Temperature Sensor Probe Segmentation for Hose Coupling Integration
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Solution Overview
Problem
Current methods for integrating temperature sensors into hose couplings require individual design and use of specific materials, limiting versatility and increasing complexity, as well as reducing the strength and accuracy of the sensors due to material constraints.
Innovation Solution
A temperature sensor design where the sensor element is separate from the media guide and connected via a thermally conductive probe, allowing for non-invasive integration and use with various materials, including glass fiber-reinforced plastics, without altering existing hose couplings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are integrated directly into injection-molded hose couplings, then the sensors can be firmly integrated into the media-carrying hose line, but the injection-molded parts must be individually designed for each sensor type, significantly increasing part variety and manufacturing complexity
Solution Approach 1:
The temperature sensor is divided into separate components: a sensor element and a mounting adapter. The adapter is designed as a universal component that can accommodate different sensor types, while the sensor element remains interchangeable. This segmentation allows the sensor to be firmly integrated without requiring individual customization of the entire assembly for each sensor type.
Solution Approach 2:
The mounting adapter is designed as a universal component that can accommodate multiple types of temperature sensors (e.g., NTC thermistors, Pt100, Pt1000). The adapter provides a standardized interface with the injection-molded hose coupling, allowing the same adapter design to work with various sensor types, thereby reducing part variety and manufacturing complexity.
2Strength
If glass fiber reinforced plastic is used to increase the strength of hose couplings, then the coupling strength is improved, but the thermal conductivity of the material is reduced, impairing the response time and accuracy of the temperature sensor
Solution Approach 1:
A thermally conductive intermediary material (such as thermal paste or a metal transition piece) is introduced between the temperature sensor and the glass fiber reinforced plastic housing. This intermediary compensates for the poor thermal conductivity of the composite material, ensuring efficient heat transfer from the medium to the sensor while allowing the housing to maintain its structural strength.
Solution Approach 2:
The housing is made from glass fiber reinforced plastic to provide mechanical strength, while a thermally conductive material is used for the sensor mounting interface or transition piece. This composite approach allows the structure to maintain strength while the sensor interface optimizes thermal conductivity for accurate temperature measurement.
3Adaptability or versatility
If temperature sensors are integrated into injection-molded parts, then the sensors can be mounted within the media-carrying hose line, but new materials such as PA66 with glass fiber reinforcement cannot be effectively used due to reduced thermal conductivity
Solution Approach 1:
The temperature measurement system is segmented into a structural component (housing made from glass fiber reinforced PA66 for versatility and strength) and a thermal interface component (thermally conductive material or metal transition piece). This segmentation allows the use of high-performance engineering plastics while maintaining effective thermal coupling for accurate temperature sensing.
Solution Approach 2:
A thermally conductive intermediary is introduced at the sensor interface to bridge the thermal gap created by using glass fiber reinforced plastics. This allows the system to benefit from both the material versatility and mechanical properties of reinforced plastics and the thermal conductivity needed for accurate temperature measurement.
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
Enables easy, cost-effective, and space-saving temperature monitoring across different media guides and couplings, maintaining strength while improving accuracy and response time, and allowing for use with a broader range of materials.
Implementation Method 1
the sensor probe (33) is designed to conduct the temperature of the medium to the sensor element
Data Source
Figure 1~2
AI summary
The present invention relates to a temperature sensor (3) with at least one sensor element (31) configured to detect the temperature of a medium within a media channel (1, 2). The temperature sensor (3) is characterized by at least one sensor probe (33) with a contact section (33a), preferably cylindrical, which is configured to be arranged within a flow path (11, 21) of the media channel (1, 2), wherein the contact section (33a) of the sensor probe (33) is configured to detect the temperature of the medium, and wherein the sensor probe (33) is configured to transmit the temperature of the medium to the sensor element (31).