Temperature sensor

Abstract

A temperature sensor is provided. The temperature sensor includes a housing, a temperature responsive sensing element, first and second sensor leads, and a grommet. The sensing element includes a first sensing element lead and a second sensing element lead. The first sensor lead and the second sensor lead are each electrically connected in series to a respective one of the first sensing element lead and the second sensing element lead at a respective first connection portion and a second connection portion. The grommet includes a flexible and elastic dielectric material and has an outer annular surface. The grommet, the sensing element, the first sensing element lead and the second sensing element lead, and the first connecting portion and the second connecting portion are disposed in an inner cavity of the housing. The sidewalls of the housing are mechanically interlocked to the grommet at the outer surface of the grommet to seal the sensing element and the sensing element lead from the ambient environment outside the interior cavity of the housing.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Patent Application No. 17 / 957,706, filed on September 30, 2022, which claims the benefit of U.S. Provisional Application No. 63 / 285,211, filed on December 2, 2021. The entire disclosure of the above application is incorporated herein by reference. Technical Field

[0003] The present disclosure relates to sensor structures and, more particularly, to a thermistor-type temperature sensor having an integral sealing grommet. Background Art

[0004] This section provides background information related to the present disclosure which is not necessarily prior art.

[0005] Sensors are used in many household appliances and commercial applications including refrigeration systems and heating, ventilation and air conditioning (HVAC) systems to measure various parameters of the surrounding environment, such as temperature. Temperature sensors typically include thermistor temperature sensors that provide a change in resistance as the temperature changes. Thermistor temperature sensors can form part of an electronic circuit to measure temperature in a system over a wide range.

[0006] Thermistor temperature sensors generally include a sensing element positioned within a thermally conductive housing. Typically, a potting material, such as epoxy, is applied to fill the housing and surround and secure the sensing element. Utility Model Content

[0007] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of the full scope of the disclosure or all of the features of the disclosure.

[0008] A sensor includes: a sensing element, a first pair of leads, a second pair of leads, a grommet, and a housing. The first pair of leads is fixed to the sensing element and is configured to receive a signal from the sensing element. The second pair of leads is electrically connected to the first pair of leads at a junction. The second pair of leads is configured to receive a signal from the first pair of leads. The grommet accommodates the junction, a portion of the first pair of leads, and a portion of the second pair of leads. The housing accommodates the sensing element, the first pair of leads, and the grommet. The housing engages with and deforms the grommet to seal an interior space defined by the housing.

[0009] The present disclosure describes a temperature sensor. In one aspect of the present disclosure, the sensor includes a housing including a deformable tubular housing, the housing having a closed distal end, an open proximal end, and a sidewall, and defining an inner cavity. A temperature-responsive sensing element is disposed in the inner cavity, the sensing element having a first sensing element lead and a second sensing element lead. The first sensor lead and the second sensor lead are each electrically connected in series to a corresponding one of the first sensing element lead and the second sensing element lead. A grommet made of a flexible and elastic dielectric material and having an outer annular surface encloses the first connection portion and the second connection portion. The grommet, the sensing element, the first sensing element lead and the second sensing element lead, and the first connection portion and the second connection portion are disposed in the inner cavity of the housing. The sidewall of the housing is mechanically interlocked to the grommet at the outer surface of the grommet to seal the sensing element and the sensing element lead from the surrounding environment outside the inner cavity of the housing.

[0010] In another aspect, the temperature sensor sidewall includes a roll-formed crimp that locally deforms the outer surface of the grommet and creates a circumferential compression seal between the housing and the grommet that isolates the sensing element and sensing element leads from the surrounding environment.

[0011] In yet another aspect, the first connection portion and the second connection portion are disposed in a staggered relationship with each other.

[0012] In yet another aspect, the grommet includes a void between the first connection portion and the second connection portion.

[0013] In yet another aspect, the outer surface of the grommet includes a plurality of annular protrusions spaced apart from one another along a longitudinal axis of the grommet. Each of the protrusions has an outer dimension greater than an inner dimension of the sidewall.

[0014] In yet another aspect of the present disclosure, at least a portion of the first and second sensing element leads and at least a portion of the first and second sensor leads are enclosed by grommets.

[0015] In addition, the housing includes an inwardly directed flange at the proximal end of the housing. The inwardly directed flange abuts against the end of the grommet. The inwardly directed flange holds the grommet together with the housing.

