Folded Conductor Temperature Sensor for Vibration Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing temperature sensors used in electric motor windings face reliability issues due to detachment of the ceramic support from electrical conductors, primarily caused by vibrations that affect soldering points, making them prone to failure and requiring replacement with the motor or winding.
Innovation Solution
A temperature sensor design with an electrically insulating alumina ceramic carrier featuring conductively connected contact layers to electrical conductors, where the conductors extend beyond the carrier's edge, allowing for folding over to create a mechanical and electrical connection, enhancing stability without significant size increase, and utilizing SMD technology for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature sensor uses traditional soldering connection between ceramic support and electrical conductors, then the manufacturing process is simple, but the reliability is poor due to vibration-induced detachment
Solution Approach 1:
The electrical conductor is designed with a folded extension that can dynamically adapt to vibrations while maintaining connection. The folded portion acts as a flexible element that absorbs vibration energy rather than transmitting it to the soldering point, thereby improving reliability under vibrational stress without significantly increasing structural complexity
Solution Approach 2:
The conductor connection is extended from a single-plane soldering joint to a three-dimensional folded structure. By folding the conductor extension back onto the ceramic support, the connection is distributed across multiple spatial dimensions, creating redundant attachment points that prevent detachment during vibration while maintaining manufacturing feasibility
2Reliability
If the electrical conductor is extended and folded over to create additional mechanical connection, then the mechanical reliability is improved, but the overall size of the temperature sensor increases
Solution Approach 1:
The folded extension of the electrical conductor is nested back onto the ceramic support structure, with the conductor folding over and attaching to the rear surface of the carrier. This nesting approach allows the additional mechanical connection to be incorporated within the existing sensor footprint without significantly increasing the overall volume, maintaining compactness while improving mechanical reliability
3Reliability
If the conductor extension is folded over and connected to the rear of the carrier, then additional mechanical support is provided, but the manufacturing process becomes more complex
Solution Approach 1:
The conductor is segmented into distinct functional portions: a straight extension portion for electrical connection and a folded mechanical support portion. This segmentation allows each portion to be optimized independently - the straight portion maintains simple electrical connectivity while the folded portion provides mechanical support, and both can be manufactured using standard processes
Solution Approach 2:
The folded extension of the conductor serves dual purposes: it provides both electrical continuity and mechanical support through its own structure. The conductor material itself becomes the mechanical fastening element by folding back and attaching to the carrier, eliminating the need for separate mechanical fasteners or additional complex assembly steps
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 design significantly improves the mechanical and electrical reliability of the temperature sensor, reducing the risk of detachment and failure, while maintaining a compact size suitable for motor windings, ensuring reliable operation under operational vibrations.
Implementation Method 1
at least one of the conductors connected to the contact layers also continues on a second edge portion of the carrier beyond its edge. The extension of the at least one conductor thus formed is folded over in such a way that it directly or indirectly covers at least part of the unfolded portion of the conductor and at least part of the folded portion of the extension is connected to the support.
Data Source
Figure 1~4
Figure 5~8
Figure 9~12
AI summary
An electrical temperature sensor is described, comprising an electrically insulating carrier (1) having a front (2), a back (20) and an edge, and bearing on its front (2) an electrically resistive layer (3) which is conductively connected to two contact layers (6, 7) located on the front (2) or on the back (20) of the carrier (1) and, in order to enable an electrical connection of the temperature sensor, conductively connected to two electrical conductors (8, 9) which are attached to the carrier (1) and extend beyond the edge of a first edge section (10) of the carrier (1).According to the invention, at least one of the conductors (8, 9) connected to the contact layers (6, 7) also extends beyond the edge of a second edge section (11) of the carrier (1), the at least one extension (16, 17) formed in this way is folded over in such a way that it covers at least part of the unfolded section of the conductor (8, 9), and at least the folded section (18, 19) of the extension (16, 17) is separately connected to the carrier (1).