Sensor Arrangement With Segmented Insulation For Fast Response
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor arrangements face challenges in providing adequate electrical protection while minimizing the restriction on the response time of the sensor element, which is crucial for rapid detection of physical properties like temperature or optical signals.
Innovation Solution
A sensor arrangement featuring a sensor element embedded in a solid plastic body with electrical connections surrounded by insulating layers, where the plastic body is made of flexible material with defined shape, and the insulating layers are designed to ensure high dielectric strength and minimal interference with the sensor's response time, allowing for simultaneous detection of temperature and optical signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor element is surrounded by thick insulating layers and embedded in a solid plastic body for electrical protection, then the dielectric strength and electrical safety are improved, but the response time of the sensor element is restricted and slowed down
Solution Approach 1:
The insulating structure is divided into multiple layers with different functions: a first insulating layer directly surrounding the sensor element for electrical isolation, a second insulating layer for additional protection, and a plastic body providing mechanical support and further insulation. This segmentation allows each layer to be optimized for its specific purpose, maintaining thin dimensions near the sensor for fast response while providing adequate overall protection.
Solution Approach 2:
Different regions of the sensor arrangement have different insulating properties tailored to local requirements. The first insulating layer has minimal thickness where it contacts the sensor element to preserve response time, while the plastic body provides thicker insulation in regions where mechanical support and electrical protection are prioritized. This local optimization resolves the contradiction between protection and speed.
2Reliability
If multiple insulating layers are used to ensure protection class II dielectric strength, then the electrical protection is improved, but the device complexity increases
Solution Approach 1:
Multiple insulating functions are merged into an integrated structure where the first and second insulating layers work together with the plastic body to achieve protection class II. The electrical connections pass through the plastic body to connect the sensor element with external circuitry, combining mechanical support, electrical isolation, and structural protection in a unified design that avoids the complexity of separate assembly steps.
Solution Approach 2:
The sensor arrangement uses composite material structures combining different insulating materials (first insulating layer material, second insulating layer material) with the plastic body material. Each material is selected for its specific properties, and their combination provides the required dielectric strength while maintaining a manageable structural complexity through coordinated material selection and integration.
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 arrangement achieves rapid and reliable detection of physical properties with protection class II dielectric strength, ensuring the response time is not severely restricted by the insulation, making it suitable for real-time monitoring of temperature and optical signals.
Implementation Method 1
At least one insulating layer, in particular a first insulating layer, is arranged between the sensor element and the plastic body, embedding the sensor element. At least a portion of the electrical connections adjacent to the sensor element is surrounded by the first insulating layer.
Implementation Method 2
The sensor element is arranged in a solid plastic body. A solid plastic body is understood to be a body made of a flexible plastic that has a defined basic shape. The plastic body is at least partially deformable, always returning to its original shape.
Implementation Method 3
The sensor element directly detects at least one physical parameter of the medium to be measured. The sensor element is, for example, designed as a temperature sensor or as an optical sensor. In the case of a temperature sensor, the temperature of the surrounding medium is detected.
Implementation Method 4
In the case of an optical sensor, optical signals are detected by the sensor assembly.
Implementation Method 5
The sensor element has electrical connections with which it is electrically contacted. The electrical connections preferably extend beyond the dimensions of the plastic body.
Data Source
Figure 1~2
Figure 3
AI summary
A sensor arrangement has at least one sensor element with electrical connections. At least one sensor element is arranged in a solid plastic-material body, at least a first insulating layer, which encloses the sensor element, being arranged between the sensor element and the plastic-material body. The sensor element senses at least one physical property of a medium to be measured.