Temperature sensor probe

Abstract

A temperature sensor, comprising a body and a thermal response element, the body being made of a thermally conductive and electrically conductive material, the body being defined by a peripheral wall extending from an open proximal end to a closed distal end along a longitudinal axis. The proximal end defines an opening leading to an internal cavity of the body. The thermal response element includes an outer surface; a temperature-sensitive resistor electrically connected to a first lead and a second lead; and a connector block substantially disposed within the internal cavity. The inner surface of the peripheral wall defines the shape of a right circular cone at the distal end. The outer surface of the temperature-sensitive resistor is in direct contact with the inner surface of the peripheral wall at the distal end. One of a thermally conductive and curable potting material and a thermally conductive grease is disposed within the cavity and substantially surrounds the temperature response element.

Description

Technical Field

[0001] The invention described in the appended claims generally relates to sensors, and more specifically but not limited to, the invention relates to a sensor having a thermistor located within a tubular probe. Background Art

[0002] Thermistors are commonly used to sense temperature in household appliances and industrial applications. Generally speaking, a thermistor is a resistor whose resistance varies significantly in response to a change in the temperature of the resistor. Typically, a negative temperature coefficient (NTC) thermistor can be made of materials such as highly sensitive metal oxides. When using a negative temperature coefficient thermistor, as the temperature of the thermistor increases, the valence electrons of the metal oxide material become more active, thereby reducing the resistance of the thermistor. To protect the thermistor, they are usually encapsulated in a thermally conductive material such as thermally conductive epoxy resin, ceramics, glass, or other suitable materials. The encapsulated thermistor and wires can be further arranged within a protective housing, for example, within a tubular probe formed of a thermally conductive material.

[0003] In an encapsulated thermistor located within a protective housing, the responsiveness of the thermistor may be affected by the properties of the material used to encapsulate the thermistor, the properties of the material used to form the housing, and the contact between the encapsulating material and the housing material itself. To improve the responsiveness of the encapsulated thermistor arranged within the protective housing to temperature changes outside the protective housing, it may be desirable to increase the total heat flow from the outside of the protective housing to the thermistor. One way to improve the total heat flow is to increase the surface area of the material used to encapsulate the thermistor that is in direct contact with the housing material, thereby increasing the transfer of thermal energy through conduction. Therefore, there is a need to provide an improved protective housing for use with a temperature sensor such as a thermistor. Summary of the Invention

[0004] New and useful systems, devices, and methods for a temperature sensor are set forth in the appended claims. Illustrative embodiments are also provided to enable those skilled in the art to make and use the claimed subject matter.

[0005] For example, a temperature sensor is proposed. The temperature sensor may include a body made of a thermally conductive and electrically conductive material. The body may be defined by a peripheral wall extending longitudinally from an open proximal end to a closed distal end. At the proximal end of the body, the peripheral wall may define an opening leading to an internal cavity of the body. The internal cavity may be defined by an inner surface of the peripheral wall. A temperature-responsive element may be disposed substantially within the internal cavity. The temperature-responsive element may have an outer surface, a temperature-sensitive resistor, a first lead, a second lead, and a connector block. A first end of the first lead may be electrically connected to a first side of the connector block, and a second end of the first lead may be electrically connected to a first side of the resistor. A first end of the second lead may be electrically connected to a second side of the connector block, and a second end of the second lead may be electrically connected to a second side of the resistor. A continuous circuit is formed between the first side of the connector block, the first lead, the resistor, the second lead, and the second side of the connector block. At the closed distal end of the body, the inner surface of the peripheral wall may be in the shape of a right circular cone. The outer surface of the temperature-sensitive resistor may be in direct contact with at least three points on the inner surface of the peripheral wall at the distal end of the body. At least two of the at least three points are spaced apart by at least 90°, where the at least 90° is measured along the perimeter defined by a plane perpendicular to the longitudinal axis of the peripheral wall. One of a thermally conductive and curable potting material and a thermally conductive grease may be disposed in the cavity and substantially surround the temperature-responsive element.

[0006] In some examples, a cross-section of the cone taken along the longitudinal axis may have an included angle θ. In some examples, θ may be in the range of about 15° to about 120°. In some examples, θ may be in the range of about 30° to about 90°. In some examples, the apex angle θ of the cone may be in the range of about 15° to about 120°. In some examples, the apex angle θ of the cone may be in the range of about 30° to about 90°. In some examples, the apex of the cone may have a radius. For example, the apex of the cone may be a hemisphere.

