Sensor Device Housing with Integrated Fastening for Electrical Components
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Solution Overview
Problem
Existing sensor devices for temperature measurement in electrical devices, such as electric motors, are complex to integrate and require cumbersome assembly and disassembly processes.
Innovation Solution
A sensor device with a temperature sensor element, preferably a thermistor, housed in a high-temperature stability and high-electric strength plastic casing, which is designed for direct contact with electrical consumers and features a mechanical fastening element for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing sensor devices are used for temperature measurement in electrical devices, then temperature measurement function is achieved, but integration complexity and assembly difficulty increase
Solution Approach 1:
The sensor device merges the sensor element, housing, and mechanical fastening element into a single integrated unit. The housing is formed as one piece with the sensor element and fastening element, eliminating the need for separate components and simplifying integration into electrical devices like electric motors.
Solution Approach 2:
The housing serves multiple functions simultaneously: it protects the sensor element, provides mechanical strength for high-temperature environments, and integrates the mechanical fastening element for secure attachment to electrical consumers. This multi-functionality reduces the number of separate components needed.
2Reliability
If existing sensor devices are used, then temperature measurement is possible, but assembly and disassembly processes become cumbersome
Solution Approach 1:
The sensor device is designed as a modular unit with the sensor element, housing, and mechanical fastening element integrated together. This segmentation allows the entire sensor assembly to be installed and removed as a single unit, simplifying the assembly and disassembly processes while maintaining measurement reliability.
3Measurement precision
If sensor device is designed for direct contact with electrical consumers, then measurement accuracy improves, but electrical safety requirements increase
Solution Approach 1:
The housing acts as an intermediary between the sensor element and the electrical consumer. It provides electrical insulation and protection while allowing thermal contact for accurate measurement. The housing material is selected to provide both thermal conductivity for measurement and electrical insulation for safety.
4Device complexity
If miniaturized design is used, then integration simplicity improves, but mechanical strength requirements increase
Solution Approach 1:
The housing is made from composite materials or specially engineered plastics that provide high mechanical strength despite miniaturization. These materials maintain structural integrity in high-temperature environments while enabling compact sensor design for easy integration into electrical devices.
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 sensor device enables fast and accurate temperature measurement of electrical components, such as busbars, with a miniaturized design and easy screwless installation, improving integration simplicity and measurement precision.
Implementation Method 1
The sensor element may comprise a thermistor material. The thermistor material can, for example, be a high-temperature conductor material or NTC thermistor material (NTC: 'negative temperature coefficient') or a low-temperature conductor material or PTC material (PTC: 'positive temperature coefficient').
Data Source
AI summary
In an embodiment a sensor device includes a sensor element in a housing, wherein a mechanical fastening element is arranged and fastened to the housing, the mechanical fastening element including a spring element, wherein the housing includes a plastic having a liquid crystal polymer filled with boron nitride, and wherein the housing includes a base part and a cover part connected to each other, and a cavity in which the sensor element is arranged.