3D Metallized Sensor Heater for Compact Temperature Control

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Solution Overview

Problem

The increasing complexity and miniaturization of components, such as sensors, lead to inadequate heat dissipation and temperature control, resulting in inefficient and insecure temperature management, particularly in environments with varying weather conditions.

Innovation Solution

A temperature control element with a metallized structure integrated into a three-dimensional plastic component, allowing for adaptable heating or cooling capabilities, optimized for specific temperature requirements and installation spaces, achieved through laser structuring and material selection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heating film is affixed to the cube, then heating function is provided, but the connection between elements is unsatisfactory and installation is difficult and time-consuming

Engineering Contradiction:

Improvetemperature control reliabilityVSAvoidinstallation ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heating element is merged with the mounting bracket to form a single integrated component. The metallized structure is embedded directly into the plastic mounting bracket during manufacturing, eliminating the need for separate heating film installation. This integration ensures reliable thermal contact while simplifying the installation process to a single operation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mounting bracket is manufactured as a composite structure combining plastic material with an integrated metallized heating element. This composite approach allows the heating function to be inherently part of the mounting structure, providing both mechanical support and thermal control in one component that is easy to install.

Inventive Principle:

Principle #40Composite materials

2Reliability

If heating film is affixed to the cube, then heating function is provided, but the heating film may only be adapted to the contour of the component with great difficulty

Engineering Contradiction:

Improvetemperature control reliabilityVSAvoidadaptability to component contour

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plastic mounting bracket is designed with a form-fitting geometry that naturally conforms to the contour of the sensor housing. The integrated metallized heating element follows this contoured shape, ensuring optimal thermal contact across the surface without requiring additional adaptation measures.

Inventive Principle:

Principle #30Flexible shells and thin films

3Device complexity

If more parts are built into small installation space, then component integration is improved, but temperature development increases due to insufficient heat dissipation space

Engineering Contradiction:

Improvecomponent integrationVSAvoidtemperature development

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The mounting bracket integrates multiple functions: mechanical mounting, electrical connection, and thermal control. By combining these functions into one component, the design reduces the number of separate parts in the limited installation space while the integrated heating element actively manages temperature to prevent overheating.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating element allows dynamic adjustment of power consumption parameters to optimize the balance between operational efficiency and heat generation. By controlling the heating power, the system can adapt to thermal conditions in the compact installation space, preventing excessive temperature buildup while maintaining necessary functionality.

Inventive Principle:

Principle #35Parameter changes

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

Ensures reliable temperature control of sensors and surrounding components, enhancing their functionality and durability in harsh environmental conditions while optimizing installation space and reducing complexity.

Implementation Method 1

The metallized structure is configured in such a manner that it assumes a heating function, in particular by energizing the metallized structure

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12177945B2Temperature control element and sensor arrangement

Publication Date: 2024.12.24 CONTI TEMIC MICROELECTRONIC GMBH

AI summary

Disclosed herein is a temperature control element for heating a sensor for detecting surroundings, having a three-dimensional plastic component, characterized in that at least one metallized structure is integrated into the plastic component or respectively provided therein, wherein the metallized structure is configured in such a manner that it assumes a heating function. A sensor arrangement for detecting surroundings is also disclosed, having a sensor for detecting surroundings as well as a temperature control element.