[0016] In yet another aspect of the present disclosure, the sensing element is spaced apart from a side wall of the housing. In addition, the sensing element is spaced apart from a distal end of the housing. Alternatively, the sensing element is in direct contact with the distal end of the housing. Each of the first sensing element lead and the second sensing element lead may include a ring-shaped portion.

[0017] In another aspect of the present disclosure, the sensor includes a thermally conductive dielectric epoxy disposed in the interior cavity of the housing near the distal end of the housing and encapsulating the sensing element and at least a portion of the first and second sensing element leads.

[0018] In yet another aspect, the housing includes an outwardly directed flange that forms a circumferential lip at the proximal end of the housing. In addition, the housing includes a first portion and a second portion. The first portion of the housing may include at least one annular channel that extends around the periphery of the sidewall. The housing is mechanically interlocked to the grommet at the at least one annular channel. The sensing element is disposed in the second portion of the housing.

[0019] In addition, the grommet may include a first portion and a second portion. The first portion of the grommet has a first diameter and a first elastic and flexible annular protrusion. The second portion of the grommet has a second diameter and a second elastic and flexible annular protrusion. The second diameter is smaller than the first diameter. In addition, both the first annular protrusion and the second annular protrusion have a third diameter greater than the first diameter.

[0020] In yet another aspect of the present disclosure, one of the outer surface of the grommet and the inner surface of the sidewall includes a plurality of longitudinally extending linear guide rails spaced apart from one another. The other of the outer surface of the grommet and the inner surface of the sidewall has a corresponding plurality of longitudinally extending linear grooves spaced apart from one another. Each of the guide rails is received in a corresponding one of the grooves.

[0021] Further areas of applicability will become apparent from the description provided herein.The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0023] Figure 1 is a front view of an example thermistor sensor according to the present disclosure.

[0024] Figure 2 yes Figure 1 A partially exploded front view of a sensor showing the cover removed from the sensing element.

[0025] Figure 3 yes Figure 1 An enlarged detailed view of a cross section of a portion of the sensor taken at boundary A.

[0026] Figure 4is a cross-sectional view of another example of a sensor according to the present disclosure.

[0027] Figure 5 is a partial cross-sectional view of a portion of another configuration of a sensor according to the present disclosure.

[0028] Figure 6 is used with Figure 4 Cross-section view of an alternative grommet for use with the sensor in.

[0029] Figure 7 is a partial cross-sectional view of another example sensor according to the present disclosure.

[0030] Figure 8 is used for Figure 7 00106] Figure 2 is a top left front perspective view of the sensor's grommet.

[0031] Fig. 9 yes Figure 8 . Right rear top perspective view of the grommet in FIG.

[0032] Fig.10 yes Figure 8 A perspective view of an alternative configuration of the grommet in FIG.

[0033] Fig.11 yes Fig.10 Another perspective view of the grommet in FIG.

[0034] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0035] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0036] These example embodiments are provided so that the present disclosure will be thorough and will fully convey the scope to those skilled in the art. Many specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, and that the example embodiments may be implemented in many different forms, and none of them should be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known techniques are no longer described in detail.

[0037] Reference Figure 1 , shows a sensor 10 according to the present disclosure. The sensor 10 may be a thermistor temperature sensor configured for use in, for example, an appliance, a refrigeration system, or an HVAC system. Alternatively, the sensor 10 may be any suitable sensor for use in any suitable system.

[0038] As reference Figure 1 and Figure 3 As will be appreciated, the sensor 10 may be a two-piece construction including the sensor probe 14 and a shell-like housing or cover 18. The shell-like housing or cover 18 may be fitted over the distal end of the sensor probe 14.

[0039] Reference Figure 2 , the sensor probe 14 may include a sensing element 22 having a sensing element lead 26 in electrical communication with a sensor lead 30. The sensing element 22 may include a suitable resistor that exhibits a change in resistance as the measured parameter changes. For example, the sensing element 22 may be a temperature responsive element such as a thermistor that is heat sensitive and exhibits a change in resistance as its temperature changes. Alternatively, the sensing element 22 may respond to a parameter other than temperature.

[0040] Sensing element leads 26 may be coupled to sensing element 22 on opposite sides of sensing element 22, respectively. Sensing element leads 26 may be formed of metal or another conductive material. Sensing element leads 26 may be coupled to sensing element 22, for example, by welding or any other suitable method.

