Rotationally Symmetrical Carrier Element for Temperature Sensor
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Solution Overview
Problem
Existing temperature sensors face challenges in simplifying production, achieving high measuring accuracy, and providing improved response behavior while covering a wide measuring range, with current designs often requiring complex assembly and limited flexibility in accommodating multiple measuring resistors or components.
Innovation Solution
A rotationally symmetrical carrier element with multiple receptacles and guides allows for the mounting of multiple measuring resistors and electronic components, enabling a compact, redundant, and versatile sensor design with improved response behavior and simplified production, using a thermally conductive plastic encapsulation for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single carrier element is used to hold measuring resistor and connecting lines, then the sensor structure is simple, but the measuring range and reliability are limited
Solution Approach 1:
The carrier element is designed with multiple receptacles and guides to accommodate different types and numbers of measuring resistors, enabling a single component to serve multiple measuring ranges and applications, thus improving versatility without proportionally increasing complexity
Solution Approach 2:
Multiple measuring resistors and their connecting lines are combined on a single carrier element, merging what would traditionally require separate sensor units into one integrated component, thereby expanding measuring range while maintaining structural simplicity
2Reliability
If multiple measuring resistors are mounted on separate carrier elements, then each sensor is simple, but the overall device complexity and assembly complexity increase
Solution Approach 1:
Multiple measuring resistors are mounted on a single carrier element, merging multiple sensor functions into one unit, which reduces assembly complexity while improving reliability through redundancy and integrated strain relief
Solution Approach 2:
The carrier element provides centralized strain relief for all connecting lines before they exit the sensor assembly, protecting against mechanical stress and improving reliability without requiring individual protection for each line
3Manufacturing precision
If connecting lines are arranged without centralized guidance, then the carrier element is simple, but strain relief and positioning accuracy are insufficient
Solution Approach 1:
The guides serve multiple functions: they position connecting lines during assembly, provide strain relief, and maintain electrical insulation, thereby improving positioning accuracy without proportionally increasing structural complexity
Solution Approach 2:
The guides act as intermediary structures that organize and control the connecting lines between the measuring resistor and the external environment, improving positioning precision while the web provides centralized insulation
4Measurement precision
If a non-rotationally symmetrical carrier element is used, then the manufacturing is simpler, but the distribution of measuring resistors is uneven affecting response behavior
Solution Approach 1:
The carrier element employs rotational symmetry rather than asymmetry, creating an evenly distributed structure for measuring resistors that ensures uniform thermal and mechanical characteristics, thereby improving measurement accuracy while remaining manufacturable through standard molding processes
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 solution enables high measurement accuracy and wide-range capability, with improved response times and reduced production complexity, allowing for even distribution of measuring resistors and enhanced reliability through redundant systems and compact design.
Implementation Method 1
using a thermally conductive plastic encapsulation for enhanced performance
Data Source
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AI summary
The invention relates to a support element (1) for an electrical sensor (2), in particular for a temperature sensor, which is elongated and has in a first end section (3) a receptacle (4) for a measuring resistor (5) and in a further section (6) adjoining the end section (3) at least two longitudinally extending guides (8) for guiding connecting wires (9), separated from each other by a web (7). According to the invention, the support element (1) is rotationally symmetrical at least in the region of the first end section (3) and the further section (6) so that it can be mapped onto itself by rotation about a longitudinal axis (A) by an angle (α), wherein the angle (α) is preferably 180°, 120° or 90°.The invention further relates to an electrical sensor (2), in particular a temperature sensor, with a carrier element (1) according to the invention, and to a method for manufacturing an electrical sensor (2), in particular a temperature sensor.