Resin-Jointed Thermal Flow Sensor for Accurate Heat Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The measurement accuracy of thermal flow velocity and flow rate sensors is limited due to the air gap between the heat generating and temperature measuring elements, which reduces heat transmission efficiency, making it difficult to improve measurement precision.
Innovation Solution
A thermal flow velocity and flow rate sensor design that includes a substrate with a heat generating element and a temperature measuring element thermally connected via a resin joint, where the lead wires are soldered and coated with resin to enhance heat conductivity and prevent moisture or dust adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air is used as the medium between the heat generating element and the temperature measuring element, then the sensor structure is simple, but the heat transmission efficiency is low due to air's low heat conductivity
Solution Approach 1:
The patent introduces a resin as an intermediary substance to replace air in the gap between the heat generating element and the temperature measuring element. This resin has higher heat conductivity than air, thereby improving heat transmission efficiency while maintaining the simplicity of the sensor structure. The resin fills the space between the two elements, acting as a thermal conductor that facilitates more efficient heat transfer compared to the air medium.
2Measurement precision
If the heat generating element and temperature measuring element are placed close together, then heat transmission efficiency improves, but the sensor becomes more susceptible to moisture and dust contamination
Solution Approach 1:
The patent employs a resin that forms a protective layer or coating between the heat generating element and the temperature measuring element. This resin layer acts as a barrier that prevents moisture and dust from contaminating the sensitive components while simultaneously improving heat transmission due to its superior heat conductivity compared to air. The resin thus serves dual functions: thermal conduction and environmental protection.
3Measurement precision
If a material with high heat conductivity is used to connect the heat generating element and temperature measuring element, then measurement accuracy improves, but the manufacturing complexity increases
Solution Approach 1:
The patent changes the thermal parameter (heat conductivity) of the medium between the heat generating element and the temperature measuring element by replacing air with a resin material. This parameter change improves heat transmission efficiency and measurement accuracy. The resin can be applied using conventional manufacturing techniques such as coating or injection molding, which maintains manufacturing simplicity while achieving the desired thermal performance.
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 configuration improves heat transmission efficiency and measurement accuracy by using a resin with higher conductivity than air, reducing the impact of moisture and dust on sensor performance, and allowing efficient manufacturing and deployment in environments prone to dew condensation.
Implementation Method 1
a joint portion made of a resin filled between the heat generating element and the temperature measuring element and thermally connecting the heat generating element and the temperature measuring element
Implementation Method 2
a heat generating element configured to generate heat in accordance with supply current
Data Source
AI summary
A thermal flow velocity and flow rate sensor includes: a substrate; a heater mounted on the substrate; a temperature measuring element mounted on the substrate; a joint portion made of a resin filled between the heater and the temperature measuring element and thermally connecting the heater and the temperature measuring element; a lead wire connected to the substrate; and a fastener fixing the lead wire to the substrate. The lead wire is soldered to the substrate. The lead wire and the fastener are coated with the resin.