RTD Temperature Probe Insert for Fast Response and Vibration Resistance
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Solution Overview
Problem
Existing temperature probes, particularly those using resistance temperature detectors (RTDs), face challenges in achieving fast response times while maintaining accuracy and stability, especially in high-precision industries like pharmaceuticals and food production, due to issues with vibration-induced lead wire breakage and loose powder fillings that provide limited vibration resistance and heat transfer.
Innovation Solution
A temperature probe design that replaces loose powder with a solid insert to press the RTD element directly onto the metal sensor end cap, providing strain relief and improved heat transfer, thereby enhancing response time and vibration resistance without compromising accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If loose powder filling is used in the temperature probe, then the RTD element can be positioned within the sheath, but the response time is slow and vibration resistance is poor
Solution Approach 1:
The patent changes the physical state of the filling material from loose powder to a solidified form. The insert is formed by solidifying material (such as epoxy resin or other potting compounds) that initially surrounds the RTD element in liquid form, then hardens to create a rigid structural support. This parameter change from liquid to solid state transforms the filling function from merely positional to also providing mechanical strength and thermal conduction, thereby improving both vibration resistance and response time.
Solution Approach 2:
The patent employs composite material structure by combining the RTD element with a solidified insert material (such as epoxy resin mixed with metallic particles or ceramic fillers). This composite provides both the electrical insulation properties needed for the RTD element and the mechanical strength for vibration resistance. The composite material also improves thermal conductivity compared to loose powder, enhancing the response time while maintaining structural integrity.
2Productivity
If loose powder filling is used in the temperature probe, then the RTD element can be suspended, but heat transfer is limited and response time increases
Solution Approach 1:
The patent changes the physical state of the filling material from loose powder to a solidified form. The insert is formed by solidifying material (such as epoxy resin or other potting compounds) that initially surrounds the RTD element in liquid form, then hardens to create a rigid structural support. This parameter change from liquid to solid state transforms the filling function from merely positional to also providing mechanical strength and thermal conduction, thereby improving both vibration resistance and response time.
Solution Approach 2:
The patent extracts the unnecessary loose powder filling and replaces it with a compact solidified insert. The insert consolidates the functions of powder filling (positioning, insulation, thermal conduction) into a single solid structure that requires less volume and provides superior performance. This extraction eliminates the limitations of loose powder while maintaining all necessary functions.
3Loss of time
If the RTD element is not pressed against the end cap, then the element is protected from stress, but the response time is slower
Solution Approach 1:
The patent segments the stress management function by introducing a dedicated insert structure that isolates the RTD element from external stresses. The insert acts as an independent stress-absorbing component that decouples the element from mechanical shocks and vibrations, protecting the lead wires while maintaining optimal thermal contact between the element and end cap for fast response time.
Solution Approach 2:
The solidified insert provides beforehand cushioning by absorbing and distributing mechanical stresses before they can reach the RTD element and lead wires. The insert material is specifically chosen to provide shock absorption and vibration damping, protecting the fragile electrical connections from vibration-induced breakage while maintaining thermal contact for fast response.
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 new design significantly reduces response time by up to 50% and improves vibration resistance, ensuring faster and more reliable temperature measurements in demanding environments.
Implementation Method 1
providing strain relief and improved heat transfer
Data Source
AI summary
A temperature probe includes a mineral-insulated cable having a metallic outer sheath surrounding a mineral insulation therein. The mineral-insulated cable has a plurality of conductors running through the mineral insulation. A temperature sensitive element has a pair of lead wires. An insert has at least one conduit to receive the pair of lead wires of the temperature sensitive element. The insert also has a recess configured to receive the temperature sensitive element. An insert sheath is configured to slide over the insert and has a first end configured to couple to the metallic outer sheath of the mineral-insulated cable and a second end. An endcap is attached to the second end of the insert sheath. The insert is configured to urge the temperature sensitive element into contact with the endcap.