[0007] More generally, a temperature sensor is proposed that has a body defined by a peripheral wall extending longitudinally from an open proximal end to a closed distal end. At the proximal end of the body, the peripheral wall may define an opening leading to an internal cavity of the body. The internal cavity may be defined by an inner surface of the peripheral wall. A temperature-responsive element may be disposed substantially within the internal cavity. The temperature-responsive element may have an outer surface. At the closed distal end of the body, the inner surface of the peripheral wall may be a cone. The outer surface of the temperature-responsive element may be in direct contact with at least two points on the inner surface of the peripheral wall at the closed distal end of the body. When measured in a plane perpendicular to the longitudinal axis, the at least two points may be spaced apart by at least 90°.

[0008] In some examples, the cone can be a right circular cone. In some examples, a cross-section of the cone taken along the longitudinal axis can have an included angle θ. In some examples, θ can be in the range of about 15° to about 120°. In some examples, the pointed angle θ of the cone can be in the range of about 30° to about 90°. In some examples, the tip of the cone can include a radius. For example, the tip of the cone can include a hemisphere. In some examples, the body can include a conductive material. In some examples, the body can include a thermally conductive material and a conductive material. In some examples, the body can include at least one of steel, aluminum, copper, brass, and stainless steel.

[0009] In some examples, the temperature-responsive element can include a temperature-sensitive resistor, a first lead, a second lead, and a connector block. The first end of the first lead can be electrically connected to the first end of the connector block, and the second end of the first lead can be electrically connected to the first side of the resistor. The first end of the second lead can be electrically connected to the second side of the connector block, and the second end of the second lead can be electrically connected to the second side of the resistor. A continuous circuit is formed between the first side of the connector block, through the first lead, the resistor, the second lead, and to the second side of the connector block.

[0010] In some examples, a thermally conductive and curable potting material can be disposed in the cavity and substantially surround the temperature-responsive element. In some examples, a curable dielectric material can be disposed in the cavity and substantially surround the temperature-responsive element. In some examples, a thermal grease can be disposed in the cavity and substantially surround the temperature-responsive element.

[0011] The objects, advantages, and preferred modes of making and using the claimed subject matter can be best understood by reference to the drawings and the following detailed description of the illustrative embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a front view of a temperature sensor in accordance with the present specification;

[0013] Figure 2 is a front view of a temperature sensor in accordance with the present specification;

[0014] Figure 3 is a front view of a temperature sensor in accordance with the present specification;

[0015] Figure 4 is a front view of a temperature sensor in accordance with the present specification;

[0016] Figure 5 is along Figure 1 the line 5-5 of Figure 1 an exemplary temperature sensor;

[0017] Figure 6 is alongFigure 2 taken along line 6-6 of Figure 2 a cross-sectional view of an exemplary temperature sensor;

[0018] Figure 7 is along Figure 3 taken along line 7-7 of Figure 3 a cross-sectional view of an exemplary temperature sensor;

[0019] Figure 8 is along Figure 4 taken along line 8-8 of Figure 4 a cross-sectional view of an exemplary temperature sensor;

[0020] Figure 9 is a partial view taken at the mark “ Figure 5 ” in Figure 9 illustrating details associated with some exemplary embodiments of the temperature sensor of Figure 5 ;

[0021] Figure 10 is along Figure 9 taken along line 10-10 of Figure 9 a cross-sectional view of an exemplary temperature sensor;

[0022] Figure 11 is a partial view taken at the mark “ Figure 6 ” in Figure 11 illustrating details that may be associated with some exemplary embodiments of the temperature sensor of Figure 6 ;

[0023] Figure 12 is along Figure 11 taken along line 12-12 of Figure 11 a cross-sectional view of an exemplary temperature sensor;

[0024] Figure 13 A partial view taken at the mark “ Figure 7 ” in Figure 13 illustrating details that may be associated with some exemplary embodiments of the temperature sensor of Figure 7 ;

[0025] Figure 14 is along Figure 13 taken along line 14-14 of Figure 13 a cross-sectional view of an exemplary temperature sensor;

[0026] Figure 15 is a partial view taken at the mark “ Figure 8 ” in Figure 15 illustrating details associated with some exemplary embodiments of the temperature sensor of Figure 8 ;

[0027] Figure 16 is taken along line 16-16 of Figure 15 the exemplary temperature sensor; Figure 15 a cross-sectional view of

