Thermistor Coil Temperature Sensor Miniaturization
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Solution Overview
Problem
Current temperature detection devices for stator coils in rotary electric machines face challenges in miniaturization and achieving high responsiveness due to increased thickness and reduced sensitivity caused by the integration of thermosensitive bodies within cases.
Innovation Solution
A temperature detection device featuring a thermosensitive body in direct contact with the coil element, enclosed by a resin with higher thermal conductivity, and a holder assembly that minimizes the thickness of the device while ensuring accurate heat conduction, eliminating the need for intervening molded products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil is bent and a case enclosing the thermosensitive body is used to attach the temperature sensor, then the temperature sensor can be fixed to the coil, but the thickness increases and the structure becomes larger
Solution Approach 1:
The invention extracts the thermosensitive body from the enclosing case structure and attaches it directly to the coil. The case is removed entirely, and the thermosensitive body is positioned in direct contact with the coil winding, eliminating the need for the case while maintaining secure attachment through the resin mold.
Solution Approach 2:
The thermosensitive body is nested directly within the resin mold structure that also encases the coil, eliminating the separate outer case. The resin mold serves multiple functions: it holds the coil, positions the thermosensitive body, and provides structural protection, consolidating what would otherwise be separate nested components.
2Ease of manufacture
If the thermosensitive body is built in the case, then the temperature sensor can be assembled, but the thermosensitive body comes into contact with the coil through the case which reduces sensitivity and responsiveness
Solution Approach 1:
The thermosensitive body is extracted from the case enclosure and placed in direct contact with the coil. This eliminates the thermal barrier of the case material between the sensor and the coil, allowing direct heat conduction from the coil to the thermosensitive body, thereby improving temperature detection accuracy and responsiveness.
Solution Approach 2:
The resin mold serves as the intermediary material between the thermosensitive body and the coil. This resin provides both mechanical support and thermal conduction pathways, replacing the case material as the mediating substance while optimizing for thermal performance rather than just structural function.
3Ease of manufacture
If a case and molded product are used to hold the thermosensitive body, then the temperature sensor can be assembled, but the device size increases and miniaturization is hindered
Solution Approach 1:
The invention merges the functions of the case, the mounting structure, and the thermal interface into a single integrated resin mold. This consolidation eliminates multiple separate components (case, mounting brackets, thermal paste layers) and reduces the overall device volume while maintaining all necessary functions of assembly, support, and heat conduction.
Solution Approach 2:
The resin mold performs multiple functions simultaneously: it provides structural support for the coil, positions and holds the thermosensitive body, creates thermal conduction pathways, and protects the internal components. This multi-functionality eliminates the need for separate specialized components, enabling miniaturization.
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 configuration allows for more accurate and responsive temperature detection by directly conducting heat from the coil to the thermosensitive body, promoting miniaturization and enhancing sensitivity through improved thermal conductivity.
Implementation Method 1
the thermosensitive body contact portion is in contact with the coil element while being enclosed with the first resin reservoir... the thermosensitive body is in contact with the coil element through a resin that is higher in thermal conductivity than the resin mold
Data Source
AI summary
A temperature detection device includes a thermistor element that includes a thermosensitive body configured to sense heat of a coil element and an electric wire electrically connected to the thermosensitive body, and a holder assembling the thermistor element to the coil element. The holder includes a thermosensitive body holder that holds a reinforcing portion of the thermosensitive body disposed sideways along a front surface of the coil element and is provided with a first resin reservoir enclosing a thermosensitive body contact portion of the thermosensitive body, and an electric wire holder holding the electric wire. The thermosensitive body contact portion is in contact with the coil element while being enclosed with the first resin reservoir. According to the temperature detection device, it is possible to more accurately detect temperature of a coil with high responsiveness while promoting miniaturization of the temperature detection device.