Flexible Circuit Thermometer Probe Assembly via Adhesive Balloon
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional thermometer devices are difficult to manufacture due to intricate assembly steps that are time-consuming and costly, requiring skilled workers and manual processes that are not repeatable, making them challenging to produce efficiently and consistently.
Innovation Solution
A flexible circuit with a heating element and temperature sensor is used, which can be bent for easy insertion into a probe tip and adhered to the inner surface using an inflatable balloon, allowing for automated and consistent assembly, enabling quicker and more reliable manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly methods are used with skilled workers, then assembly precision can be achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The probe tip is divided into multiple curved segments that can be separately manufactured and then assembled. This segmentation allows for automated manufacturing of individual segments while maintaining precision, resolving the contradiction between manual assembly precision and manufacturing efficiency.
Solution Approach 2:
A curved adhesive layer is introduced as an intermediary element between the probe tip segments. This adhesive layer facilitates precise alignment and bonding of segments during automated assembly, enabling high-precision assembly without requiring skilled manual workers.
2Reliability
If intricate assembly steps are used, then device functionality is ensured, but manufacturing complexity and time consumption increase
Solution Approach 1:
Multiple assembly operations are merged into a single automated process. The curved segments are positioned and bonded simultaneously using automated equipment with the adhesive layer, reducing the number of discrete steps while ensuring device functionality through consistent geometric relationships.
Solution Approach 2:
The geometry of the probe tip is changed from a monolithic structure to segmented curved sections with specific radii of curvature. This parameter change enables automated manufacturing while maintaining the functional requirements of the probe tip through controlled geometric parameters.
3Productivity
If automated manufacturing is implemented, then productivity increases, but assembly precision and consistency become more difficult to maintain
Solution Approach 1:
By defining specific geometric parameters for the curved segments (radii of curvature, segment angles, positioning locations), automated manufacturing can consistently reproduce the same geometric relationships in every assembly, ensuring precision and consistency across all manufactured devices.
Solution Approach 2:
The curved segment design serves as a reusable template or copy that can be manufactured and assembled repeatedly with identical geometric properties. This copying approach ensures that each probe tip assembly has consistent dimensions and relationships, maintaining precision across high-volume production.
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
This method simplifies the manufacturing process, ensures consistent preheating, and reduces the need for skilled labor, resulting in a more efficient and reliable temperature sensing device with improved assembly precision and duplication.
Implementation Method 1
adhering, via the adhesive layer, the flexible detecting component to the curved inner surface
Implementation Method 2
heating element 116 may be a resistor, etched foil, nichrome, or any other element that can rapidly heat a surface
Implementation Method 3
Temperature sensor 112 may be a thermistor, thermocouple or any other device that can accurately sense temperature
Implementation Method 4
Temperature sensor 112 may be a thermistor, thermocouple or any other device that can accurately sense temperature
Implementation Method 5
Probe 104 is typically manufactured from metal or any other material that is a good heat conductor
Data Source
AI summary
A method of manufacturing a thermometer probe includes: obtaining a hollow housing having an open end and a curved inner surface; obtaining a flexible detecting component having an adhesive layer; obtaining an insertion component; detachably attaching the flexible detecting component to the insertion component; inserting the insertion component, having the flexible detecting component attached thereto, through the open end of the hollow housing and into the hollow housing such that the adhesive layer is disposed between the insertion component and the inner surface; and adhering, via the adhesive layer, the flexible detecting component to the curved inner surface.