[0041] The sensor leads 30 are electrically connected to the sensing element leads 26 and may include terminal connectors protruding from their respective proximal ends. The sensor leads 30 may be used to electrically connect or integrate the sensor 10 into a control circuit (not shown), such as an appliance, a refrigeration system, or an HVAC system. For example, the control circuit may measure or determine the resistance and / or the change in resistance over time on the sensing element 22 via the sensor leads 30. The resistance and / or the change in resistance may be interpreted by a controller (not shown) of the control circuit. The sensor leads 30 may be formed of metal or another conductive material and may be connected to the sensing element leads 26, such as by welding or any other suitable method.

[0042] An electrically insulating covering may be formed on the connection between the sensor lead 30 and the sensing element lead 26. Figure 2 As shown, the electrically insulating cover may take the form of a generally cylindrical grommet 34 having a tapered conical shape portion at the front or distal end. After forming the connection between the sensor lead 30 and the sensing element lead 26, the grommet 34 may be molded in place over the connection.

[0043] Grommet 34 can electrically insulate the electrical connection between sensor lead 30 and sense element lead 26 from each other. Additionally, housing 18 can be crimped (or otherwise mechanically interlocked) to grommet 34 (as described below) to seal, isolate, and protect sense element 22 and sense element lead 26 from the surrounding environment.

[0044] Grommet 34 may be formed of a flexible and resilient dielectric material, such as an elastomer (e.g., rubber) or a thermoplastic. By forming grommet 34 from a flexible and resilient material, grommet 34 is able to deform and mold into and around the contour of housing 18 when housing 18 is crimped, deformed, or otherwise mechanically interlocked to grommet 34 to provide a secure seal from the surrounding environment and help inhibit or prevent dust, debris, moisture, air, etc. from entering sensor 10 and / or inhibiting or preventing the function or performance of sensing element 22 and / or the electrical connection between sensing element 22 and sensing element leads 26 from being affected.

[0045] The housing 18 may take the form of a housing or shell having a tubular configuration and being closed at a distal end 38. As described below, the housing 18 may be metal, such as, for example, aluminum, or other material that may be deformed or crimped to interlock and / or fit tightly and securely around the grommet 34. The housing 18 is preferably thermally conductive.

[0046] The housing 18 may include a proximal large diameter portion 42 and a distal small diameter portion 46. The large diameter portion 42 may have a size and shape corresponding to the size and shape of the grommet 34 and define an interior space. The diameter of the large diameter portion 42 may be slightly larger (e.g., 1% to 5% larger) than the diameter of the grommet 34 so that the grommet 34 may be received within the interior space defined by the large diameter portion 42, preferably without interference, to facilitate assembly of the components (as further described herein). The diameter of the small diameter portion 46 may be slightly larger (e.g., 2% to 10% larger) than the width of the sensing element 22 so that the sensing element 22 and the sensing element lead 26 may be received within the interior space defined by the small diameter portion 46.

[0047] The housing 18 may include a lip 50 located on the proximal end of the cover 18. The diameter of the lip 50 may increase from the large diameter portion 42, for example, the lip 50 may form an outwardly extending flange at the proximal end of the cover 18. A pair of annular grooves or channels 54 may extend around the outer peripheral surface 58 of the large diameter portion 42. The channels 54 may define the following location: at this location, the housing 18 can be mechanically deformed (such as by crimping) during assembly of the sensor 10 to interlock with the grommet 34 and / or seal against the grommet 34 for isolating the sensing element 22 and the sensing element leads 26 from the surrounding environment. The channels 54 can also be a matching feature that aligns the housing 18 on the grommet 34 during assembly and before deforming the cover 18.

[0048] A preferred method of manufacturing the sensor 10 according to the present disclosure can be described as follows. The sensing element lead 26 is electrically connected to the sensor lead 30. Thereafter, the grommet 34 is molded in place over the electrical connection between the sensing element lead 26 and the sensor lead 30 to form the sensor probe 14 subassembly. The sensor probe 14 is inserted into the interior space of the housing 18 along the direction of the longitudinal axis of the cover 18. After the sensor probe 14 is inserted, the sensing element 22, the sensing element lead 26, and the grommet 34 are all disposed within the interior space defined by the housing 18, and wherein the sensor lead 30 extends outwardly from the interior space. Figure 2 and Figure 3 As shown, the grommet 34 fits within the large diameter portion 42, and the lip 50 of the large diameter portion 42 extends beyond the proximal end of the grommet 34. The large diameter portion 42 of the housing 18 is crimped or mechanically deformed at the location of the passage 54 to tightly engage the grommet 34 around the proximal end of the housing 18 defined by the lip 50 and seal the sensing element 22 and sensing element leads 26 within the housing 18 and from the surrounding environment.

