Temperature Sensor Fillet Geometry for Heat Dissipation Control
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Solution Overview
Problem
Existing temperature sensors experience heat dissipation issues from the element electrode wire to the terminal via the fillet portion, affecting measurement accuracy and durability.
Innovation Solution
A temperature sensor design with a fillet portion where the maximum fillet width (A) is less than or equal to the boundary width (B) in specific cross sections, reducing the area orthogonal to the overlapping direction and suppressing heat dissipation, while ensuring the fillet pieces are formed to crawl up from the main surface, enhancing durability and measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the fillet portion is formed to connect the element electrode wire to the terminal, then the connection strength is improved, but heat dissipation from the element electrode wire to the terminal increases
Solution Approach 1:
The fillet portion is designed with non-uniform cross-sectional area along its length, creating local quality variations. The cross-sectional area is smaller near the element electrode wire and larger near the terminal, optimizing both connection strength and heat dissipation characteristics at different locations of the fillet portion
Solution Approach 2:
The invention controls the fillet portion's geometry in three-dimensional space by defining specific cross-sectional area ratios at different positions along its length. This dimensional control allows optimization of both mechanical strength (through adequate fillet volume) and thermal performance (through controlled heat conduction path)
2Reliability
If the fillet portion has a larger cross-sectional area, then the connection reliability is improved, but the temperature measurement responsiveness deteriorates
Solution Approach 1:
The fillet portion exhibits varying cross-sectional properties along its length, with smaller cross-sectional area near the temperature sensing element side to maintain responsiveness and larger cross-sectional area near the terminal side to ensure connection reliability
Solution Approach 2:
The fillet portion geometry is pre-optimized during manufacturing to have specific cross-sectional area ratios, ensuring that the connection structure inherently balances reliability and responsiveness without requiring additional components or adjustments
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 effectively reduces heat dissipation from the element electrode wire to the terminal, improving temperature measurement responsiveness and accuracy, and enhancing the sensor's durability by maintaining the fillet pieces' structural integrity.
Implementation Method 1
a maximum length in the width direction of the fillet portion is defined as a fillet maximum width A, and a length in the width direction between a pair of boundary portions between a pair of the fillet pieces and the specific main surface is defined as a boundary width B, the temperature sensor has, at least partly in the sensor axis direction, a specific cross section satisfying B≤A
Data Source
AI summary
The temperature sensor includes a temperature sensing element, a pair of element electrode wires, and a pair of terminals. An overlapping wire portion of each of the element electrode wires is connected to the terminal in such a manner as to overlap the terminal in an overlapping direction. A fillet portion is disposed on a side surface of the overlapping wire portion. The fillet portion has a pair of fillet pieces formed in such a manner as to crawl up from a specific main surface that is a main surface at the overlapping wire portion side in the terminal. In a cross section of the temperature sensor orthogonal to a sensor axis direction and passing through the fillet portion, the maximum length in a width direction of the fillet portion is defined as a fillet maximum width A, and a length in a width direction between a pair of boundary portions between the pair of fillet pieces and the specific main surface is defined as a boundary width B. The temperature sensor has, at least partly in the sensor axis direction, a specific cross section satisfying B≤A, as a cross section of the temperature sensor orthogonal to the sensor axis direction and passing through the fillet portion.