High-Voltage Conductor Temperature Sensor With Insulating Heat Path
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Solution Overview
Problem
Temperature sensors for high-voltage conductors face challenges in achieving accurate and reliable temperature measurement while being cost-effective, with existing solutions often involving expensive materials or complex insulation methods that increase manufacturing costs and reduce response time.
Innovation Solution
A temperature sensor design utilizing a preformed insulating elastomer mat with a heat exchange portion and insulation portion, integrated into a two-part sensor housing, which allows for efficient thermal energy transfer and increased insulation without the need for potting or heat shrink tubing, enabling cost-effective mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If double or reinforced insulation is achieved by hermetically insulated sensor with potting or double-walled shrink tube, then protection against flashovers is improved, but manufacturing cost increases and response time slows
Solution Approach 1:
The patent uses a flexible insulation mat made of elastomeric material with integrated heat exchange channels. This thin film structure provides the necessary insulation while allowing thermal energy to pass through to the sensor, avoiding the need for bulky potting compounds or double-walled shrink tubes. The flexible nature of the elastomeric material enables direct contact with the conductor surface while maintaining electrical insulation.
Solution Approach 2:
The insulation mat acts as an intermediary element between the high-voltage conductor and the temperature sensor. It provides electrical insulation while simultaneously facilitating thermal transfer through its heat exchange portion. This mediator approach eliminates the need for separate insulation and thermal coupling components, reducing manufacturing complexity and cost.
2Reliability
If hermetically insulated sensor with potting or double-walled shrink tube is used, then insulation is improved, but response time slows
Solution Approach 1:
The thin elastomeric insulation mat with integrated heat exchange channels provides insulation without creating a thick thermal barrier. The flexible film structure allows thermal energy to quickly reach the sensor while maintaining electrical insulation, solving the response time issue associated with traditional potting or double-walled shrink tube methods.
Solution Approach 2:
The insulation mat has different properties in different regions: the heat exchange portion allows thermal energy transfer while the surrounding areas provide electrical insulation. This local differentiation of material properties enables simultaneous optimization of both response time and insulation performance.
3Loss of time
If ceramic or metallic sensor plate is used to improve response time, then response time is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses a flexible elastomeric insulation mat with heat exchange channels instead of rigid ceramic or metallic sensor plates. This flexible film approach achieves rapid thermal response through direct contact with the conductor surface while being more cost-effective and easier to manufacture than ceramic or metal alternatives.
Solution Approach 2:
The insulation mat is made of composite elastomeric material combining insulating properties with thermal conductivity in the heat exchange portion. This composite structure provides both rapid thermal response and electrical insulation without requiring expensive ceramic or metallic components.
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 achieves rapid temperature measurement feedback with improved insulation, reduced manufacturing costs, and enhanced durability, while maintaining high accuracy and stability over a wide temperature range.
Implementation Method 1
the heat exchange portion extending through the measuring window to the high-voltage conductor in a heat transfer direction to conduct thermal energy between the high-voltage conductor and the temperature sensor element adjacent to the heat exchange portion
Implementation Method 2
the insulation portion extending around the measuring window to electrically insulate the temperature sensor element from the high-voltage conductor
Data Source
AI summary
A temperature sensor includes a sensor housing for forming a chamber having a base plate with a measuring window for attaching to a high-voltage conductor and a lid for covering the chamber. A temperature sensor element for measuring the temperature of the high-voltage conductor and for outputting an electrical temperature signal to a low-voltage network is arranged in the chamber. A preformed elastomer mat is enclosed between the base plate and the lid in the chamber and has an insulation portion extending around the measuring window to electrically insulate the temperature sensor from the high-voltage conductor. The elastomer mat includes a heat exchange portion, surrounded by the insulation portion, the heat exchange portion extending through the measuring window to the high-voltage conductor in a heat transfer direction to conduct heat energy between the high-voltage conductor and the temperature sensor element adjacent to the heat exchange portion.