Zirconium Oxide Sensor with Insulating Intermediate Layer
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Solution Overview
Problem
Existing temperature sensor units with zirconium oxide carrier layers fail or are destroyed at higher temperatures, and the thermal insulating layer develops conductivity, causing electrical connection issues, limiting their use in high-temperature applications.
Innovation Solution
A thermally insulating carrier layer made partially of zirconium oxide with an electrically insulating intermediate layer prevents electrical connection by applying the active measurement layer on this intermediate layer, which is also applied below the carrier layer, ensuring thermal and electrical decoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a thermally insulating carrier layer made of zirconium oxide is used, then thermal decoupling between heating unit and temperature sensor is improved, but the layer develops electrical conductivity at high temperatures causing measurement errors
Solution Approach 1:
An electrically insulating intermediate layer is introduced between the thermally insulating carrier layer and the active measurement layer. This intermediate layer acts as a mediator that maintains electrical insulation even when the carrier layer becomes conductive at high temperatures, thereby preventing measurement errors while preserving thermal decoupling stability.
Solution Approach 2:
The sensor structure employs a composite multi-layer design combining the zirconium oxide carrier layer (for thermal insulation) with an electrically insulating intermediate layer (for electrical isolation). This composite structure leverages the complementary properties of different materials to simultaneously achieve thermal decoupling and electrical insulation stability at high temperatures.
2Measurement precision
If the temperature sensor and heating unit are thermally decoupled using zirconium oxide carrier layer, then measurement accuracy is improved, but the sensor unit fails at higher temperatures due to layer conductivity
Solution Approach 1:
The electrically insulating intermediate layer serves as a protective intermediary that prevents electrical conduction between measurement layers at elevated temperatures. This enables the sensor to maintain measurement precision while operating at higher temperatures without failure.
Solution Approach 2:
The sensor structure is segmented into functionally distinct layers: the zirconium oxide carrier layer for thermal decoupling and the electrically insulating intermediate layer for electrical isolation. This segmentation allows each layer to independently perform its specific function, enabling the sensor to withstand higher operating temperatures while maintaining measurement accuracy.
3Stability of the object's composition
If zirconium oxide is used as carrier layer for thermal insulation, then thermal decoupling is achieved, but electrical connection issues occur at high temperatures
Solution Approach 1:
The electrically insulating intermediate layer acts as a protective intermediary positioned between the thermally insulating carrier layer and the active measurement layer. It specifically counteracts the harmful electrical conductivity effect that develops in the zirconium oxide carrier layer at high temperatures, thereby eliminating measurement interference while preserving thermal insulation stability.
Solution Approach 2:
Different layers are assigned specific functional qualities: the zirconium oxide carrier layer provides thermal insulation with the understanding that it may become conductive at high temperatures, while the electrically insulating intermediate layer is specifically positioned to address the electrical conductivity issue locally at the interface with measurement layers, allowing each region to optimize its primary function.
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 accurate temperature measurement and flow monitoring at high temperatures by preventing conductive connection between layers, thus protecting the sensor units from thermal stress and maintaining measurement accuracy.
Implementation Method 1
at least one essentially electrically on and/or in the carrier layer insulating intermediate layer is applied
Implementation Method 2
at least one essentially thermally insulating carrier layer, which consists at least partially of zirconium oxide
Data Source
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AI summary
The invention relates to a device for measuring and/or monitoring at least one process variable, wherein at least one substantially thermally insulating carrier layer (1) is provided, wherein at least one substantially electrically insulating intermediate layer (4) is applied to and/or in the carrier layer (1), and wherein at least one layer (2) active with respect to the measurement of the process variable is applied to and/or in the intermediate layer (4). The invention further relates to a method for manufacturing a corresponding sensor unit.