Resin-Layered Temperature Sensor for Curved Surface Contact
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Solution Overview
Problem
Conventional temperature sensors face challenges in reducing thickness, increasing contact area, and improving measurement accuracy, particularly in adapting to curved surfaces and maintaining durability in harsh environments.
Innovation Solution
A temperature sensor design featuring a thermistor element and lead wires covered by an inner and outer layer of resin materials, with the outer layers having a flat, curved surface shape and infrared reflectivity, allowing for flexibility and improved contact with the object being measured, while maintaining heat and oil resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double tube structure including inner layer tube and outer layer tube is used to cover the thermistor element and lead wires, then durability such as heat resistance and chemical resistance is improved, but the thickness cannot be reduced and curved-surface shape cannot be formed
Solution Approach 1:
The patent replaces the rigid double tube structure with thin film-like resin layers that can be formed into curved surfaces. The resin material is applied as a coating that conforms to the thermistor element and lead wires, providing protection while enabling flexible shaping and reduced thickness.
Solution Approach 2:
The patent changes the physical state and properties of the protective material from tubular structures to resin material that can be heated and cured or melted and solidified. This parameter change allows the material to flow and conform to complex shapes during formation, then solidify to provide durable protection with reduced thickness.
2Reliability
If a double tube structure including inner layer tube and outer layer tube is used to cover the thermistor element and lead wires, then durability such as heat resistance and chemical resistance is improved, but it is difficult to increase contact area with the object whose temperature is to be measured
Solution Approach 1:
The thin film resin layers enable the temperature sensor to be formed into curved surfaces that can conform to the object being measured. This flexibility increases the contact area between the sensor and the measurement surface, improving thermal coupling while maintaining protective durability.
Solution Approach 2:
The patent enables formation of curved-surface shapes by using resin material that can be molded during heating and curing or melting and solidifying. The curved surface configuration allows the sensor to adapt to curved measurement surfaces, maximizing contact area for temperature measurement.
3Device complexity
If insulating sheets are used to cover the thermosensitive element with adhesive attachment, then the structure is simplified, but the sheets do not form a double structure and the thermosensitive element protrudes to the outer surface
Solution Approach 1:
The resin material is applied as thin film layers that can be formed into flat or curved surfaces as needed. The material flows during heating and curing or melting and solidifying to fill gaps and create a flush surface, preventing protrusion while maintaining simplified structure.
Solution Approach 2:
The patent uses parameter changes in the resin material during heating and curing or melting and solidifying to achieve proper filling and surface formation. The material transitions from a flowable state during application to a solidified state that maintains flatness and prevents protrusion.
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 achieves reduced thickness, increased contact area, and enhanced measurement accuracy, with improved durability and flexibility to conform to various surface shapes, effectively addressing the limitations of existing sensors.
Implementation Method 1
an inner layer formed by heating and curing or by melting and solidifying a pair of sheet-like inner layer materials made of a resin material
Implementation Method 2
an inner layer formed by heating and curing or by melting and solidifying a pair of sheet-like inner layer materials made of a resin material
Implementation Method 3
a material that reflects infrared rays is disposed on one surface of the outer layers
Data Source
AI summary
A temperature sensor and a device are provided, in which the temperature sensor is capable of reducing thickness, increasing a contact area with an object whose temperature is to be measured, and improving measurement accuracy. A temperature sensor is provided with: a thermistor element; a lead-out wire connected to the thermistor element; a lead wire connected to the lead-out wire; an inner layer formed by heating and curing or by melting and solidifying a pair of sheet-like inner layer materials formed of a resin material; and outer layers formed of a pair of sheet-like outer layer materials formed of a resin material and having flat surfaces on both sides. The thermistor element, the lead-out wire, and a connection part between the lead-out wire and the lead wire are covered with the inner layer, and are also covered with the pair of outer layers by being sandwiched therebetween.