[0028] Figure 17 is a cross-sectional view showing additional details associated with some examples of the temperature sensor of Figure 5 ;

[0029] Figure 18 is a cross-sectional view showing additional details associated with some examples of the temperature sensor of Figure 6 ;

[0030] Figure 19 is a cross-sectional view showing additional details associated with some examples of the temperature sensor of Figure 7 ;

[0031] Figure 20 is a cross-sectional view showing additional details associated with some examples of the temperature sensor of Figure 8 ;

[0032] Figure 21 is a partial view taken at the mark " Figure 17 " in Figure 21 showing details associated with some embodiments of the temperature sensor of Figure 17 ;

[0033] Figure 22 is a partial view taken at the mark " Figure 18 " in Figure 22 showing details associated with some embodiments of the temperature sensor of Figure 18 ;

[0034] Figure 23 is a partial view taken at the mark " Figure 19 " in Figure 23 showing details associated with some embodiments of the temperature sensor of Figure 19 ;

[0035] Figure 24 is a partial view taken at the mark " Figure 20 " in Figure 24 showing details associated with some embodiments of the temperature sensor of Figure 20 ;

[0036] Figure 25 is an X-ray image of a conventional temperature sensor with an undetermined cone at the tip end; and

[0037] Figure 26 is Figure 2 an X-ray image of the temperature sensor 200. DETAILED DESCRIPTION

[0038] The following description of the exemplary embodiments provides information that enables a person skilled in the art to make and use the subject matter set forth in the appended claims, but the following description may omit certain details that are well known in the art. Accordingly, the following detailed description should be considered illustrative and not restrictive.

[0039] Figure 1 is a front view of the temperature sensor 100 according to this specification. As Figure 1 shown, some examples of the temperature sensor 100 include a protective housing such as the housing 102. In some examples, the body of the housing 102 can be formed of a single piece of material. In some embodiments, the body of the housing 102 can be formed of multiple pieces of material. In some examples, the body of the housing 102 can be formed of a conductive material. In some examples, the body of the housing 102 can be formed of a thermally conductive material. For example, the body of the housing 102 can be formed of a metallic material such as iron, steel, stainless steel, brass, copper, or aluminum. According to some examples, the housing 102 can be formed by a peripheral wall 104 extending from a proximal end 106 to a distal end 108. The peripheral wall 104 can be substantially radially symmetric about an axis 110 extending from the center of the housing 102 at the proximal end 106 to the center of the housing 102 at the distal end 108. The housing 102 can have an open or substantially open proximal end 106 and a closed or substantially closed distal end 108. In some examples, the housing 102 can include a first portion 112 extending a distance from the proximal end 106 toward the distal end 108, a second portion 114 extending a distance from the distal end 108 toward the proximal end 106, and a third portion 116 between the first portion 112 and the second portion 114. In some examples, the second portion 114 can include a base 118 near the third portion 116 and a tip end 120 near the distal end 108.

[0040] As in Figure 1As illustrated in the examples, certain embodiments of the distal end portion 120 may define a rounded cone, or a frustum of a cone having a spherical or hemispherical cap at the apex or vertex of the cone. For example, the inner surface of the peripheral wall 104 at the distal end portion 120 may define a cone. In some examples, the outer surface of the peripheral wall 104 at the distal end portion 120 may define a cone. The first portion 112 may have a width or diameter defined by a length 122 measured in a direction substantially orthogonal to the axis 110. The third portion 116 may have a width or diameter defined by a length 124 measured in a direction substantially orthogonal to the axis 110. The base 118 may have a width or diameter defined by a length 126 measured in a direction substantially orthogonal to the axis 110. In some examples, an annular ridge or protrusion 128 may be formed on the peripheral wall 104 at the first portion 112. In some embodiments, the peripheral wall 104 may have a thickness of about 0.2 millimeters. According to some examples, the length of the first portion 112 may be about 24.2 millimeters, the length of the second portion 114 may be about 3.5 millimeters, and the length of the third portion may be about 4.7 millimeters. In some examples, the length 122 may be about 5.5 millimeters, the length 124 may be about 2.5 millimeters, and the length 126 may be about 2 millimeters.

