Integrated Clamp Temperature Sensor for Air Ducts
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Solution Overview
Problem
Existing temperature sensor attachment methods for air ducts in electric or hybrid motor vehicles are cumbersome, increasing product dimensions, manufacturing costs, and limiting temperature measurement to a single direction, with insufficient air-tightness and requiring separate parts for fixation.
Innovation Solution
A compact temperature sensor design featuring a clamp with a shaft member, engaging member, and thermistor, integrated by insert molding, allowing attachment from outside the air duct with 360° temperature measurement capability and secure air-tight fixation without additional parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a clamp is integrally formed in the side of the temperature sensor to enable attachment, then the attachment function is improved, but the product dimension is increased
Solution Approach 1:
The clamp (12) is integrally formed with the shaft member (11) as a single unit through insert molding, combining the attachment function and temperature sensing function into one component. This eliminates the need for separate attachment parts while maintaining compact dimensions.
2Reliability
If hot melt resin is used to fill the housing after thermistor insertion to secure attachment, then the fixation reliability is improved, but the number of manufacturing processes is increased
Solution Approach 1:
The clamp (12) is pre-formed as an integral part of the shaft member (11) through insert molding before final assembly. This preliminary integration eliminates the need for subsequent hot melt resin filling processes, reducing manufacturing steps while ensuring reliable fixation.
3Measurement precision
If the clamp is attached toward the outside from the tubular inner part of the duct to enable temperature measurement, then the measurement capability is improved, but the attachment work becomes troublesome and difficult
Solution Approach 1:
Instead of attaching the clamp from inside the duct toward the outside, the clamp (12) is designed to be attached from the outside by simply inserting the shaft member (11) into the opening (Bh). This inverted attachment approach simplifies the work while maintaining 360° temperature measurement capability through the tubular structure.
4Reliability
If separate parts such as grommet and tie wrap are used to hold the sensor main body to ensure fixation, then the fixation reliability is improved, but the device complexity is increased
Solution Approach 1:
The clamp (12), shaft member (11), and thermistor (100) are merged into a single integrated component through insert molding. This eliminates the need for separate grommets, tie wraps, or other attachment parts, reducing device complexity while maintaining secure fixation.
5Reliability
If multiple separate parts are used for sensor fixation to ensure air-tightness, then the air-tightness is improved, but the manufacturing cost is increased
Solution Approach 1:
The clamp (12) and shaft member (11) are formed as an integral composite structure through insert molding, creating a seamless joint that ensures air-tightness without requiring multiple separate parts. This single-step manufacturing process reduces costs while maintaining reliability.
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 solution simplifies attachment, reduces manufacturing steps and costs, ensures air-tightness, and allows for comprehensive 360° temperature measurement, enhancing the ease and effectiveness of temperature sensing in motor vehicle battery cooling systems.
Implementation Method 1
a thermistor (100)
Data Source
AI summary
A temperature sensor includes a clamp and a thermistor. The clamp is adapted to be inserted into an opening formed in an object, and has a shaft member. A flange member is extended from the shaft member in a direction orthogonal to an inserting direction in which the clamp is inserted into the opening. An engaging member extended from an end part of the shaft member toward the flange member in a direction inclined with the inserting direction. The thermistor is provided in the shaft member and is disposed in the end part. The engaging member and the flange member are adapted to clamp the object therebetween when the clamp is inserted into the opening.