Temperature Sensor Covering Structure for Faster Thermal Response
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Solution Overview
Problem
Existing temperature sensors face challenges in improving responsiveness and installation flexibility, particularly in small-sized designs, due to the influence of the covering body on the thermosensitive element and lead wire.
Innovation Solution
A temperature sensor design with a covering body made of resin, featuring a rectangular cross-section and dimensions tailored to prioritize a smaller region covering the thermosensitive element compared to the lead wire, achieved through a manufacturing process involving heating and pressure forming to create distinct thickness and width differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the covering body has a constant thickness determined by the lead wire diameter, then the lead wire is adequately protected, but the thermosensitive element region has excessive wall thickness that reduces responsiveness
Solution Approach 1:
The covering body is designed with different wall thicknesses in different regions: a first wall thickness in the lead wire covering region and a second wall thickness in the thermosensitive element covering region. The second wall thickness is smaller than the first wall thickness, allowing the thermosensitive element to respond faster to temperature changes while the lead wire region maintains adequate protection.
2Ease of manufacture
If the covering body has a constant thickness, then the manufacturing process is simple, but the installation flexibility in various shapes and dimensions is limited
Solution Approach 1:
The covering body features non-uniform wall thickness with a first wall thickness for the lead wire region and a second wall thickness for the thermosensitive element region. This local differentiation enables the sensor to adapt to various installation shapes and dimensions while maintaining manufacturing feasibility through controlled thickness variation.
3Speed
If the wall thickness of the covering body is reduced to improve responsiveness, then heat conduction is enhanced, but the mechanical strength and protection are compromised
Solution Approach 1:
The covering body is designed with spatially varying wall thickness: thinner wall thickness in the thermosensitive element covering region to enhance heat conduction and responsiveness, and thicker wall thickness in the lead wire covering region to maintain mechanical strength and protection. This local differentiation resolves the contradiction between responsiveness and strength.
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 design enhances responsiveness by reducing heat capacity and improving installation flexibility, allowing sensitive temperature detection and stable placement on various objects.
Implementation Method 1
a heating step of heating the material
Implementation Method 2
a pressure forming step of pressurizing the material to form the material in a shape having a rectangular cross-section
Data Source
AI summary
A temperature sensor includes: a thermosensitive element including a thermosensitive body, an extension wire having one end electrically connected to the thermosensitive body, and a sealing body made of an insulation material and covering a part of the extension wire and the thermosensitive body; a lead wire electrically connected to another end of the extension wire; and a covering body made of a resin and having a long shape and a rectangular cross-section, the covering body covering a part of the lead wire and the thermosensitive element. In a lateral direction of the covering body, a dimension of a region of the covering body covering the thermosensitive element is set less than a dimension of a region of the covering body covering the lead wire.