Cable Connector With Integrated Temperature Sensor
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Solution Overview
Problem
Cables used in motor vehicle brake systems require robust, cost-effective manufacturing with high impermeability to liquids, and existing solutions struggle to ensure reliable performance in harsh environments.
Innovation Solution
A cable design featuring a core and sheath with a liquid-tight dielectric housing, incorporating a temperature-sensitive measuring resistor and metallic element for thermal connection, overmoulded for enhanced reliability and sealing, and a connector with crimped contacts for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector is manufactured by injection molding to create a liquid-tight housing, then impermeability to liquids is improved, but device complexity increases due to the need for additional sealing structures and manufacturing processes
Solution Approach 1:
The patent combines the housing and dielectric element into a single integrated injection-molded component. The housing serves dual functions as both structural enclosure and sealing barrier, while the dielectric element is formed as an integral part of the housing rather than a separate component. This merging eliminates the need for separate sealing structures and reduces assembly steps while maintaining liquid tightness.
Solution Approach 2:
The connector utilizes composite construction by integrating the dielectric material directly into the housing structure through injection molding. The dielectric element and housing are formed as a unified composite structure, combining structural integrity with electrical insulation properties in a single manufactured part, thereby simplifying the overall device complexity.
2Measurement precision
If additional sensors are added for temperature measurement and brake wear detection, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent employs the existing electrical current flowing through the connector contacts as the measurement medium. The contact resistance, which naturally varies with temperature and wear conditions, serves as the sensing mechanism. By monitoring changes in the electrical properties of the existing contacts, the system achieves temperature measurement and wear detection without requiring separate sensor components.
Solution Approach 2:
The electrical contacts serve multiple functions simultaneously: they provide electrical connection for power and signal transmission, and also function as temperature sensors and wear indicators. The same conductive elements that carry current are used to detect changes in resistance that indicate temperature variations and mechanical wear, eliminating the need for dedicated sensing components.
3Reliability
If the cable is designed with robust sealing and protective structures for harsh environments, then reliability is improved, but ease of manufacture decreases due to more complex manufacturing processes
Solution Approach 1:
The patent incorporates sealing features and protective structures directly into the injection molding process itself. The housing geometry includes integrated sealing surfaces, O-ring grooves, and protective protrusions that are formed during the initial molding operation rather than requiring subsequent assembly steps. This preliminary incorporation of protective features simplifies the overall manufacturing process while ensuring robust sealing.
Solution Approach 2:
The protective housing and sealing structures are merged into a single injection-molded component. The housing simultaneously provides mechanical protection, environmental sealing, and structural support for the connector elements. By combining multiple protective functions into one manufactured part, the design reduces the number of manufacturing steps and assembly operations required.
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
The cable provides reliable electrical and thermal monitoring with hermetic sealing, enabling effective detection of brake wear and temperature measurement without additional sensors, ensuring durable and cost-effective performance in harsh conditions.
Implementation Method 1
a temperature-sensitive measuring resistor (3), which is electrically connected to the at least one wire in such a way that at least part of the electrical current that can be conducted through the at least one contact flows through the measuring resistor
Implementation Method 2
a metallic element (4) is also arranged on the housing and is thermally connected to the measuring resistor
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a cable comprising a conductor (1) having at least one core (1.1) and a connector (2). The connector (2) has at least one contact (2.1) and a liquid-tight dielectric housing (2.3), wherein the at least one contact (2.1) is electrically connected to the at least one core (1.1) so that an electric current can flow from the at least one core (1.1) to the contact (2.1). A temperature-sensitive measuring resistor (3) is arranged in the housing (2.3) and is electrically connected to the at least one core (1.1) such that at least a portion of the electric current that can flow through the at least one contact (2.1) flows through the measuring resistor (3). Furthermore, a metallic element (4) is arranged on the housing (2.3) and is thermally connected to the measuring resistor (3) (Figure 1).