Porous Metal Heat Transfer Element for Temperature Sensor

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Solution Overview

Problem

Conventional temperature sensors face challenges in achieving fast response times and accurate measurements due to impaired thermal conductivity caused by ceramic materials used for protection and vibration resistance in high-temperature applications, such as automotive environments.

Innovation Solution

A temperature sensor design incorporating a heat transfer element made from porous metal, such as knitted wire mesh, which provides enhanced thermal conductivity and mechanical flexibility, replacing traditional ceramic fillers to ensure efficient heat transfer and protection of the temperature sensing element.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ceramic material is used to fill the space between the protective housing and temperature sensitive element, then the temperature sensor becomes robust against vibration and can withstand elevated temperatures, but the thermal conductivity between the temperature sensitive element and the outside medium is impaired

Engineering Contradiction:

Improverobustness against vibration and elevated temperature resistanceVSAvoidthermal conductivity and measurement accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent applies porous metal materials (such as sintered metal or metal foam) as the heat transfer element. These porous materials provide both mechanical robustness for vibration resistance and maintained thermal conductivity through their interconnected pore structures, resolving the contradiction between protection and heat transfer efficiency

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite structures combining metal matrices with porous configurations. This composite approach integrates the strength and vibration resistance of metal materials with the thermal conductivity properties, eliminating the need for ceramic fillers while maintaining both protective and thermally conductive functions

Inventive Principle:

Principle #40Composite materials

2Temperature

If ceramic material is used to protect the temperature sensitive element, then the temperature sensor can withstand elevated temperatures up to 1000° C., but the response time is slowed due to impaired thermal conduction

Engineering Contradiction:

Improveelevated temperature resistanceVSAvoidresponse time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

Porous metal materials are used to create a heat transfer element that maintains excellent thermal conductivity even at elevated temperatures up to 1000° C. The porous structure allows rapid heat transfer to the sensing element while the metal material itself provides high-temperature stability, thus reducing response time while maintaining temperature resistance

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent changes the material parameter from ceramic to porous metal, which fundamentally alters the thermal conductivity properties. This parameter change enables fast thermal response at high temperatures by utilizing the superior thermal conductivity of metal materials while the porous structure provides the necessary protection and vibration resistance

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

The solution significantly improves thermal conduction and response time while maintaining robustness and long-term stability, reducing mechanical stress on the temperature sensing element and eliminating the need for ceramic fillers, thus enhancing measurement accuracy and durability.

Implementation Method 1

The heat transfer element has an outer surface in heat conductive contact with an inner wall of the protective housing and receives at least a part of the temperature sensing element

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11131587B2Temperature sensor with heat transfer element and fabrication method

Publication Date: 2021.09.28 MEAS FRANCE

AI summary

A temperature sensor comprises a temperature sensing element, a protective housing, and a heat transfer element. The temperature sensing element transduces a sensed temperature into an electrical output signal. The protective housing at least partly encases the temperature sensing element. The heat transfer element has an outer surface in heat conductive contact with an inner wall of the protective housing and receives at least a part of the temperature sensing element. The heat transfer element is formed separately from the temperature sensing element.