Temperature Sensor Intermediate Assembly for Uniform Overmolding
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Solution Overview
Problem
Existing fluid connectors for automobiles face issues such as corrosion, short-circuiting, and leaks, particularly when used with electrical conductive fluids, and existing solutions for temperature sensing often result in inconsistent thickness of overmolded thermoplastic material, affecting precision and robustness.
Innovation Solution
A method involving a temperature sensor with metal branches and electrical connection pins, secured by a plastic casing with flexible arms, allowing precise positioning and overmolding to achieve a uniform thickness of thermoplastic material, enhancing robustness and measurement precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensitive head of the sensor is in direct contact with the fluid, then temperature measurement reactivity is improved, but corrosion and short-circuiting risks increase
Solution Approach 1:
A thermoplastic material is introduced as an intermediary substance between the sensor's sensitive head and the fluid. This material allows thermal energy to pass through (maintaining measurement reactivity) while providing electrical insulation and corrosion protection. The thermoplastic acts as a mediator that transmits heat but blocks electrical current and chemical corrosion.
Solution Approach 2:
A thin thermoplastic layer is applied over the sensitive head, forming a flexible protective shell. This thin film maintains close thermal contact with the fluid for rapid temperature detection while providing the necessary protection against corrosion and electrical short-circuiting.
2Reliability
If a polymer or resin covers the sensitive head, then corrosion and short-circuiting risks are reduced, but thermal conduction properties deteriorate
Solution Approach 1:
The thickness of the thermoplastic material is precisely controlled and optimized. By adjusting this critical parameter, the material provides sufficient protection against corrosion and short-circuiting while maintaining adequate thermal conduction properties for accurate temperature measurement.
3Measurement precision
If the thickness of thermoplastic material over the sensitive head is reduced, then temperature measurement precision is improved, but manufacturing control becomes more difficult
Solution Approach 1:
A support structure is provided beforehand that defines the precise positioning of the sensitive head within the connector body. This preliminary structural arrangement ensures that when thermoplastic material is applied, it achieves the desired thin and uniform thickness without requiring complex manufacturing control processes.
4Manufacturing precision
If a cradle structure is used to hold the sensor, then positioning precision is improved, but tolerance accumulation increases
Solution Approach 1:
The complex cradle structure is removed and replaced with a simpler support structure that defines the sensor's position. This extraction of unnecessary structural elements reduces the number of interfaces and potential sources of tolerance accumulation, while still achieving the required positioning precision for thin thermoplastic application.
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 ensures a uniform and thin thermoplastic layer on the temperature sensor, improving measurement precision and robustness while minimizing corrosion and leaks, maintaining fluid flow integrity.
Implementation Method 1
providing two electrical connection pins, each having an attachment portion and a connection portion... assembling a plastic casing formed by at least two inserts positioned against the electrical connection pins... in order to form an intermediate assembly for the temperature measuring device
Implementation Method 2
To obtain precise and rapid detection of the temperature of the fluid, it is advantageous for the polymer or resin material placed on the sensitive head to exhibit good thermal conduction properties
Data Source
AI summary
An intermediate assembly for a temperature measuring device comprises: a temperature sensor including a measuring cell and two metal branches, two electrical connection pins each having an attachment portion and a connection portion, both of the metal branches respectively being electrically linked to both of the electrical connection pins, at their attachment portion; the attachment portions of the two pins extending in a main plane and an end of the measuring cell occupying a predetermined position with respect to a reference point of the electrical connection pins, a plastic casing formed by at least two inserts positioned against the electrical connection pins, on either side of the main plane, the casing defining a clamp to hold the measuring cell along at least one transverse axis normal to the main plane.