Temperature Sensor Insulator Using Green Ceramic and Intermediate Stop
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Solution Overview
Problem
Existing temperature sensor manufacturing methods result in fragile sensors prone to damage and high production costs due to the use of brittle ceramic insulators and time-consuming processes, which fail to provide effective moisture barriers for the sensing elements.
Innovation Solution
A temperature sensor design featuring an intermediate stop to secure the insulator around the wires, a sleeving to protect the wires, and an insulating material to create a moisture barrier, with a sheath that secures the components and reduces the outer dimension to compact the insulator, enhancing durability and reducing manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard fired ceramic insulators are used, then insulation performance is improved, but the sensor becomes brittle and susceptible to damage from vibration or impact
Solution Approach 1:
The patent changes the physical state and properties of the ceramic material by using a green (unfired) ceramic composition instead of hard fired ceramic. This transformation allows the material to maintain insulating properties while gaining flexibility and mechanical durability, directly resolving the contradiction between insulation performance and mechanical strength.
Solution Approach 2:
The patent employs a composite structure combining green ceramic composition with metal sheath and conductor wires. This composite approach allows the ceramic to provide insulation while the metal components provide mechanical strength and flexibility, resolving the contradiction between insulation performance and mechanical durability.
2Ease of manufacture
If preformed crushable ceramic insulator is used, then assembly is simplified, but the ceramic powder is loosely distributed and does not provide effective moisture barrier
Solution Approach 1:
The patent applies adhesive to the metal sheath before inserting the green ceramic composition, creating a preliminary bonding layer that ensures the ceramic material adheres properly and forms an effective moisture barrier, while still allowing for simple assembly procedures.
Solution Approach 2:
The patent changes the ceramic material from loose powder to a cohesive green (unfired) composition that can be inserted as a single piece. This transformation maintains assembly simplicity while ensuring the material distributes properly and provides effective moisture protection when adhered to the sheath.
3Manufacturing precision
If multiple manufacturing steps including swaging and powder insertion are used, then insulator compaction is achieved, but production time and cost increase
Solution Approach 1:
The patent pre-forms the ceramic insulator as a green composition with appropriate dimensions and properties before assembly. This preliminary preparation eliminates the need for subsequent swaging and powder insertion steps, achieving both proper compaction and improved production efficiency.
Solution Approach 2:
The patent combines multiple manufacturing operations into a single assembly step by using pre-formed green ceramic composition that requires only insertion and adhesive bonding. This merging of operations reduces production time and cost while maintaining insulator compaction quality.
4Ease of manufacture
If sensing element is left in open un-insulated space, then assembly is simplified, but the sensing element lacks moisture protection
Solution Approach 1:
The patent applies adhesive to the metal sheath before inserting the green ceramic composition, creating a preliminary bonding layer that ensures the ceramic material adheres properly and forms an effective moisture barrier around the sensing element, while still allowing for simple assembly procedures.
Solution Approach 2:
The green ceramic composition serves multiple functions simultaneously: it provides electrical insulation, mechanical support, and moisture protection for the sensing element. This multi-functionality eliminates the need for separate protective components, maintaining assembly simplicity while ensuring comprehensive moisture protection.
Data Source
AI summary
Temperature sensors and methods of manufacturing thereof, having an intermediate stop disposed along a set of wires, the intermediate stop is secured to the set of wires such that an insulator can be properly positioned around proximal end portions of the set of wires during assembly of the temperature sensor.