Wireless Temperature Sensors Using Ceramic Substrates
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Solution Overview
Problem
Existing temperature sensors are inadequate for measuring temperatures in harsh conditions such as high temperatures (700° C. to 1,800° C.), elevated pressures (200 psi to 50,000 psi), corrosive environments, and environments with radiation, due to limitations in wireless transmission, profile size, and durability.
Innovation Solution
The development of wireless temperature sensors using a substrate with a polymer-derived ceramic and a conductive patch, where the substrate is arranged between the patch and a ground plane, allowing for far-field interrogation and maintaining a low profile, enabling accurate temperature measurement up to 1,000° C. or greater.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If functional electronics (batteries, chips, wires) are used in temperature sensors, then the sensors can perform measurements and wireless transmission, but they malfunction when exposed to high temperatures
Solution Approach 1:
The patent removes all functional electronics (batteries, chips, wires) from the sensor design. The temperature sensing is achieved through passive electromagnetic resonance of an LC circuit formed by conductive traces on a ceramic substrate, eliminating components that fail at high temperatures while maintaining measurement capability through wireless electromagnetic coupling.
Solution Approach 2:
The patent replaces mechanical/electronic systems with electromagnetic resonance. Instead of using active electronic components that require power and signal processing, the sensor uses passive LC resonance where the resonant frequency shifts with temperature, detected wirelessly through electromagnetic coupling between antennas.
2Measurement precision
If LC circuits are used for wireless temperature sensing, then temperature can be measured, but the read range is limited to centimeters due to near field coupling
Solution Approach 1:
The patent transitions from near-field magnetic coupling to far-field electromagnetic radiation by designing the LC circuit resonant frequency to operate in the microwave regime. This allows the sensor to be interrogated through free-space electromagnetic waves rather than requiring close proximity magnetic coupling, extending the read range from centimeters to meters.
3Ease of operation
If a low profile sensor is used, then it can be placed in certain locations without disrupting flow profiles, but existing sensor designs lack the necessary durability for harsh conditions
Solution Approach 1:
The patent uses a ceramic substrate that provides localized high-temperature and pressure resistance at the sensor location. The ceramic material properties are specifically selected to withstand harsh environmental conditions while maintaining the low-profile geometry needed for installation in flow-sensitive locations.
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
These sensors can measure temperatures in real-time with high accuracy and reliability in extreme conditions, offering a low profile and resistance to high temperatures, pressures, and corrosive environments, with a resonant frequency that can be converted to temperature readings.
Implementation Method 1
determining the resonant frequency of the receiving antenna; and converting the resonant frequency to a temperature at the location
Implementation Method 2
a substrate (i) including a polymer derived ceramic, and (ii) having a dielectric constant (εr) at 25° C. of about 2 to about 15
Data Source
AI summary
Devices, including wireless temperature sensors, are provided. The devices may include a patch including a conductive material, a substrate, and a ground plane. The devices may be used in the systems and methods provided herein to measure a temperature. The substrates of the devices may include a dielectric material.