Polymer-Shell Sensor Assembly for Faster Temperature Response
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Solution Overview
Problem
Existing temperature sensors have limitations in response time and dynamics of temperature measurement, necessitating improvements in sensor assemblies to enhance thermal coupling and reduce measurement errors in inhomogeneous temperature fields.
Innovation Solution
A sensor assembly with a sensor element partially or fully enclosed in a polymer shell, featuring asymmetrical thermal resistances between different heat conduction areas, utilizing materials with varying specific thermal resistances and thicknesses to optimize heat transfer towards the object being measured while minimizing heat transfer from the sensor element to its surroundings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor element is enclosed in a polymer shell with uniform thermal properties, then the sensor is protected and structurally stable, but the thermal coupling to the object being measured is insufficient and response time is slow
Solution Approach 1:
The patent applies local quality by creating asymmetric thermal resistance distribution within the polymer shell. The first heat conduction area (between sensor and coupling surface) has lower thermal resistance than the second heat conduction area (between sensor and outer surface), with thermal resistance ratio ≥ 1.1. This localized thermal property differentiation optimizes heat flow from the object to the sensor while maintaining structural protection.
Solution Approach 2:
The patent implements asymmetry through the non-uniform thermal resistance design. The polymer shell is configured with asymmetric thermal conductivity in different spatial directions - better thermal coupling towards the object being measured and higher thermal resistance towards the outer surface. This asymmetric configuration reduces response time while maintaining reliability.
2Loss of time
If thermal coupling to the object being measured is improved, then response time is reduced, but heat transfer from the sensor element to surrounding environments increases causing measurement errors
Solution Approach 1:
The patent uses local quality by assigning different thermal resistance values to different regions of the polymer shell. The first heat conduction area has lower thermal resistance for improved coupling to the object, while the second heat conduction area has higher thermal resistance to suppress heat loss to the environment. This localized thermal property control achieves both fast response and high measurement precision.
Solution Approach 2:
The patent converts the potentially harmful effect of heat transfer to surrounding environments into a beneficial asymmetric thermal management system. By deliberately designing higher thermal resistance in the second heat conduction area, the patent prevents environmental heat interference from affecting the sensor, thereby improving measurement accuracy while maintaining fast response through the first heat conduction area.
3Ease of manufacture
If existing sensor elements and sensor carrier units are used without modification, then manufacturing cost is reduced, but thermal coupling and dynamics of temperature measurement remain insufficient
Solution Approach 1:
The patent applies universality by designing a polymer shell that serves multiple functions: it provides structural protection for the sensor element, acts as a thermal management component with asymmetric heat conduction, and functions as a mounting structure with the coupling surface. This multi-functional design allows use of existing sensors while achieving improved thermal coupling and measurement dynamics.
Solution Approach 2:
The polymer shell acts as an intermediary between the sensor element and the thermal environments (object being measured and outer surroundings). It mediates heat transfer by providing asymmetric thermal resistance - facilitating heat flow from the object to the sensor while blocking heat flow from the sensor to the outer environment. This intermediary function enables use of existing sensors with improved measurement dynamics.
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 design enhances the dynamics of temperature measurement by improving thermal coupling and reducing response times, particularly in dynamic and inhomogeneous temperature environments, minimizing systematic errors and enabling rapid detection of temperature changes.
Implementation Method 1
a first heat conduction area is formed between the top surface of the sensor element and the outer surface, and at least a second heat conduction area is formed between the bottom surface of the sensor element and the coupling surface
Data Source
Figure 1~2a
Figure 2b~3
Figure 4~5
AI summary
The invention relates to a sensor assembly 50 with a sensor element 20 which is arranged at least partially, preferably completely, in a polymer shell 30, wherein the polymer shell has a coupling surface 31 for contacting an object 100 to be measured and an outer surface 32 opposite the coupling surface 31, wherein the sensor element 20 has a bottom surface 22 facing the coupling surface 31 and a top surface 23 facing the outer surface 32, wherein a first heat conduction area 61 is formed between the top surface 23 of the sensor element 20 and the outer surface 32 and at least a second heat conduction area 62 is formed between the bottom surface 22 of the sensor element 20 and the coupling surface 31, wherein the thermal resistance of the first heat conduction area 61 is at least 10% greater than the thermal resistance of the second heat conduction area 62.