Soldering Iron Tip With Segmented Heater And Sensor Holes
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Solution Overview
Problem
Conventional soldering irons with high-output heaters pose a risk of premature temperature sensor failure due to excessive heat and measurement noise interference, leading to inaccurate temperature readings and short sensor lifespan.
Innovation Solution
The soldering iron design features separate, independently formed holes within the iron tip for the heater and temperature sensor, with insulation to prevent direct heat transfer and noise interference, allowing for accurate temperature measurement even with high-output heaters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large output heater is used to increase heating capability, then the heating power is improved, but the temperature sensor deteriorates faster due to excessive heat and noise interference
Solution Approach 1:
The iron tip main body is divided into separate accommodation spaces: a first hole part for the heater and a second hole part for the temperature sensor. This segmentation isolates the temperature sensor from the high-heat heater environment, allowing the heater to operate at high output (300-500W) without compromising sensor reliability.
Solution Approach 2:
The iron tip main body acts as an intermediary structure between the heater and temperature sensor. By forming separate hole parts within this intermediary structure, the patent creates a physical barrier that reduces direct heat exposure and noise interference while maintaining the functional relationship between heating and temperature detection.
2Device complexity
If the temperature sensor lead wire is wired through the heater center for compact design, then the device complexity is reduced, but the temperature sensor is exposed to high heat causing breaking wire
Solution Approach 1:
Instead of routing the temperature sensor lead wire through the heater center, the patent segments the wiring paths by providing separate hole parts: the heater occupies the first hole part while the temperature sensor occupies the second hole part. This segmentation prevents the lead wire from暴露 to high heat while maintaining compact overall structure.
Solution Approach 2:
The temperature sensor and its lead wire are extracted from the heater's thermal path. By placing the temperature sensor in a separate second hole part away from the heater's first hole part, the lead wire is taken out from the high-heat zone, preventing breaking wire while keeping the design simple.
3Measurement precision
If the temperature sensor is placed close to the heater for accurate measurement, then the measurement precision is improved, but the sensor is interfered with by noise from the heater current
Solution Approach 1:
The patent segments the spatial arrangement by providing separate hole parts for the heater and temperature sensor within the iron tip main body. This segmentation allows the temperature sensor to be positioned near the heater for accurate measurement of iron tip temperature while simultaneously isolating it from electromagnetic noise generated by heater current.
Solution Approach 2:
The iron tip main body serves as an intermediary structure that enables close proximity positioning for accurate temperature measurement while providing physical separation to reduce noise interference. The separate hole parts within this intermediary structure allow both heating and sensing functions to operate effectively in close proximity without mutual interference.
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
This configuration extends the lifespan of the temperature sensor, ensures accurate temperature measurement, and prevents overheating, enabling a soldering iron with a large output and long service life.
Implementation Method 1
a heater configured to heat the iron tip main body... the temperature reaches about 1000 degree Celsius at a center of the heater
Implementation Method 2
an iron tip main body of a thermal conductive material... heat the iron tip main body
Implementation Method 3
a temperature sensor configured to detect a temperature of the leading end side of the iron tip... a thermos couple is used
Data Source
AI summary
A soldering iron including an iron main body; and an iron tip having a leading end configured to fuse solder, the iron tip including an iron tip main body of a thermal conductive material; a heater configured to heat the iron tip main body, and a temperature sensor configured to detect a temperature of the leading end side of the iron tip, wherein, a first hole part accommodating the heater and a second hole part accommodating the temperature sensor are formed independent of each other inside the iron tip main body.