Non-Metallic Thermal Probe Assembly for Accurate Fluid Temperature Sensing

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Solution Overview

Problem

Traditional thermal probes in vehicles suffer from inaccuracies due to metal housings causing heat sink issues, high assembly costs, and connector degradation from harsh environments, leading to unreliable temperature readings.

Innovation Solution

A thermal probe assembly with a non-metallic housing, using a thermoplastic material like polyethersulfone, that includes a temperature sensing device with a non-metallic connector assembly, sealed with an O-ring, and a removable installation mechanism, ensuring accurate temperature readings and reduced assembly time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a metal housing is used for the thermal probe, then the housing provides structural strength and durability, but the metal acts as a heat sink and draws heat away from the sensing element causing inaccurate temperature readings

Engineering Contradiction:

Improvetemperature reading accuracyVSAvoidhousing structural strength

Core Design Contradiction:

Measurement precisionVSStrength

Solution Approach 1:

The patent removes the metal housing component entirely from the thermal probe design. Instead of using metal for the housing, the invention employs a non-metallic housing material that does not interfere with thermal measurements, thereby eliminating the heat sink effect while maintaining structural integrity through alternative materials.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent utilizes composite or non-metallic materials for the housing construction. These materials provide the necessary structural strength and durability while being thermally non-conductive, thus preventing heat transfer from the sensing element and ensuring accurate temperature readings in harsh automotive environments.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If a metal housing with hexagonal portion is used, then the device can be screwed into threaded aperture for secure installation, but the assembly process becomes time-consuming and costs increase

Engineering Contradiction:

Improveassembly time and manufacturing costVSAvoidinstallation security

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the traditional mechanical screw-threaded connection system with an alternative installation mechanism. This substitution eliminates the need for time-consuming threading operations while maintaining secure installation through different mechanical engagement methods that are faster and more cost-effective to manufacture.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The housing is designed as a multi-component assembly with separate sections that can be manufactured independently and then quickly assembled. This segmentation allows for simplified manufacturing processes, reduced assembly time, and lower production costs while ensuring secure installation through precise interlocking of the segmented components.

Inventive Principle:

Principle #1Segmentation

3Reliability

If wiring connectors are used to connect the thermal probe to the controller, then electrical connection is established, but moisture and humidity induce conductivity between individual wires and resistance changes over time leading to signal inaccuracies

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidmoisture and humidity exposure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces protective intermediary elements such as sealing gaskets, conformal coatings, or hermetic seals between the wiring connectors and the harsh environment. These intermediaries prevent moisture and humidity from causing unintended conductivity between wires, thereby maintaining stable electrical connections and accurate signal transmission in automotive applications.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 non-metallic housing provides accurate temperature readings by minimizing heat loss, reduces assembly costs, and enhances durability against environmental factors, improving the reliability of temperature sensing.

Implementation Method 1

The non-metallic housing provides accurate temperature readings by minimizing heat loss

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Implementation Method 2

a temperature sensing device packaged within a non-metallic housing that can be removably installed in a probe receptacle

Methodology Applied

Scientific EffectResistive Temperature Detection: Electrical Resistance

Data Source

PatentUS12467796B2Thermal probe assembly

Publication Date: 2025.11.11 COOPER STANDARD AUTOMOTIVE INC

AI summary

An assembly of a thermal probe and a probe fitting arranged to measure the temperature of a fluid medium flowing in a passage of the probe fitting. The assembly comprises a temperature sensing assembly that produces a resistance which varies with the temperature. A connector assembly that is connected to the temperature sensing assembly that transmits the resistance to external circuitry. A non-metallic housing includes a sensor portion incasing the temperature sensing assembly and a connector portion housing the connector assembly. A probe receptacle attached to the probe fitting is arranged to receive the sensor portion of the thermal probe, positioning the temperature sensing assembly in the passage to sense the temperature of the fluid medium flowing in the passage.