[0049] The sealed closure provided by the grommet 34 and the housing 18 provides an improved sensor 10. The sealed closure improves the manufacturing and performance of the sensor 10. Where previous sensors used epoxies or adhesives, the crimped cover 18, grommet 34, and fixed connection between the sensing element leads 26 and the sensor leads 30 of the present disclosure provide a more secure mechanical connection that is less susceptible to damage and less prone to failure. Where previous manufacturing required the application and placement of epoxies, adhesives, or other potting materials, the crimped housing 18 and grommet 34 are easily assembled and crimped without potting, thereby providing a manufacturing method that is easily repeatable and less likely to deviate. In addition, by providing a seal and isolation for the interior space that houses the sensing element 22 and the sensing element leads 26, the grommet 34 eliminates the need to apply shrink tubing electrical insulators to the sensor 10 assembly. Since the shrink tubing electrical insulator and potting material are eliminated, the manufacturing of the sensor 10 can be easily automated, thereby providing cost reductions and other manufacturing process improvements.

[0050] Now refer to Figure 4 and Figure 5 , which shows a sensor 100 according to the present disclosure. Sensor 100 may be similar to sensor 10. Sensor 100 may be a thermistor temperature sensor configured for use in an appliance, a refrigeration system, or an HVAC system. Alternatively, sensor 100 may be any suitable sensor for use in any suitable system.

[0051] The sensor 100 may be a two-piece sensor including a sensor probe 104 and a shell-like housing or cover 108. The shell-like housing or cover 108 may be fitted over the distal end of the sensor probe 104.

[0052] The sensor probe 104 may include a sensing element 112 having a sensing element lead 116 in electrical communication with the sensor lead 120. The sensing element 112 may include a suitable resistor that exhibits a change in resistance as the measured parameter changes. For example, the sensing element 112 may be a temperature responsive element, such as a thermistor, that is heat sensitive and exhibits a change in resistance as its temperature changes. Alternatively, the sensing element 112 may respond to a parameter other than temperature.

[0053] The sensing element 112 may include an epoxy coating. The epoxy coating may provide a sealing barrier to isolate the sensing element 112 from moisture, dust, debris, etc. The epoxy coating may also provide physical protection for the sensing element 112 and add electrical insulation.

[0054] Sensing element leads 116 may be coupled to sensing element 112 on opposite sides of sensing element 112, respectively. Sensing element leads 116 may be formed of metal or another conductive material. Sensing element leads 116 may be coupled to sensing element 112, for example, by welding or any other suitable method.

[0055] The sensor lead 120 is electrically connected to the sensing element lead 116 and may include a pair of terminal connectors protruding from their respective proximal ends. The sensor lead 120 can be used to electrically connect or integrate the sensor 100 into a control circuit (not shown) such as an appliance, a refrigeration system, or an HVAC system. For example, the control circuit can measure or determine the resistance and / or the change of resistance over time on the sensing element 112 through the sensor lead 120. The change of resistance and / or resistance can be parsed by a controller (not shown) of the control circuit. The sensor lead 120 can be formed of metal or another conductive material and can be connected to the sensing element lead 116, for example, at a connection 128. For example, the connection 128 can be formed by welding, automatic splicing, spray welding, a connector, or any other suitable method. The connection 128a of one sensor lead 120 can be staggered with the connection 128b of another sensor lead 120.

[0056] An electrically insulating covering may be formed on and accommodate the connections 128a, 128b between the sensor leads 120 and the sensing element leads 116. For example, the electrically insulating covering may take the form of a grommet 132 having a generally cylindrical shape. After the connections 128a, 128b are formed between the sensor leads 120 and the sensing element leads 116, the grommet 132 may be molded in place over the connections 128a, 128b. Alternatively or additionally, the connections 128a, 128b of the sensor leads 120 may be separated by a void or a shrink core 131 in the grommet 132.

