatus, the coating material having an emissivity detectable at the determined temperature in the spectral range of the thermal measurement apparatus, the coating material having an emissivity higher than that of the surface in the spectral range of the thermal measurement apparatus.