Temperature Sensor Epoxy Resin Segmentation
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Solution Overview
Problem
Conventional temperature sensors have reduced strength and responsiveness due to thin epoxy resin coatings and complex heat transfer mechanisms involving multiple resin layers, which compromise their temperature measurement accuracy and reliability.
Innovation Solution
A temperature sensor design featuring a pair of lead frames with a thermistor covered by a first resin part made of epoxy resin for structural rigidity and a second resin part for chemical resistance, where the first resin part is exposed near the thermistor, enhancing thermal conductivity and structural integrity while maintaining exposure for improved responsiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin epoxy resin coating is applied to protect the thermistor and lead wire, then the temperature sensor achieves chemical resistance and compact outer shape, but the strength of the temperature sensor is reduced
Solution Approach 1:
The resin coating is divided into two distinct layers: a first resin layer (epoxy resin) providing chemical resistance and a second resin layer providing mechanical strength. This segmentation allows each layer to specialize in its primary function, resolving the contradiction between chemical resistance and strength.
Solution Approach 2:
The invention uses a composite structure of two different resin materials with complementary properties. The epoxy resin layer provides chemical resistance while the second resin layer provides mechanical strength, creating a composite coating system that achieves both requirements simultaneously.
2Strength
If a thick epoxy resin coating is applied to increase strength, then the temperature sensor achieves higher mechanical strength, but the response time is reduced due to increased thermal resistance
Solution Approach 1:
The resin coating is segmented into two layers with the first layer (epoxy resin) positioned adjacent to the thermistor to provide chemical resistance while maintaining thin thickness for fast thermal response. The second layer is applied externally to provide mechanical strength without interfering with heat transfer to the thermistor.
Solution Approach 2:
Different regions of the resin coating have different thicknesses and material properties optimized for their specific functions. The first resin layer near the thermistor is thin for thermal conductivity, while the second outer resin layer is thicker for mechanical protection, achieving local optimization of both response time and strength.
3Shape
If the outer shape of the epoxy resin follows the outer shape of the thermistor and lead wire, then the temperature sensor achieves compact design, but the manufacturing precision is reduced
Solution Approach 1:
The manufacturing process is segmented into two sequential molding steps: first forming the epoxy resin layer conformally around the thermistor and lead wire, then forming the second resin layer to provide a regular outer shape. This segmentation allows the first layer to follow the component contours for compactness while the second layer provides manufacturing precision and uniform dimensions.
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 design improves the strength and responsiveness of the temperature sensor by ensuring efficient heat transfer through the high thermal conductivity epoxy resin and reduces thermal resistance, leading to enhanced temperature measurement accuracy and manufacturability.
Implementation Method 1
a first resin part composed of an epoxy resin and covering the thermistor and a part of the pair of lead frames near the thermistor with predetermined rigidity
Data Source
AI summary
A temperature sensor includes a pair of lead frames, a thermistor provided on the pair of lead frames, a first resin part composed of an epoxy resin and covering the thermistor and a part of the pair of lead frames near the thermistor with predetermined rigidity, and a second resin part covering a portion of the first resin part and a part of the pair of lead frames so that a portion of the first resin part near the thermistor is exposed.