Flexible Temperature Sensor With Coiled RTD Element
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Solution Overview
Problem
There is a need for flexible sensors that can withstand multiple flexes and high heat, requiring robust and efficient assembly configurations for use in various applications and environments.
Innovation Solution
A coreless flexible temperature sensor design featuring elongate sections with polytetrafluoroethylene jackets, a coiled resistance temperature detector element, and crimping bands to secure the sensor sections, providing mechanical and electrical interconnects while maintaining flexibility and high-temperature compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible sensor is designed to withstand multiple flexes and high heat, then reliability is improved, but device complexity increases due to the need for robust assembly configurations
Solution Approach 1:
The sensor is divided into distinct segments: a flexible conductor section, a sensor section housing the RTD element, and connection sections. Each segment is independently constructed with appropriate materials and protection, allowing the flexible portions to handle flexing while the sensor section maintains measurement accuracy even when bent at sharp angles.
Solution Approach 2:
The RTD element is nested within a protective sensor section housing made of flexible material. This housing is further nested within or connected to flexible conductor sections with insulation layers. The nested structure provides multiple levels of protection while maintaining flexibility, allowing the inner RTD element to be protected from mechanical stress and environmental factors.
2Strength
If the sensor section envelops and overlaps the elongate sections, then mechanical strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The sensor section employs a flexible housing or sheath that can envelop and overlap the rigid elongate conductor sections. This flexible shell accommodates variations in assembly alignment and provides mechanical reinforcement without requiring precise fitting, as the flexible material can deform to match the underlying structure while maintaining protective coverage.
3Reliability
If resistance welding is used to connect the RTD element to flexible conductors, then electrical conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical connection methods (such as soldering or crimping) with resistance welding to join the RTD element leads to the flexible conductor. Resistance welding provides strong, reliable electrical connections that can withstand flexing and thermal cycling, while the process can be automated for efficient production, offsetting the initial complexity with long-term reliability benefits.
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 solution enables sensors to effectively measure temperature in harsh conditions, offering robustness, flexibility, and reliability across a range of applications, including high-temperature environments, by using polytetrafluoroethylene materials and crimping bands to secure the sensor elements.
Implementation Method 1
a sensor section housing an elongate flexible tubular shape, including polytetrafluoroethylene material, and having a resistance temperature detector element coiled therein
Implementation Method 2
a first elongate section having a first flexible conductor enveloped by a first polytetrafluoroethylene jacket; a second elongate section having a second flexible conductor enveloped by a second polytetrafluoroethylene jacket
Implementation Method 3
with the sensor section at least partially enveloping and overlapping the first elongate section and the second elongate section, with a first band crimping the sensor section to the first elongate section, and a second band crimping the sensor section to the second elongate section
Implementation Method 4
which is resistance welded to the first flexible conductor at a first weld and to the second flexible conductor at a second weld
Data Source
AI summary
One example of the present subject matter includes a first elongate section having a first flexible conductor enveloped by a first jacket; a second elongate section having a second flexible conductor enveloped by a second jacket; and an sensor section having an elongate flexible tubular shape, the sensor section housing a resistance temperature detector element which is at least partially coiled and which is resistance welded to the first flexible conductor at a first weld and to the second flexible conductor at a second weld; wherein the sensor section at least partially envelops and overlaps the first elongate section and the second elongate section, with a first band crimping the sensor section to the first elongate section, and a second band crimping the sensor section to the second elongate section, and with the first and second welds disposed between the first and second bands.