High-Voltage Conductor Temperature Sensor With Elastomer Heat Path
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Solution Overview
Problem
Existing temperature sensors for high-voltage conductors are expensive, slow to respond, and require complex insulation methods like potting or ceramic/metallic components, which increase costs and manufacturing complexity.
Innovation Solution
A temperature sensor design using a preformed insulating elastomer mat with a heat exchange portion and insulation portion, integrated into a two-part sensor housing, allowing for efficient thermal transfer and enhanced insulation without the need for additional insulation methods.
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 and production time increase
Solution Approach 1:
The elastomer mat is divided into functionally distinct regions: a heat exchange portion with high thermal conductivity for rapid temperature measurement, and an insulation portion with low thermal conductivity for electrical protection. This segmentation allows each region to be optimized for its specific function while being manufactured as a single integrated component, resolving the contradiction between reliability and ease of manufacture.
Solution Approach 2:
The elastomer mat utilizes composite material structures with varying thermal conductivities in different regions. The heat exchange portion employs materials or structures optimized for thermal conduction, while the insulation portion uses materials optimized for electrical isolation. This composite approach enables simultaneous achievement of rapid response and enhanced insulation without requiring separate insulation components or complex assembly processes.
2Speed
If ceramic or metallic sensor plate is used to improve response time, then thermal monitoring speed is improved, but manufacturing cost increases
Solution Approach 1:
The elastomer mat exhibits local quality variations through its differentiated thermal conductivity distribution. The heat exchange portion is specifically engineered with higher thermal conductivity to enable rapid temperature sensing, while other portions maintain lower conductivity for insulation. This localized optimization achieves fast response time without requiring expensive ceramic or metallic sensor plates throughout the entire structure.
Solution Approach 2:
The patent changes the thermal conductivity parameter of the elastomer mat in different regions to achieve the desired performance. By adjusting the thermal conductivity of the heat exchange portion to be higher than that of the insulation portion, the system achieves rapid thermal response without the need for expensive alternative materials, thereby resolving the contradiction between speed and manufacturing cost.
3Reliability
If complex insulation methods like potting or ceramic components are used, then insulation performance is improved, but device complexity increases
Solution Approach 1:
The patent merges the insulation function and the structural support function into a single elastomer mat component. The mat simultaneously provides electrical insulation, mechanical support for the sensor element, and thermal management through its differentiated thermal conductivity regions. This consolidation eliminates the need for separate insulation components, potting materials, or complex assembly processes, thereby reducing device complexity while maintaining or improving insulation performance.
Solution Approach 2:
The elastomer mat serves multiple functions: it provides electrical insulation, structural support, thermal conduction in the heat exchange portion, and mechanical protection. This multi-functionality eliminates the need for multiple specialized components, simplifying the overall device structure while maintaining high insulation performance and reducing manufacturing complexity.
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 enables cost-effective, rapid temperature measurement with improved insulation and tolerance compensation, facilitating mass production and reducing manufacturing costs while maintaining accuracy and safety.
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
Implementation Method 2
the insulation portion extending around the measuring window to electrically insulate the temperature sensor from the high-voltage conductor
Data Source
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AI summary
The present invention relates to a temperature sensor (10) for a high-voltage conductor. The temperature sensor (10) comprises a sensor housing for forming a chamber, the sensor housing having a base plate (100) with a measuring window (110) for attaching to the high-voltage conductor and a lid (200) for covering the chamber. Further, the temperature sensor (10) comprises a temperature sensor element (410) for measuring the temperature of the high-voltage conductor and for outputting an electrical temperature signal to a low-voltage network, wherein the temperature sensor element (410) is arranged in the chamber. Further, the temperature sensor (10) comprises a preformed elastomer mat (300) enclosed between the base plate (100) and the lid (200) in the chamber, wherein the elastomer mat (300) has an insulation portion (310) extending around the measuring window (110) to electrically insulate the temperature sensor from the high-voltage conductor, and wherein the elastomer mat (300) further comprises a heat exchange portion (330), surrounded by the insulation portion (310), the heat exchange portion (330) extending through the measuring window (110) to the high-voltage conductor in a heat transfer direction (W) to conduct heat energy in the heat transfer direction (W) between the high-voltage conductor and the temperature sensor element (410) adjacent to the heat exchange portion.