[0041] Figure 2 is a front view of the temperature sensor 200 according to the present specification. The temperature sensor 200 may be substantially similar to the Figure 1 temperature sensor 100 except that the base 118 of the temperature sensor 100 may be omitted. As Figure 2 shown, the distal end portion 202 of the temperature sensor 200 may extend a substantial distance from the distal end 108 toward the third portion 116. For example, the distal end portion 202 of the temperature sensor 200 may extend from the distal end 108 toward the third portion a distance equal to the combined length of the base 118 and the distal end portion 120 of the temperature sensor 100 measured along the axis 110. Certain embodiments of the distal end portion 202 may define a rounded cone or a frustum of a cone with a spherical cap at the tip or apex. The base of the distal end portion 204 may be defined as the portion of the distal end portion 204 that is farthest from the distal end 108. The base of the distal end portion 204 may have a width or diameter that may be defined by a length 204 measured in a direction substantially orthogonal to the axis 110. In some examples, the length 204 may be about 2 millimeters.

[0042] Figure 3 is a front view of the temperature sensor 300 according to the present specification. The temperature sensor 300 may be similar to the Figure 1The temperature sensor 100 is substantially similar, and the distal end portion 302 may define a cone such as a right circular cone that tapers to a point at the tip or apex of the cone.

[0043] Figure 4 is a front view of the temperature sensor 400 according to the present specification. Except for the distal end portion 402 similar to the distal end portion 202, the temperature sensor 400 may be substantially similar to Figure 2 the temperature sensor 200, and the distal end portion 402 may define a cone such as a right circular cone that tapers to a point at the tip or apex of the cone.

[0044] Figure 5 is along Figure 1 the line 5-5 taken Figure 1 a cross-sectional view of the exemplary temperature sensor 100. As Figure 5 illustrated, the peripheral wall 104 of the housing 102 may define a cavity 502 that has an opening at the proximal end 106. A temperature-responsive element such as a temperature sensing unit 504 may be substantially disposed within the cavity 502. In some examples, the temperature sensing unit 504 may include a temperature-sensitive element, such as a temperature-sensitive resistor unit 506. The temperature-sensitive resistor unit 506 may include a thermistor whose resistance varies with its temperature, such as a thermistor that may be obtained from Therm-O-Disc of Incorporated of Mansfield, Ohio. The thermistor of the temperature-sensitive resistor unit 506 may be operatively coupled to a connection block 508. For example, a first side of the thermistor of the temperature-sensitive resistor unit 506 may be electrically connected to a first side 510 of the connection block 508 via a first wire or lead such as wire 512, and a second side of the thermistor of the temperature-sensitive resistor unit 506 may be electrically connected to a second side 514 of the connection block 504 via a second wire or lead such as wire 516. Thus, the thermistor of the temperature-sensitive resistor unit 506, wire 512, connection block 504, and wire 516 may form a continuous circuit. In some examples, the temperature-sensitive resistor unit 506 may include an outer surface 518. In some examples, the temperature-sensitive resistor unit 506 may be disposed within the cavity 502 such that at least a portion of its outer surface 518 physically contacts at least a portion of the inner surface of the peripheral wall 104 near the tip or apex of the cone of the distal end portion 120.

[0045] Figure 6 is along Figure 2 the line 6-6 taken Figure 2 a cross-sectional view of the exemplary temperature sensor 200. Figure 6 the temperature sensor 200 may be similar to Figure 5The temperature sensor 100 is substantially similar, except that in some examples, the thermoresistive resistor unit 506 may be disposed within the cavity 502 such that at least a portion of its outer surface 518 physically contacts at least a portion of the tip or apex of the cone of the inner surface of the peripheral wall 104 near the distal end 202.

[0046] Figure 7 is taken along Figure 3 line 7-7 of Figure 3 a cross-sectional view of an exemplary temperature sensor 300. Figure 7 The temperature sensor 300 can be substantially similar to Figure 5 the temperature sensor 100, except that in some examples, the thermoresistive resistor unit 506 may be disposed within the cavity 502 such that at least a portion of its outer surface 518 physically contacts at least a portion of the tip or apex of the cone of the inner surface of the peripheral wall 104 near the distal end 302.

[0047] Figure 8 is taken along Figure 4 line 8-8 of Figure 4 a cross-sectional view of an exemplary temperature sensor 400. Figure 8 The temperature sensor 400 can be substantially similar to Figure 5 the temperature sensor 100, except that in some examples, the thermoresistive resistor unit 506 may be disposed within the cavity 502 such that at least a portion of its outer surface 518 physically contacts at least a portion of the tip or apex of the cone of the inner surface of the peripheral wall 104 near the distal end 402.

