Surface-Mounted Temperature Sensor With Thermal Recess for PCB Assembly
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Solution Overview
Problem
Existing storage modules for electrical energy in household appliances face high production costs and assembly errors due to manual attachment of temperature sensors using through-hole assembly, which complicates automated manufacturing and quality control, and increases the risk of assembly errors and material costs from additional electrical lines.
Innovation Solution
The temperature sensor is surface-mounted on the printed circuit board with a recess filled with thermally conductive material, allowing for automated assembly and optical inspection, reducing manual effort and costs, while ensuring effective thermal connection and visibility for quality assurance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If through-hole assembly is used to attach the temperature sensor to the circuit board, then the temperature sensor can be securely attached, but the production cost increases and automated assembly becomes difficult
Solution Approach 1:
The circuit board is segmented by creating a recess (through-hole) that separates the sensor mounting area from the rest of the board. This allows the temperature sensor to be surface-mounted in a dedicated recess rather than requiring through-hole assembly, enabling automated SMD placement while maintaining secure attachment through the recess structure and thermally conductive material.
Solution Approach 2:
Thermally conductive material is introduced as an intermediary substance that fills the recess and creates both mechanical and thermal connection between the temperature sensor and the storage cell. This mediator enables the sensor to be surface-mounted while still achieving reliable attachment and thermal coupling without requiring traditional through-hole soldering.
2Reliability
If the temperature sensor is attached using through-hole assembly, then the sensor can be securely mounted, but the sensor becomes invisible and visual quality control becomes impossible
Solution Approach 1:
The recess creates a localized cavity that holds the temperature sensor in a specific position on the surface of the circuit board. This segmentation allows the sensor to remain visible on the board surface for visual inspection while still providing secure mechanical attachment through the recess structure and thermally conductive material fill.
3Manufacturing precision
If manual assembly is used for temperature sensor attachment, then precise positioning can be achieved, but the production time increases and productivity decreases
Solution Approach 1:
The recess provides a pre-defined, precisely positioned cavity that guides automatic placement machines to position the temperature sensor accurately. This eliminates the need for manual positioning while maintaining high precision, as the recess structure itself ensures correct sensor placement during automated assembly.
Solution Approach 2:
The recess is pre-formed in the circuit board before sensor assembly, creating a ready-made positioning feature that guides automated placement. This preliminary preparation of the mounting structure enables high-speed automated assembly while maintaining precise sensor positioning without requiring manual intervention during the assembly process.
4Reliability
If additional electrical lines are used to contact the temperature sensor, then the sensor can be electrically connected, but the material cost and assembly complexity increase
Solution Approach 1:
The electrical connection function is merged with the mechanical attachment structure. The same recess that provides mechanical support and thermal coupling also serves as the electrical connection pathway, eliminating the need for separate electrical lines or cables to contact the temperature sensor.
Solution Approach 2:
The recess structure performs multiple functions simultaneously: it provides mechanical support for the sensor, creates thermal coupling through the thermally conductive material, and establishes electrical connection pathways. This multi-functionality eliminates the need for additional electrical lines and reduces overall assembly complexity.
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 approach significantly reduces production costs, enhances module quality, and minimizes assembly errors by enabling fully automated production and visual inspection of the temperature sensor's attachment, ensuring reliable thermal monitoring and safety in household appliances.
Implementation Method 1
The temperature sensor is connected to the storage cell in a heat-transferring manner via a recess in the printed circuit board that is at least partially filled with thermally conductive material
Data Source
Figure 1
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AI summary
The invention relates to a storage module (10) for electrical energy for a household appliance, comprising one or more storage cells (12a-12g) for storing electrical energy, a printed circuit board (16) and at least one temperature sensor (20, 20a, 20b), which is attached to the printed circuit board (16) and is configured to detect the temperature of at least one storage cell (12e), wherein the temperature sensor (20, 20a, 20b) is surface-mounted on the printed circuit board (16) and is connected to at least one of the storage cells (12e) via a heat-transferring recess (24) in the printed circuit board (16) which is at least partially filled with thermally conductive material (26).