[0057] Grommet 132 can electrically insulate sensor leads 120 from each other. Grommet 132 can also electrically insulate connection portions 128a, 128b from each other. Figure 4 and Figure 5 , the grommet 132 can extend over the sensor lead 120 and the connection portions 128a, 128b. In addition, the housing 108 can be mechanically deformed (such as by crimping, as further described below) to interlock with the sensing element 112 and the sensing element lead 116 and / or to seal, isolate and protect the sensing element 112 and the sensing element lead 116 from the surrounding environment.

[0058] Alternatively, the grommet 132 may be formed on the sensor lead 120 instead of the connection portions 128a, 128b.

[0059] Grommet 132 may be formed of a flexible and resilient dielectric material, such as an elastomer (e.g., rubber or polypropylene) or a thermoplastic sealing material (e.g., polyvinyl chloride (PVC)). By forming grommet 132 from a flexible and resilient material, grommet 132 is able to deform and mold into and around the contour of housing 108 when housing 108 is mechanically deformed (e.g., crimped) to provide a seal. Figure 4 As seen in the figure, the housing 108 may include a crimp portion 136 that forms a secure circumferential compression seal 136a with the grommet 132 to help inhibit or prevent dust, debris, moisture, air, etc. from entering the sensor 100 from the surrounding environment and / or inhibit or prevent affecting the function or performance of the sensing element 112 and / or the electrical connections 128a, 128b with the sensing element leads 116.

[0060] As in Figure 4 , Figure 6As best seen in Figure 1 , the grommet 132 may include one or more annular protrusions or ribs 140 formed around the perimeter of the grommet 132. The plurality of protrusions 140 may be spaced apart along the longitudinal axis of the grommet 132. The protrusions 140 may engage with the inner surface of the housing 108 to provide an additional seal or redundant seal between the housing 108 and the grommet 132, thereby further isolating the sensing element 112 and the sensing element leads 116. For example, the protrusions 140 may provide the functionality of an O-ring type seal in addition to the compression seal created at the crimp 136. The protrusions 140 may be integrally and monolithically formed with the grommet 132 such that the protrusions 140 are also flexible and resilient and are capable of deforming against the housing 108 to seal the sensing element 112 and the sensing element leads 116 from the surrounding environment.

[0061] The housing 108 may take the form of a housing or shell having a tubular configuration and being closed at the distal end 144. The housing 108 may be metal (such as, for example, aluminum), plastic, or other material as described herein that may be deformed or crimped to fit snugly and securely around the grommet 132. The housing 18 may also be thermally conductive.

[0062] The housing 108 may include a large diameter portion 148 at a proximal end and a small diameter portion 152 at a distal end. The large diameter portion 148 may have a size and shape corresponding to the size and shape of the grommet 132 and define an interior space. The diameter of the large diameter portion 148 may be slightly larger (e.g., 1% to 5% larger) than the diameter of the grommet 132 so that the grommet 132 may be received within the interior space defined by the large diameter portion 148 without causing air compression when the grommet 132 is inserted. The diameter of the small diameter portion 152 may be slightly larger (e.g., 2% to 10% larger) than the width of the sensing element 112 so that the sensing element 112 and the sensing element leads 116 may be received within the interior space defined by the small diameter portion 152.

[0063] A thermally conductive heat transfer compound 156 may be provided to fill the interior space defined by the small diameter portion 152 between the housing 108 and the sensing element 112 and between the housing 108 and the exposed portion of the sensing element leads 116. For example, the heat transfer compound 156 may be a dielectric epoxy or another suitable compound. The heat transfer compound 156 may support the sensing element 112 and the sensing element leads 116 within the small diameter portion 152 and may provide heat transfer from the housing 108 or the atmosphere surrounding the housing 108 to the sensing element 112.

[0064] The housing 108 may include an inwardly extending (i.e., extending inwardly relative to the longitudinal axis of the housing 108) retention flange 160 at the distal proximal end of the housing 108. The retention flange 160 may abut the grommet 132 to retain the grommet 132 within the housing 108, thereby inhibiting or preventing the grommet 132 from being removed from or separated from the housing 108 after manufacture of the sensor 100. The retention flange 160 may engage the grommet 132 such that the housing 108 abuts directly against the end of the grommet 132 such that there is no space or gap between the housing 108 and the grommet 132.

