Self-Heated NTC Thermistor Assembly for Faster Sensor Soldering
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Solution Overview
Problem
Conventional methods for manufacturing NTC thermistor sensors with plastic coatings are inefficient, requiring time-consuming thermal processing steps and extensive material usage, which can alter the properties of the NTC thermistor material and prolong the manufacturing process.
Innovation Solution
A method involving self-heating of the NTC thermistor element using electrical current to form solder bonds with connection wires and apply a polymer coating, eliminating the need for thermal pre- and post-treatment steps and reducing material waste, while maintaining precise resistance tolerances and high-strength solder bonds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional thermal processing methods are used to assemble and coat NTC sensors, then the manufacturing process is complete and functional sensors are produced, but the process is time-consuming and requires extensive thermal pre- and post-treatment steps
Solution Approach 1:
The invention extracts and eliminates the time-consuming thermal pre- and post-treatment steps from the conventional manufacturing process. By using self-heating of the NTC thermistor element during assembly and coating, the process removes the need for separate thermal processing stages, thereby significantly reducing total manufacturing time while maintaining complete functionality of the final sensor product
Solution Approach 2:
The invention merges multiple process steps into a single integrated operation. The self-heating phase serves dual purposes: it provides the necessary heat for soldering the connection wires to the thermistor element and simultaneously melts the coating material to form the protective layer. This consolidation of heating, soldering, and coating operations into one continuous process eliminates the need for separate thermal treatment stages, dramatically improving manufacturing efficiency
2Productivity
If conventional thermal processing methods are used, then complete coating and assembly is achieved, but extensive material usage and waste are required
Solution Approach 1:
The self-heating method enables localized melting and application of the coating material precisely where needed on the thermistor element surface. This localized processing reduces the overall quantity of coating material required compared to conventional methods that require extensive material to ensure complete coverage during thermal processing, thereby minimizing material waste while achieving complete and functional coating
3Productivity
If self-heating is used to form solder bonds and apply coating, then thermal pre- and post-treatment steps are eliminated, but precise control of heating is required to maintain resistance tolerances
Solution Approach 1:
The manufacturing method incorporates feedback control mechanisms to monitor and regulate the self-heating process. By continuously monitoring the heating phase and adjusting parameters accordingly, the process maintains precise control over the thermal conditions, ensuring that the NTC thermistor element's resistance tolerances remain within specified limits while still eliminating the need for separate thermal pre- and post-treatment steps
Solution Approach 2:
The invention carefully controls and adjusts critical parameters during the self-heating phase, including temperature, heating duration, and power levels. By optimizing these parameters, the process achieves the dual objective of eliminating extensive thermal treatment steps while maintaining precise resistance tolerances of the NTC thermistor element throughout the manufacturing process
4Ease of manufacture
If conventional assembly methods are used, then connection wires are attached to NTC thermistor element, but the process requires separate heating and cooling stages
Solution Approach 1:
The invention combines the soldering of connection wires and the application of coating material into a single integrated heating phase. The self-heating of the NTC thermistor element simultaneously performs both functions: melting the solder to form electrical connections and melting the coating material to form the protective layer. This merging of operations simplifies the manufacturing process by eliminating separate heating and cooling stages, making the overall assembly process more efficient and easier to implement
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 method significantly shortens the manufacturing process, omits time-consuming thermal treatments, and achieves high-strength solder bonds and precise resistance control, enabling efficient mass production of NTC sensors with improved properties.
Implementation Method 1
the NTC thermistor element is self-heated by application of an electrical current
Implementation Method 2
the polymer coating material is melted by the heat generated by the NTC thermistor element
Data Source
AI summary
In an embodiment a method for assembling NTC sensor includes providing an NTC thermistor element and connection wires having terminals for contacting the NTC thermistor element; and self-heating the NTC thermistor element while applying an electrical current during the following steps: dispensing solder paste to the terminals of the connection wires, applying the connection wires to the NTC thermistor element and melting the solder paste by a generated heat of the NTC thermistor element thereby forming solder bonds between the NTC thermistor element and the connection wires.