Tubular Sensor Support With Integrated Component Recess

Solution Overview

Problem

Existing temperature sensors face challenges in achieving high measurement accuracy and response behavior while being easily integratable into media-carrying pipe or line systems without compromising the system's tightness, as they often require opening the pipe system, leading to potential leaks, or can only indirectly measure medium temperature.

Innovation Solution

A tubular carrier element with a partially open cavity that accommodates electrical or electronic components, such as measuring resistors, which is overmolded for protection and precise positioning, allowing for integration without opening the pipe system and enabling high measurement accuracy and optimized response times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the temperature sensor is immersed in the medium by opening the pipe system wall, then high measurement accuracy is achieved, but the system tightness is compromised and leaks may occur

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidsystem tightness

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The sensor is nested within the pipe system through an integrated sensor recess in the pipe wall. The sensor housing fits into this recess, allowing the sensor to be positioned close to the medium for accurate measurement while remaining enclosed within the pipe structure, thus maintaining system tightness without requiring wall openings.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

A thermally conductive paste is introduced as an intermediary substance between the sensor's measuring element and the pipe wall. This paste establishes efficient thermal contact, allowing the sensor to accurately measure medium temperature through the pipe wall without direct immersion, thereby preserving system tightness while achieving high measurement accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If the pipe wall is opened for sensor installation, then direct medium contact is achieved, but installation complexity and potential leaks increase

Engineering Contradiction:

Improvedirect medium temperature measurementVSAvoidinstallation simplicity

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The sensor is nested within the pipe system through an integrated sensor recess in the pipe wall. The sensor housing fits into this recess, allowing the sensor to be positioned close to the medium for accurate measurement while remaining enclosed within the pipe structure, thus maintaining system tightness without requiring wall openings.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

A thermally conductive paste is introduced as an intermediary substance between the sensor's measuring element and the pipe wall. This paste establishes efficient thermal contact, allowing the sensor to accurately measure medium temperature through the pipe wall without direct immersion, thereby preserving system tightness while achieving high measurement accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a non-invasive sensor design is used, then system tightness is maintained, but measurement accuracy and response time deteriorate

Engineering Contradiction:

Improvesystem tightnessVSAvoidtemperature measurement accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

A thermally conductive paste is introduced as an intermediary substance between the sensor's measuring element and the pipe wall. This paste establishes efficient thermal contact, allowing the sensor to accurately measure medium temperature through the pipe wall without direct immersion, thereby preserving system tightness while achieving high measurement accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The sensor is nested within the pipe system through an integrated sensor recess in the pipe wall. The sensor housing fits into this recess, allowing the sensor to be positioned close to the medium for accurate measurement while remaining enclosed within the pipe structure, thus maintaining system tightness without requiring wall openings.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 allows for precise and leak-free integration of sensors into media-carrying lines, maintaining system tightness while achieving high measurement accuracy and improved response behavior, enabling the sensor to accurately measure medium properties like temperature without reducing the flow cross-section.

Implementation Method 1

A thermally conductive paste establishes thermal contact between the measuring element and the inner wall of the housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3588028B1Electrical sensor

Publication Date: 2024.11.27 PGT THERMPROZESSTECHN

Figure 1
Figure 2
Figure 3

AI summary

The invention relates to a support element (1) for an electrical sensor (2), in particular for a temperature sensor, wherein the support element (1) is at least partially tubular and defines a cavity (3) that is open at least on one side. According to the invention, at least one receptacle (6) for an electrical or electronic component (7) is formed in a surface (4) facing the cavity (3) and/or in a surface (5) of the support element (1) facing away from the cavity (3). The invention further relates to an electrical sensor (2), in particular a temperature sensor, with a support element (1) according to the invention, and to a media-carrying line with an electrical sensor (2) according to the invention.