Temperature Sensor Multi-Weld Zone Design for Vibration Resistance
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Solution Overview
Problem
Temperature sensors with welded element electrode wires and sheath core wires experience reduced binding capability and stress due to vibrations and thermal cycling, leading to potential weld zone separation, especially when mounted on motor vehicles or internal combustion engines.
Innovation Solution
A temperature sensor design featuring a temperature-sensing element with element electrode wires and second electrode wires made of different thermal expansion coefficients, with multiple weld zones arranged along the longitudinal direction to enhance binding strength and reduce stress on weld zones, including a front-side, rear-side, and central weld zone configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If element electrode wires are welded to sheath core wires at two points in the longitudinal direction, then the structure is simple and manufacturing is easy, but the binding capability decreases and weld zones may break under vibration and thermal stress
Solution Approach 1:
The overlap region is divided into multiple weld zones (first weld zone at front end, second weld zone at rear end, and optionally third weld zone at center) instead of using a single weld zone or two-point weld. This segmentation distributes the binding function across multiple locations, preventing stress concentration at any single weld zone and maintaining integrity under vibration and thermal cycling conditions.
Solution Approach 2:
Different regions of the overlap region are provided with different weld zone configurations. The front and rear ends of the overlap region (which experience higher stress during vibration) are ensured to have weld zones, while the binding capability varies along the longitudinal direction. This local differentiation optimizes the balance between manufacturing ease and reliability by placing weld zones where they are most needed.
2Ease of manufacture
If the distances from weld zones to longitudinal ends of overlap region are large, then manufacturing is easier with fewer constraints, but binding capability falls significantly and vibrations cause weld zone separation
Solution Approach 1:
The overlap region is segmented into multiple weld zones including at least one at the front end and one at the rear end of the overlap region. This ensures that the distances from weld zones to the longitudinal ends are minimized, maximizing binding capability while maintaining manufacturing feasibility through standardized welding positions.
Solution Approach 2:
The weld zone distribution is optimized locally at critical positions (front and rear ends of overlap region) where binding capability is most needed to prevent separation under vibration. This localized reinforcement at stress-critical areas achieves high binding capability without requiring excessive welding constraints throughout the entire overlap region.
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 multi-weld zone configuration effectively suppresses stress and enhances the binding force between electrode wires, minimizing the risk of separation and maintaining sensor functionality under severe vibration and thermal conditions.
Implementation Method 1
each second electrode wire is welded to the overlap section of the corresponding element electrode wire at a plurality of weld zones
Implementation Method 2
made of a kind of metal having a different thermal expansion coefficient than the element electrode wires
Data Source
AI summary
A temperature sensor includes a pair of element electrode wires extending rearward from a temperature-sensing portion. A pair of second electrode wires are welded to the element s electrode wires, and made of a kind of metal having a different thermal expansion coefficient than the element electrode wires. Each second electrode wire includes an overlap section overlapping with an overlap section of the corresponding element electrode wire over an overlap region in a longitudinal direction in which the overlap sections of the each second electrode wire and element electrode wire extend longitudinally. The overlap section of each second electrode wire is welded to the overlap section of the corresponding element electrode wire at weld zones arranged in the longitudinal direction, which include: one at a front-side end of the overlap region; and another at a rear-side end of the overlap region.