[0048] Figure 9 is a partial view taken at Figure 5 the mark " Figure 9 " in Figure 5 illustrating details associated with some exemplary embodiments of the temperature sensor 100. As Figure 9 illustrated, the distal end 120 can define a cone whose base is closer to the proximal end 106 and whose tip or apex is positioned closer to the distal end 108. Generally, the perimeter of the base of the cone is referred to as the "directrix", and each line segment in the line segment between the directrix and the tip or apex is referred to as a "generatrix (generatrix orgeneratrix line)". Figure 9 Illustrates a first generatrix 902 and a second generatrix 904 of the cone of the distal end 120, which intersect at the tip or apex 906 of the cone. Generally, the "aperture" of the cone is the maximum angle θ between two generatrices, which can also be referred to as the apex angle or vertex angle. For example, as Figure 9As shown, the angle θ can be the angle 908 formed between the first bus bar 902 and the second bus bar 904. In some examples, the angle 908 can be in the range of about 15° to about 120°. In some examples, the angle 908 can be in the range of about 30° to about 90°.

[0049] Figure 9 The figure shows additional details that can be associated with some exemplary embodiments of the temperature-sensitive resistor unit 506. As illustrated in Figure 9 The temperature-sensitive resistor unit 506 can include a thermistor 910. A first side of the thermistor 910 can be electrically connected to the wire 512, and a second side of the thermistor 910 can be electrically connected to the wire 516. In some examples, the thermistor 910 can be encapsulated within a packaging member 912 such as a thermally conductive bead. In some examples, the packaging member 912 can be a glass bead, a ceramic bead, or an epoxy bead. In some examples, an outer surface of the packaging member 912 can form the outer surface 518 of the temperature-sensitive resistor unit 506. As illustrated in Figure 9 At least a portion of the outer surface 518 can contact an inner surface of a portion of the cone that forms the tip end 120 of the peripheral wall 104.

[0050] Figure 10 is a cross-sectional view of an exemplary temperature sensor 100 taken along line 10-10 of Figure 9 As illustrated in Figure 9 At least a portion of the outer surface 518 can contact an inner surface of a portion of the cone that forms the tip end 120 of the peripheral wall 104. For example, the outer surface 518 can contact the inner surface of the peripheral wall 104 at a plurality of contact points 1002. In some examples, the outer surface 518 can contact the inner surface of the peripheral wall at two or more contact points 1002. In some examples, the outer surface 518 can contact the inner surface of the peripheral wall at three or more contact points 1002. As illustrated in Figure 10 In some examples, at least two of the contact points 1002 can be spaced apart by at least 90 degrees as measured along the perimeter defined in a plane perpendicular to a longitudinal axis such as axis 110 of the peripheral wall 104. In some examples, there can be eight or more contact points 1002. Figure 10 As illustrated in

[0051] Figure 11 is a partial view taken at the mark " Figure 6 " in Figure 11 illustrating what can be associated with Figure 6Details associated with some exemplary embodiments of temperature sensor 200. Except that the first bus bar 1102 and the second bus bar 1104 are formed by the cone of the tip portion 202, temperature sensor 200 may be substantially similar to Figure 9 temperature sensor 100. The first bus bar 1102 and the second bus bar 1104 may intersect at the tip or apex 1106 of the cone. As shown in Figure 11 , the angle θ may be the angle 1108 formed between the first bus bar 1102 and the second bus bar 1104. In some examples, the angle 1108 may be in the range of about 15° to about 120°. In some examples, the angle 1108 may be in the range of about 30° to about 90°.

[0052] Figure 12 is a cross-sectional view of exemplary temperature sensor 200 taken along line 12-12 of Figure 11 . As illustrated in Figure 11 , at least a portion of the outer surface 518 may contact an inner surface of a portion of the cone forming the tip portion 202 of the peripheral wall 104. For example, the outer surface 518 may contact the inner surface of the peripheral wall 104 at a plurality of contact points 1202. In some examples, the outer surface 518 may contact the inner surface of the peripheral wall at two or more contact points 1202. In some examples, the outer surface 518 may contact the inner surface of the peripheral wall at three or more contact points 1202. As illustrated in Figure 12 , in some examples, at least two of the contact points 1202 may be spaced apart by at least 90 degrees as measured along the perimeter defined in a plane perpendicular to a longitudinal axis such as axis 110 of the peripheral wall 104. In some examples, there may be eight or more contact points 1202. Figure 12

