HVAC controller with a temperature sensor mounted on a flex circuit
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Solution Overview
Problem
HVAC controllers, such as thermostats, face challenges in effectively managing internal heat generated by electrical components, which can affect temperature sensor accuracy and overall system performance.
Innovation Solution
The HVAC controller incorporates a temperature sensor mounted on a flexible circuit or flextail, positioned adjacent to a lower part of the housing where less internal heat resides, connected to a printed wiring board to minimize heat interference and improve accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the temperature sensor is mounted near the electrical components, then the sensor can be positioned in a convenient location for connection, but the sensor accuracy deteriorates due to internal heat interference
Solution Approach 1:
The temperature sensor is extracted from the heat-generating area by mounting it on the flextail circuit board that extends away from the electrical components. The sensor is positioned in a lower portion of the housing where internal heat does not reside, separating the sensing function from the heat-generating components while maintaining electrical connection through the flextail.
2Measurement precision
If the flextail is made longer to position the sensor away from heat, then the sensor accuracy improves, but the device complexity increases
Solution Approach 1:
The flextail serves multiple functions simultaneously: it provides electrical connection between the sensor and the printed wiring board, acts as a mounting structure for the sensor, and positions the sensor in the optimal thermal location. This consolidation of functions reduces overall device complexity despite the extended length required for thermal isolation.
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 configuration enhances the accuracy of temperature sensing by isolating the sensor from heat-producing components, leading to improved system performance and user experience.
Implementation Method 1
The temperature sensor may be any suitable temperature sensor, such as a thermistor
Data Source
AI summary
A Heating, Ventilation, and Air Conditioning (HVAC) controller may include a housing, a display, a printed wiring board, a flextail, and a temperature sensor. The housing may be configured to house the display, the printed wiring board, the flextail, and the temperature sensor. The flextail may extend from, for example, the display or other component of the HVAC controller, along the interior surface of the housing, and connect to a connector on the printed wiring board. The temperature sensor may be mounted on the flextail, and connected to the printed circuit board via the flex tail or other connection. In some cases, the temperature sensor may be positioned on the flextail such that when the flextail is connected to the printed wiring board, the temperature sensor is positioned adjacent a lower part of the housing, where less internal heat generated by the internal electrical components of the HVAC controller will reside.