Temperature Sensor Unit with Central Conductors and Liquid Insulation
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Solution Overview
Problem
Temperature sensors in high-temperature environments, such as automobile engines, experience breakdowns due to weak soldering or welding between conductors and terminals, leading to premature failure from vibrations and heat exposure.
Innovation Solution
A method involving a temperature sensor unit with a sheath, conductors, and insulating materials, where the conductors are positioned closer to the sheath center than the sensors, using a liquid insulating material to secure the sensors and allow for laser soldering or welding without damaging the sensor, and a third insulating layer to protect the solderings from vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldering or welding is used to connect conductors to terminals, then the connection is made, but the soldering/welding breaks down under vibration and heat exposure
Solution Approach 1:
The patent applies preliminary action by pre-positioning the temperature sensor and conductors within the sheath before final assembly. The sensor is placed in a recessed area with the conductors positioned closer to the center, creating a predetermined arrangement that facilitates stronger soldering connections while protecting the sensor from direct heat exposure during the soldering process.
Solution Approach 2:
The patent uses an intermediary insulating material filled in the space between the conductors and the sheath. This insulating material serves as a mediator that maintains proper spacing, provides thermal insulation to protect the sensor from heat during soldering, and mechanically stabilizes the arrangement to prevent vibration-induced breakdown of connections.
2Strength
If laser soldering or welding is used to strengthen connections, then the soldering strength is improved, but the heat generated may damage the temperature sensor
Solution Approach 1:
The insulating material acts as a thermal intermediary that blocks direct heat transfer from the laser soldering process to the temperature sensor. By positioning the sensor in a recessed area and filling the surrounding space with this insulating material, the laser heat is contained and directed only to the soldering areas, preventing sensor damage while achieving strong connections.
Solution Approach 2:
The patent applies local quality by creating different thermal zones within the sheath. The area containing the temperature sensor is insulated and protected from direct laser heat, while the areas where soldering occurs are exposed to the laser energy. This localized approach allows strong soldering connections to be made without transferring harmful heat to the sensor.
3Strength
If the conductors are positioned closer to the sheath center than the sensors, then the soldering connections are strengthened, but the space for insulating material is reduced
Solution Approach 1:
The patent segments the internal space of the sheath into distinct functional zones: a central region for conductor positioning and soldering, a recessed region for sensor placement, and surrounding regions for insulating material. This segmentation allows the conductors to be positioned closer to the center for stronger soldering while maintaining adequate space for the insulating material to fill the gaps and provide necessary insulation.
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 method enhances the durability and operational lifespan of temperature sensors by providing stronger connections and protecting them from heat and vibrations, reducing the risk of damage and improving retention within the sensor unit.
Implementation Method 1
curing the second insulating material, so as to bring the second insulating material from a liquid state to a solid state
Implementation Method 2
soldering and/or welding the set of conductors to the set of terminals
Data Source
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AI summary
A method of manufacturing a temperature sensor unit comprising the steps of: providing the conductors in the sheath such that in a first zone a space is defined between the sheath and the conductors; providing the second insulating material in liquid form in the space; positioning the sensors in the space such that the conductors are provided closer to the centre of the sheath than the sensors; and soldering and/or welding the set of conductors to the set of terminals. A temperature sensor in which sets of conductors and one or more temperature sensors are arranged inside a sheath and with respect to each other such that the conductors are provided closer to the centre of the sheath than the temperature sensors.