[0053] Figure 13 Figure 7 is a partial view taken at the mark " Figure 13 " in Figure 7 , illustrating details associated with some exemplary embodiments of temperature sensor 300 which may be substantially similar to Figure 9 temperature sensor 100. Except that the first bus bar 1302 and the second bus bar 1304 are formed by the cone of the tip portion 302, the first bus bar 1302 and the second bus bar 1304 may intersect at the tip or apex 1306. In some examples, the tip or apex 1306 may be disposed at the same position as the distal end 108. As shown in Figure 13 ​​As shown, the angle θ can be the angle 1308 formed between the first bus bar 1302 and the second bus bar 1304. In some examples, the angle 1308 can be in the range of about 15° to about 120°. In some examples, the angle 1308 can be in the range of about 30° to about 90°.

[0054] Figure 14 is taken along Figure 13 the line 14-14 of Figure 11 an exemplary temperature sensor 200. As shown in Figure 14 , at least a portion of the outer surface 518 can contact an inner surface of a portion of the cone that forms the tip end 302 of the peripheral wall 104. For example, the outer surface 518 can contact the inner surface of the peripheral wall 104 at a plurality of contact points 1402. In some examples, the outer surface 518 can contact the inner surface of the peripheral wall at two or more contact points 1402. In some examples, the outer surface 518 can contact the inner surface of the peripheral wall at three or more contact points 1402. As shown in Figure 14 , in some examples, at least two of the contact points 1402 can be separated by at least 90 degrees as measured along the perimeter defined in a plane perpendicular to a longitudinal axis such as axis 110 of the peripheral wall 104. In some examples, there can be eight or more contact points 1402.

[0055] Figure 15 is a partial view taken at the mark " Figure 8 " in Figure 15 and illustrates details associated with some exemplary embodiments of a temperature sensor 400 that can be Figure 8 . The temperature sensor 400 can be substantially similar to Figure 9 's temperature sensor 100, except that the first bus bar 1502 and the second bus bar 1504 are formed by the cone of the tip end 402. The first bus bar 1502 and the second bus bar 1504 can intersect at a tip or apex 1506. In some examples, the tip or apex 1506 can be located at the same position as the distal end 108. As shown in Figure 15 , the angle θ can be the angle 1508 formed between the first bus bar 1502 and the second bus bar 1504. In some examples, the angle 1508 can be in the range of about 15° to about 120°. In some examples, the angle 1508 can be in the range of about 30° to about 90°.

[0056] Figure 16 is taken along Figure 15 the line 16-16 of Figure 15 an exemplary temperature sensor 400. As shown in Figure 16As shown, at least a portion of the outer surface 518 may contact an inner surface of a portion of the conical shape forming the distal end portion 402 of the peripheral wall 104. For example, the outer surface 518 may contact the inner surface of the peripheral wall 104 at a plurality of contact points 1602. In some examples, the outer surface 518 may contact the inner surface of the peripheral wall at two or more contact points 1602. In some examples, the outer surface 518 may contact the inner surface of the peripheral wall at three or more contact points 1602. As shown in Figure 14 As shown, in some examples, at least two of the contact points 1602 may be spaced apart by at least 90 degrees as measured along the perimeter defined in a plane perpendicular to a longitudinal axis such as axis 110 of the peripheral wall 104. In some examples, there may be eight or more contact points 1602.

[0057] Figure 17 is a cross-sectional view showing additional details associated with some examples of the temperature sensor 100 that may be associated with Figure 5 As shown in Figure 17 As shown, potting material or dielectric material 1702 may be disposed in the cavity 502. The dielectric material 1702 may fill most of the second portion 114 near the distal end 108. In some examples, the dielectric material 1702 may include a thermally conductive base plastic material such as epoxy resin. In some examples, the epoxy resin may be enhanced with additives. In some examples, the additives may be electrically insulating but have better thermal conductivity than the base plastic material. In some examples, the dielectric material 1702 may include a curable dielectric material. In some examples, the dielectric material may include a thermally conductive and curable potting material. In some examples, the dielectric material 1702 may include thermal grease.

[0058] Figure 18 is a cross-sectional view showing additional details associated with some examples of the temperature sensor 200 that may be associated with Figure 6 As shown in Figure 18 As shown, potting material or dielectric material 1702 may be disposed within the cavity 502 to fill most of the second portion 114 of the temperature sensor 200 near the distal end 108.

