Thermocouple Temperature Sensor Assembly With Insulation-Piercing Contacts
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Solution Overview
Problem
Existing temperature sensors with thermocouples are complex to manufacture and expensive, and they suffer from measurement errors due to the distance between the thermocouple free ends and the reference temperature sensor on the circuit board.
Innovation Solution
The temperature sensor features a contact element with a measuring cable contact section equipped with a cutting element that cuts through the insulation of the measuring cable to establish an electrical connection with the conductor, allowing for a simple and reliable assembly without the need for additional connection elements like screws or crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional connection methods (screws, crimping) are used to connect thermocouple cables to the printed circuit board, then the connection is mechanically strong, but the manufacturing process becomes complex and expensive
Solution Approach 1:
The patent combines the cutting function and electrical contact function into a single integrated contact element. The contact element includes cutting edges that cut through the cable insulation and simultaneously establish electrical contact with the conductor, eliminating the need for separate cutting and connection operations. This merging of functions simplifies the manufacturing process while maintaining reliable electrical connection.
Solution Approach 2:
The contact element performs self-cutting and self-contacting during the insertion process. As the contact element is inserted into the receptacle, its cutting edges automatically cut through the insulation and establish electrical contact with the conductor without requiring additional manual operations or tools. This self-service mechanism reduces manufacturing complexity and cost.
2Adaptability or versatility
If the thermocouple free ends are positioned far from the reference temperature sensor on the circuit board, then the measurement range is extended, but measurement errors increase due to temperature differences
Solution Approach 1:
The patent incorporates a heating element that pre-heats the circuit board and surrounding structures to match the temperature of the thermocouple measurement point. By preliminarily adjusting the temperature of the reference environment, the system compensates for temperature differences between the thermocouple free ends and the reference sensor, thereby maintaining measurement accuracy while allowing greater distance between components.
3Reliability
If multiple separate connection elements and connection steps are used, then the electrical connection is reliable, but the assembly time and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functions (cutting insulation, establishing electrical contact, and mechanical retention) into a single contact element that is inserted in one operation. This eliminates the need for multiple separate connection elements and multiple connection steps, thereby increasing assembly speed while maintaining reliable electrical connection through the integrated design.
Solution Approach 2:
The contact element is pre-configured with cutting edges and contact surfaces in the correct positions and orientations. During insertion, all necessary actions (cutting and contacting) are performed in the correct sequence automatically, eliminating the need for multiple manual steps and improving productivity without compromising connection reliability.
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 solution simplifies the manufacturing process, reduces costs, and ensures accurate temperature measurement even under hostile conditions and high vibrations, as the electrical contact performs well without being critical of contact resistance.
Implementation Method 1
at least one cutting element is arranged, which is provided and arranged in order to cut through an insulation enclosing an electrical conductor of the measuring cable
Implementation Method 2
If two electrically conductive measuring wires made of different metallic materials are connected to one another and if this connection point and the free ends of the measuring wires are exposed to different temperatures, a thermal voltage is generated between the free ends, the strength of which is directly proportional to the temperature difference
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a Temperature sensor having a housing (10) in which a printed circuit board (30) is at least partially accommodated, the temperature sensor having a thermocouple (20) which has a first and a second measuring cable (21, 22), the measuring cables (21, 22) are electrically conductively connected to one another at a first contact point at a first end and are contacted in the region of a line section, preferably in the region of their second end, at a second contact point in each case by means of a contact element (40) with an electrical circuit, preferably an ASIC (31), of the printed circuit board (30). In order to reduce the assembly effort the invention suggest that at least one of the contact elements (40) has a measuring cable contact section (46) on which at least one cutting element (47.3) is arranged, which is provided and arranged in order to cut through an insulation (23) enclosing an electrical conductor (24) of the measuring cable (21, 22), and in that the cutting element (47.3) and/or a contact section (48.1, 48.2) adjoining the cutting element (47.3) establishes an electrical connection with the electrical conductor (24).