[0065] During manufacture of the sensor 100, a heat transfer compound 156 is dispensed into the small diameter portion 152 of the distal end of the housing 108. The sensor probe 104 (i.e., the subassembly of the sensing element 112, sensing element leads 116, sensor leads 120, and the overmolded grommet 132) is inserted into the interior space defined by the housing 108 until the distal end of the sensor probe 104 is submerged in the heat transfer compound 156 and the grommet 132 is completely located inside the cover 108.

[0066] like Figure 4 As shown, the sensing element 112 can be positioned so that the gap between the sensing element 112 and the housing 108 surrounds the sensing element 112 on all sides. Preventing the sensing element 112 from contacting the housing 108 promotes more uniform heat transfer from the surrounding environment through the thermally conductive cover and the heat transfer compound to the sensing element 112 and enables the sensor 100 to be less sensitive to the effects of temperature spikes.

[0067] Alternatively, the sensing element 112 may be positioned such that there is a gap between the sensing element 112 and the housing 108 around the perimeter of the sensing element 112, but the sensing element 112 contacts or engages the housing 108 at the distal end or tip of the distal end of the sensing element 112, such as at Figure 5 As shown in Figure 5 As shown, when the sensing element 112 is in contact with the housing 108 in this manner, the distance between the sensing element 112 and the grommet 132 can be reduced, such as by bending or looping the sensing element lead 116. Placing the distal tip of the sensing element 112 in contact with the housing 108 can produce a sensor 100 that is more sensitive to ambient temperature changes and / or has a faster thermal response.

[0068] Regardless of the positioning of the sensing element 112 in the small diameter portion 152, the grommet 132 fits within the large diameter portion 148 of the housing 108, and a retaining flange 160 is formed at the proximal end of the large diameter portion 42 to engage the grommet 132. The large diameter portion 148 may include a crimp 136 that locally deforms the grommet 132 and creates a circumferential compression seal 136a between the housing 108 and the outer surface of the grommet 132 to help seal, isolate, and protect the sensing element 112 and sensing element leads 116 from the surrounding environment.

[0069] The closed sealed construction of the sensor 100 improves the manufacturability and performance response of the sensor 100. The disclosed deformed or crimped housing 108, grommet 132, and fixed connection between the sensing element leads 116 and the sensor leads 120 provide a more secure mechanical connection that is less susceptible to damage and less susceptible to failure than previous designs that used potting compound only between the wiring and the housing. In addition, the grommet 132 eliminates the need to apply shrink tubing electrical insulation to the sensor 100 assembly.

[0070] Reference Figures 7 to 9 , an alternative grommet 200 for sensor 10 or sensor 100 is illustrated. The grommet 200 can accommodate and provide dielectric insulation for the electrical connection between the sensing element lead 26, 116 and the sensor lead 30, 120. As shown, the grommet 200 can include a body and one or more integral raised annular ribs or protrusions 208. The grommet 200 can be received within the cover 18, 108, and the protrusion 208 can be operated to provide an O-ring type seal between the grommet 200 and the housing 18, 108.

[0071] The body can be a cylindrical body. For example, the body can be formed of a flexible and elastic dielectric material, such as an elastomer (e.g., rubber or polypropylene) or a thermoplastic sealing material (e.g., polyvinyl chloride (PVC)). The body can include a large diameter portion 212 and a small diameter portion 216. The large diameter portion 212 can include a longitudinal aperture 220 to accommodate the sensor leads 30, 120. The small diameter portion 216 can accommodate the sensing element leads 26, 116 or both the sensing element leads 26, 116 and the sensing element 22, 112.

[0072] The projection 208 may be annular and disposed around the periphery of the body. For example, the projection 208 may be disposed around the small diameter portion 216, the large diameter portion 212, or around both the small diameter portion 216 and the large diameter portion 212. When the projection 208 is disposed on both the small diameter portion 216 and the large diameter portion 212, the projection 208 may be sized differently with a larger diameter projection on the small diameter portion 216 and a smaller diameter projection on the large diameter portion 212 such that the outer diameters of the two projections 208 are at least approximately the same. When the grommet 200 is assembled in the housing 18, 108, the projection 208 may engage with the housing 18, 108 and be deformed by the action of the housing 18, 108. The projection 208 may be similar to the projection 140 described previously.