[0059] Figure 19 is a cross-sectional view showing additional details associated with some examples of the temperature sensor 300 that may be associated with Figure 7 As shown in Figure 19 As shown, potting material or dielectric material 1702 may be disposed within the cavity 502 to fill most of the second portion 114 of the temperature sensor 300 near the distal end 108.

[0060] Figure 20FIG. shows additional details associated with some examples of temperature sensor 400 that can be associated with Figure 8 FIG. is a cross-sectional view. As shown in Figure 20 , potting material or dielectric material 1702 can be disposed within cavity 502 to fill most of the second portion 114 of temperature sensor 400 near distal end 108.

[0061] Figure 21 FIG. is a partial view taken at the mark “ Figure 17 ” in Figure 21 FIG., showing details associated with some embodiments of temperature sensor 100 that can be associated with Figure 17 FIG. As shown in Figure 21 , in some examples, substantially the entire temperature-sensitive resistor unit 506 of temperature sensor 100 can be covered by potting material or dielectric material 1702.

[0062] Figure 22 FIG. is a partial view taken at the mark “ Figure 18 ” in Figure 22 FIG., showing details associated with some embodiments of temperature sensor 200 that can be associated with Figure 18 FIG. As shown in Figure 22 , in some examples, substantially the entire temperature-sensitive resistor unit 506 of temperature sensor 200 can be covered by potting material or dielectric material 1702.

[0063] Figure 23 FIG. is a partial view taken at the mark “ Figure 19 ” in Figure 23 FIG., showing details associated with some embodiments of temperature sensor 300 that can be associated with Figure 19 FIG. As shown in Figure 21 , in some examples, substantially the entire temperature-sensitive resistor unit 506 of temperature sensor 300 can be covered by potting material or dielectric material 1702.

[0064] Figure 24 FIG. is a partial view taken at the mark “ Figure 20 ” in Figure 24 FIG., showing details associated with some embodiments of temperature sensor 400 that can be associated with Figure 20 FIG. As shown in Figure 24 , in some examples, substantially the entire temperature-sensitive resistor unit 506 of temperature sensor 400 can be covered by potting material or dielectric material 1702.

[0065] The systems, devices, and methods described herein can provide significant advantages. For example, Figure 25 FIG. is an X-ray image of a conventional temperature sensor with an undefined cone at the tip end.Figure 26 is Figure 2 an X-ray image of the temperature sensor 200. As Figure 26 shown, by providing a tapered tip portion, the number of contact points between the outer surface of the temperature-sensitive resistor unit and the inner surface of the portion of the tapered wall forming the tip portion can be increased, thereby improving the thermal response time of the temperature sensor and improving the overall consistency of temperature measurement. Additionally, by providing a tapered structure at the distal end of the housing, the assembly time can be reduced. For example, by providing a tapered structure having a relatively wide base, it is easier to accommodate the temperature-sensitive resistor unit within the tip portion.

[0066] Although shown in some illustrative embodiments, those of ordinary skill in the art will recognize that the systems, devices, and methods described herein are susceptible to various changes and modifications that fall within the scope of the appended claims. Additionally, unless the context clearly requires otherwise, the description of various alternatives using terms such as "or" does not require mutual exclusivity, and the indefinite articles "a" or "an" do not limit the subject matter to a single example unless the context clearly requires otherwise. For purposes of sale, manufacture, assembly, or use, components may also be combined or removed in various configurations.

[0067] The appended claims set forth the novel and inventive aspects of the above-described subject matter, but the claims may also cover other subject matter not specifically recited in detail. Certain features, elements, or aspects, for example, may be omitted from the claims if it is not necessary to distinguish certain novel and inventive features from those known to those of ordinary skill in the art. Features, elements, and aspects described in the context of some embodiments may also be omitted, combined, or replaced by alternative features having the same, equivalent, or similar purpose without departing from the scope of the invention as defined by the appended claims.

