Thermal Anemometer Slit Grooves and Gold Plating
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Solution Overview
Problem
Conventional thermal mass air velocity sensors face issues such as vortex formation due to simple circular hole designs, increased resistance due to longer lead distances, and potential malfunctions during assembly of the heating element and temperature sensor.
Innovation Solution
The anemometer employs a thermal mass air velocity sensor with slit grooves on either side of the heating element and temperature sensor holes to minimize vortex formation and gold plating to reduce electrical resistance and improve connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple circular hole design is used for the heating element and temperature sensor, then the device complexity is reduced, but vortex formation occurs which degrades measurement precision
Solution Approach 1:
The circular hole is segmented into multiple slit grooves arranged radially. Each slit groove acts as an independent flow passage, dividing the flow path to eliminate vortex formation while maintaining structural simplicity. This segmentation approach resolves the contradiction by improving measurement precision through better flow characteristics without significantly increasing device complexity.
Solution Approach 2:
The slit grooves are arranged asymmetrically in a radial pattern rather than using a symmetric circular shape. This asymmetric configuration optimizes the flow distribution and eliminates vortex formation, thereby improving measurement precision while keeping the overall structure simple and easy to manufacture.
2Ease of manufacture
If longer lead wires are used to connect the heating element and temperature sensor, then the ease of manufacture is improved, but electrical resistance increases which degrades measurement precision
Solution Approach 1:
The lead wire connections are transitioned from a planar arrangement to a three-dimensional configuration by forming soldering holes at specific depths. This allows the leads to be connected more directly, reducing the effective path length and minimizing electrical resistance while maintaining ease of assembly through the hole formation process.
Solution Approach 2:
Soldering holes act as intermediary structures that facilitate the connection between leads and external circuits. These holes provide optimized electrical pathways that reduce resistance while simplifying the assembly process, effectively resolving the contradiction between ease of manufacture and measurement precision.
3Ease of manufacture
If the heating element and temperature sensor are assembled traditionally, then the ease of manufacture is maintained, but malfunctions occur during assembly
Solution Approach 1:
Soldering holes are formed in advance during the manufacturing process, preparing the substrate for subsequent lead connections. This preliminary action ensures proper positioning and alignment, preventing assembly malfunctions while maintaining ease of manufacture by integrating the connection preparation into the fabrication process.
Solution Approach 2:
The traditional mechanical assembly process is replaced with a combination of precision hole formation and soldering techniques. This substitution eliminates mechanical misalignment issues and assembly malfunctions, improving reliability while maintaining manufacturing ease through standardized processes.
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 the sensitivity and reaction speed of the anemometer, allowing for accurate measurement of very low flow rates by reducing ambient temperature dependence and minimizing electrical resistance.
Implementation Method 1
heat generated in a hot wire, that is, a heating element, of a small cross-section is differently conducted according to the moving speed of the fluid
Implementation Method 2
energy taken from the heating element due to the flow of a fluid (convection)
Data Source
AI summary
Proposed is an air velocity sensor (meter) for measuring the flow velocity of a fluid, particularly, the air velocity of gas. More specifically, proposed is a technical field related to an air velocity sensor which measures air velocity or temperature through the heat transfer of a fluid by using a hot wire, that is, a heating element, of a small cross-section, and which expands the surface areas of a temperature sensor, the heating element, and a soldering part in order to further improve the accuracy of a hot wire flow velocity sensor having higher accuracy, even with respect to a low flow velocity, than a general mechanical anemometer, so as to minimize resistance, and thus can easily measure very low flow rates by inducing a quick change in a current to quickly respond to minute changes in resistance and sensitively operate, that is, by improving reaction speed.