[0073] The protrusion 208 may be formed integrally and monolithically with the body. Alternatively, the protrusion 208 may be a separate portion formed of an elastomer, but may be disposed on a surface of the body or in a channel formed on the body. By forming the body and protrusion 208 from a flexible and resilient material, the protrusion 208 is able to deform when assembled in the cover 18, 108. As previously described, the protrusion 208 may form a circumferential compression seal 208a between the housing 18, 108 and the grommet 200 to help seal, isolate and protect the sensing element 112 and the sensing element leads 116 from the surrounding environment and inhibit or prevent dust, debris, moisture, etc. from entering the sensor 10, 100.

[0074] Reference Figure 6 , which is a cross-sectional view showing an alternative embodiment of the grommet 133. In some embodiments, the outer surface 135 of the grommet 133 may additionally or alternatively include one or more radially or outwardly protruding longitudinal protrusions or guide tracks 164. The guide track 164 may extend linearly on the outer surface 135 parallel to the longitudinal axis of the grommet 133 and along a portion or the entire length of the grommet 133 intermittently or continuously. The track 164 may cooperate with and / or be received in corresponding and / or matching channels or recesses included in or on or along the inner surface of the housing 108. For example, during the manufacture of the sensor 100, the guide track 164 and the channel can be used for rotational positioning and orientation of the grommet 133 and the probe 104 subassembly within the housing 108, and / or can be used to guide the grommet 133 and the probe 104 subassembly into the housing 108.

[0075] Similar to and referring to previously described Fig.10 and Fig.11, the grommet 200 may alternatively incorporate a groove or channel 224 into an outer surface 225 of the grommet 200, and the shell 108 may include corresponding and / or matching protrusions or guide tracks on or along the inner surface of the side wall of the shell 108, which protrusions or guide tracks may be pre-formed or formed during mechanical deformation of the shell 108.

[0076] The foregoing description of each embodiment is provided for the purpose of illustration and description. The foregoing description is not intended to be exhaustive or limit the present disclosure. Each element or feature of a particular embodiment is generally not limited to the particular embodiment, but even if not specifically shown or described, each element or feature of a particular embodiment is interchangeable and can be used for selected embodiments when applicable. Each element or feature of a particular embodiment can also be changed in many ways. Such a change is not considered to be out of the present disclosure, and all such modifications are intended to be included in the scope of the present disclosure.

[0077] The terms used herein are only for the purpose of describing specific example embodiments, and are not intended to be restrictive. As used herein, unless the context clearly indicates otherwise, the singular forms "one", "a kind of" and "the" may be intended to also include plural forms. The terms "include", "comprise", "include", "contain" and "have" are inclusive, and therefore indicate the existence of the features, wholes, steps, operations, elements and / or parts described, but do not exclude the existence or addition of one or more other features, wholes, steps, operations, elements, parts and / or their groups. Unless specifically indicated as the order of execution, the method steps, processes and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or described. It should also be understood that additional or alternative steps can be adopted.

[0078] When an element or layer is referred to as "on another element or layer", "engaged to", "connected to" or "coupled to" another element or layer, the element or layer may be directly on another element or layer, directly engaged to, directly connected to or directly coupled to another element or layer, or there may be an intermediate element or layer. On the contrary, when an element is referred to as "directly on another element or layer", "directly engaged to", "directly connected to" or "directly coupled to" another element or layer, there may be no intermediate element or layer. Other words used to describe the relationship between elements (for example, "between" and "directly between", "adjacent" and "directly adjacent", etc.) should be interpreted in a similar manner. As used herein, the term "and / or" includes any combination and all combinations of one or more of the associated listed items.

[0079] Although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or section from another region, layer or section. Unless the context clearly indicates, the order or sequence is not implied when using terms such as "first", "second" and other numerical terms in this article. Therefore, without departing from the teachings of the example embodiments, the first element, first component, first region, first layer or first section discussed below can be referred to as the second element, second component, second region, second layer or second section.

[0080] For ease of description, spatially relative terms such as "inside", "outside", "below", "below", "lower", "above", "upper", etc. may be used herein to describe the relationship between an element or feature and another (other) element or feature as illustrated in the figure. Spatially relative terms may be intended to cover different orientations of the device in use or operation in addition to the orientation depicted in the figure. For example, if the device in the figure is turned over, the elements described as "below" or "below" other elements or features will then be oriented to be "above" other elements or features. Therefore, the example term "below" can cover both above and below orientations. The device can be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially relative descriptors used herein can be interpreted accordingly.

