28
Adaptable
Sensor Packaging for High Temperature Fossil Fuel Energy Systems—Sporian
Microsystems, Inc., 515 Courtney Way, Suite B, Lafayette, CO
80026-8821; 303-516-9075
Mr.
Wenge Zhang, Principal Investigator, wenge@sporian.com
Dr.
Brian Schaible, Business Official, Brian@sporian.com
DOE
Grant No. DE-FG02-05ER84213
Amount:
$749,429
Avanced,
integrated control systems will be essential to achieving the cost and
performance targets of high-efficiency, low emissions fossil-fuel plants.
Micro-electric-mechanical-systems
(MEMS) and other types of micro-sensors will play an important role by providing
critical real-time measurements that are needed to optimize these processes.
Although micro-sensor technologies have been demonstrated, better
packaging is needed that will protect the micro-sensors from harsh environments,
allow the sensors to be exposed to the gas stream, and interface the sensors
with high temperature electronics, housings, and hardware.
This project will develop a standard, engineered testing package, with an
integrated protective housing, for applying micro-sensors in high temperature
harsh environments. The technical
approach will leverage established ceramic microelectronics packaging and high
temperature thermocouple concepts, by using proper design and material
selection. Phase I developed a
design framework for a general purpose high temperature sensor package and
conducted experiments to evaluate feasibility.
Phase II will develop a prototype, standard, engineered testing package. Specific
tasks include: (1) the development
of key structural components; (2) the development and testing of high
temperature electrical interconnect and “die attach” technologies; (3) the
finalization of a design for, and fabrication of, a prototype package; and (4)
the experimental demonstration of the prototype in high-fidelity laboratory
testing and external stimulant application test systems.
Commercial
Applications and other Benefits as described by the awardee:
The sensor packaging technology would allow end
application integrators, such as gas turbine and fuel cell manufacturers, to
realize the benefits associated with the advanced sensors.
These sensors could be designed sensors into their equipment using a
common, standardized packaging infrastructure.
In addition to energy generation, a low-cost high reliability packaging
for harsh environmentals would be useful in a wider range of other commercial
applications such as propulsion, aerospace, automotive, and the military. The
public as a whole would benefit from reduced emissions, enhanced efficiency, and
overall lower operating costs.