Temperature Sensor Insulation Segmentation for Wet Environment Short Circuit Prevention
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Solution Overview
Problem
Existing temperature sensors face challenges in preventing short circuits when used in wet environments due to moisture ingress, particularly between electric wires, which can lead to electrical shorts.
Innovation Solution
The temperature sensor design includes a sensor element with a thermosensitive body and electric wires, where the second electric wires have insulation coverings separated at the connection point, allowing for a longer creepage distance and contact at a predetermined position, with a filling body comprising multiple insulating layers to prevent moisture ingress and enhance insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electric wires are arranged close together to reduce space, then the device size is reduced, but the risk of short circuit in wet atmosphere increases
Solution Approach 1:
The patent divides the insulation structure into multiple segments: a first covering layer that individually covers each electric wire, and a second covering layer that covers the first covering layer. This segmentation allows the electric wires to be arranged close together while maintaining adequate insulation, as each wire is individually protected and the layered structure prevents moisture bridging between adjacent wires.
Solution Approach 2:
The patent employs composite insulation structures with at least two different covering layers having different material properties. The first covering layer provides individual wire insulation, while the second covering layer provides overall protection and moisture barrier. This composite approach enables compact wire arrangement while ensuring reliable short circuit prevention through multiple insulation barriers.
2Reliability
If the creepage distance between electric wires is increased to prevent short circuit, then the reliability in wet atmosphere is improved, but the device complexity increases
Solution Approach 1:
The patent segments the insulation function into two distinct covering layers, each performing a specific role. The first covering layer provides individual wire insulation and the second covering layer provides collective protection. This segmentation achieves effective creepage distance without requiring overly complex single-layer structures, as each layer is optimized for its specific function.
Solution Approach 2:
The first covering layer is designed to individually cover each electric wire, providing localized insulation where it is most needed. The second covering layer provides broader protection. This local quality approach allows the creepage distance to be effectively increased at critical locations without unnecessarily complicating the entire insulation structure uniformly.
3Ease of manufacture
If a single covering layer is used to simplify the structure, then the manufacturing process is simplified, but the insulation effectiveness against moisture is reduced
Solution Approach 1:
The patent employs composite insulation structures with at least two different covering layers having different material properties. The first covering layer provides individual wire insulation, while the second covering layer provides overall protection and moisture barrier. This composite approach enables compact wire arrangement while ensuring reliable short circuit prevention through multiple insulation barriers.
Solution Approach 2:
The patent divides the insulation structure into multiple segments: a first covering layer that individually covers each electric wire, and a second covering layer that covers the first covering layer. This segmentation allows the electric wires to be arranged close together while maintaining adequate insulation, as each wire is individually protected and the layered structure prevents moisture bridging between adjacent wires.
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 effectively increases the creepage distance between electric wires, reducing the likelihood of short circuits even in wet conditions by maintaining insulation and preventing moisture entry, thus ensuring reliable operation.
Implementation Method 1
a filling body that lies between the protective tube and the sensor element inside the protective tube
Implementation Method 2
Insulation coverings of the pair of second electric wires are separated from each other, on the front side at which the pair of second electric wires are connected to the pair of first electric wires
Implementation Method 3
a sensor element including a thermosensitive body and a pair of electric wires that are electrically connected to the thermosensitive body
Data Source
AI summary
A temperature sensor comprises: a sensor element including a thermosensitive body and a pair of electric wires that are electrically connected to the thermosensitive body; a protective tube for accommodating the sensor element; and a filling body that lies between the protective tube and the sensor element inside the protective tube. The pair of electric wires includes a pair of first electric wires and that are connected to the thermosensitive body, and a pair of second electric wires and that are connected to the pair of first electric wires and, respectively. The pair of second electric wires and are connected to the pair of first electric wires and on its front side at which insulation coverings thereof are separated from each other.