Claims

1. A temperature sensor, characterized in that: The temperature sensor comprises: a housing comprising a deformable tubular outer shell having a closed distal end, an open proximal end, and a sidewall, and defining an inner cavity; a temperature-responsive sensing element, the sensing element comprising a first sensing element lead and a second sensing element lead; a first sensor lead and a second sensor lead, each of the first sensor lead and the second sensor lead being electrically connected in series to a respective one of the first sensing element lead and the second sensing element lead at respective first and second connections; a grommet comprising a flexible and resilient dielectric material and having an outer annular surface; wherein the grommet, the sensing element, the first sensing element lead and the second sensing element lead, and the first connecting portion and the second connecting portion are disposed in the inner cavity of the housing; and Wherein the side wall of the housing is mechanically interlocked to the grommet at an outer surface of the grommet to seal the sensing element and sensing element leads from the ambient environment outside the inner cavity of the housing.

2. The temperature sensor according to claim 1, characterized in that: The side wall of the housing includes a roll-formed crimp that locally deforms the outer surface of the grommet and creates a circumferential compression seal between the housing and the grommet that isolates the sensing element and sensing element leads from the surrounding environment.

3. The temperature sensor according to claim 1, characterized in that: The first connection portion and the second connection portion are disposed in a staggered relationship with each other.

4. The temperature sensor according to claim 3, characterized in that: The first connection portion and the second connection portion are enclosed by the grommet.

5. The temperature sensor according to claim 4, characterized in that: The grommet includes a void; and Wherein, the gap is located between the first connecting portion and the second connecting portion.

6. The temperature sensor according to claim 1, characterized in that: The outer surface of the grommet includes a plurality of annular protrusions spaced apart from one another along a longitudinal axis of the grommet, wherein an outer dimension of each of the protrusions is greater than an inner dimension of the sidewall.

7. The temperature sensor according to claim 1, characterized in that: At least a portion of the first and second sensing element leads and at least a portion of the first and second sensor leads are enclosed by the grommet.

8. The temperature sensor according to claim 1, characterized in that: said housing comprising an inwardly directed flange at said proximal end of said housing; and Wherein, the inwardly directed flange abuts against the end of the grommet.

9. The temperature sensor according to claim 8, characterized in that: An inwardly directed flange holds the grommet to the housing.

10. The temperature sensor according to claim 1, characterized in that: The sensing element is spaced apart from the side wall of the housing.

11. The temperature sensor according to claim 10, characterized in that: The sensing element is spaced apart from the distal end of the housing.

12. The temperature sensor according to claim 11, characterized in that: The temperature sensor also includes a thermally conductive dielectric epoxy disposed in the interior cavity of the housing near the distal end of the housing and encapsulating the sensing element and at least a portion of the first and second sensing element leads.

13. The temperature sensor according to claim 10, characterized in that The sensing element is in direct contact with the distal end of the housing.

14. The temperature sensor according to claim 13, characterized in that: Each of the first sensing element lead and the second sensing element lead includes a loop portion.

15. The temperature sensor according to claim 1, characterized in that The housing includes an outwardly directed flange forming a circumferential lip at the proximal end of the housing.

16. The temperature sensor according to claim 15, characterized in that The housing comprises a first portion and a second portion; wherein the first portion of the housing includes at least one annular channel extending around a periphery of the side wall; wherein said housing is mechanically interlocked to said grommet at said at least one annular channel; and Wherein, the sensing element is arranged in the second part of the housing.

17. The temperature sensor according to claim 1, characterized in that The grommet includes a first portion and a second portion; wherein the first portion of the grommet has a first diameter and a resilient and flexible first annular protrusion; wherein the second portion of the grommet has a second diameter and a resilient and flexible second annular protrusion, wherein the second diameter is smaller than the first diameter; Wherein, both the first annular protrusion and the second annular protrusion have a third diameter greater than the first diameter.

18. The temperature sensor according to claim 17, characterized in that One of the outer surface of the grommet and the inner surface of the sidewall includes a plurality of longitudinally extending linear guide rails spaced apart from one another; wherein the other of the outer surface of the grommet and the inner surface of the sidewall comprises a corresponding plurality of longitudinally extending linear grooves spaced apart from one another; and Wherein, each of the guide rails is received in a corresponding one of the grooves.

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