Claims

1. A temperature sensor, comprising: a body made of a thermally conductive and electrically conductive material and defined by a peripheral wall extending along a longitudinal axis from an open proximal end to a closed distal end; wherein, at the proximal end of the body, the peripheral wall defines an opening leading to an internal cavity of the body, the internal cavity being defined by an inner surface of the peripheral wall; a temperature-responsive element disposed within the internal cavity, the temperature-responsive element including an outer surface, a temperature-sensitive resistor, a first lead, a second lead, and a connector block, wherein the temperature-sensitive resistor is encapsulated within an encapsulation member, and an outer surface of the encapsulation member forms the outer surface of the temperature-sensitive resistor; wherein a first end of the first lead is electrically connected to a first side of the connector block, and a second end of the first lead is electrically connected to a first side of the resistor; wherein a first end of the second lead is electrically connected to a second side of the connector block, and a second end of the second lead is electrically connected to a second side of the resistor; wherein a continuous circuit is formed between the first side of the connector block via the first lead to the resistor and via the second lead to the second side of the connector block; wherein, at the closed distal end of the body, the inner surface of the peripheral wall includes the shape of a right circular cone; wherein an outer surface of the encapsulated temperature-sensitive resistor is in direct contact with at least three points on the inner surface of the peripheral wall at the distal end of the body, wherein at least two of the at least three points are spaced apart by at least 90°, the at least 90° being measured along the perimeter of the peripheral wall defined perpendicular to the longitudinal axis; and wherein one of a thermally conductive and curable potting material and a thermally conductive grease is disposed within the cavity and surrounds the temperature-responsive element.

2. The temperature sensor according to claim 1, wherein, a cross-section of the cone taken along the longitudinal axis includes an included angle θ; wherein 15° ≤ θ ≤ 120°.

3. The temperature sensor according to claim 1, wherein, a cross-section of the cone taken along the longitudinal axis includes an included angle θ; wherein 30° ≤ θ ≤ 90°.

4. The temperature sensor according to claim 1, wherein, the apex angle (θ) of the cone is 15° ≤ θ ≤ 120°.

5. The temperature sensor according to claim 1, wherein, the apex angle (θ) of the cone is 30° ≤ θ ≤ 90°.

6. The temperature sensor according to claim 1, wherein, the apex of the cone includes a radius.

7. The temperature sensor according to claim 1, wherein, the apex of the cone includes a hemisphere.

8. A temperature sensor, comprising: a body defined by a peripheral wall extending along a longitudinal axis from an open proximal end to a closed distal end; wherein, at the proximal end of the body, the peripheral wall defines an opening leading to an internal cavity of the body, the internal cavity being defined by an inner surface of the peripheral wall; A temperature-responsive element, the temperature-responsive element being encapsulated within a packaging member, an outer surface of the packaging member forming an outer surface of the temperature-responsive element, the temperature-responsive element being disposed within the internal cavity; Wherein, at the closed distal end of the body, the inner surface of the peripheral wall is a cone; Wherein, an outer surface of the encapsulated temperature-responsive element is in direct contact with at least two points on the inner surface of the peripheral wall at the closed distal end of the body; Wherein, when measured in a plane perpendicular to the longitudinal axis, the at least two points are spaced apart by at least 90°; 9. The temperature sensor according to claim 8, Wherein, The cone includes a right circular cone; 10. The temperature sensor according to claim 8, Wherein, A cross-section of the cone taken along the longitudinal axis includes an included angle θ; Wherein, 15° ≤ θ ≤ 120°; 11. The temperature sensor according to claim 8, Wherein, The apex angle (θ) of the cone is 30° ≤ θ ≤ 90°; 12. The temperature sensor according to claim 8, Wherein, The apex of the cone includes a radius; 13. The temperature sensor according to claim 8, Wherein, The apex of the cone includes a hemisphere; 14. The temperature sensor according to claim 8, Wherein, The body includes a conductive material; 15. The temperature sensor according to claim 8, Wherein, The body includes a thermally conductive material and a conductive material; 16. The temperature sensor according to claim 8, Wherein, The body includes at least one of steel, aluminum, copper, brass, and stainless steel; 17. The temperature sensor according to claim 8, Wherein, The temperature-responsive element includes a temperature-sensitive resistor, a first lead, a second lead, and a connector block; Wherein, a first end of the first lead is electrically connected to a first side of the connector block, and a second end of the first lead is electrically connected to a first side of the resistor; Wherein, a first end of the second lead is electrically connected to a second side of the connector block, and a second end of the second lead is electrically connected to a second side of the resistor; and Wherein, a continuous circuit is formed between the first side of the connector block via the first lead to the resistor and via the second lead to the second side of the connector block; 18. The temperature sensor according to claim 8, further comprising a thermally conductive and curable potting material disposed within the cavity and surrounding the temperature-responsive element; 19. The temperature sensor according to claim 8, further comprising a curable dielectric material disposed within the cavity and surrounding the temperature-responsive element; 20. The temperature sensor according to claim 8, further comprising a thermally conductive grease disposed within the cavity and surrounding the temperature-responsive element;

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