Wire-Mounted Temperature Sensor Retainers Without Insert Molding

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Solution Overview

Problem

The existing manufacturing process for rotating electrical machines, which involves embedment of temperature sensors in a mold member, is labor-intensive and costly, hindering the reduction of manufacturing costs.

Innovation Solution

A physical quantity detection device comprising first and second retainers that sandwich a wire and a physical quantity sensor fixed to the wire by these retainers, allowing for detection of the wire's physical quantity without the need for insert molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If temperature sensor is embedded together with wire in mold member using insert molding, then temperature detection is achieved, but manufacturing cost increases and manufacturing complexity increases

Engineering Contradiction:

Improvetemperature detectionVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent extracts the temperature sensor from the mold member structure and attaches it directly to the wire instead. This eliminates the need for insert molding process while maintaining temperature detection capability, thereby reducing manufacturing cost and complexity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent segments the temperature sensor assembly from the mold member into a separate component that is attached to the wire. This allows independent manufacturing of the sensor and wire, avoiding the complex insert molding process and reducing overall manufacturing cost

Inventive Principle:

Principle #1Segmentation

2Measurement precision

If temperature sensor is embedded together with wire in mold member using insert molding, then temperature detection is achieved, but device complexity increases

Engineering Contradiction:

Improvetemperature detectionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of embedding the sensor in the mold member (conventional approach), the patent inverts the approach by attaching the sensor to the wire itself. This simplifies the overall device structure and manufacturing process

Inventive Principle:

Principle #13The other way round (Inversion)

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 reduces manufacturing costs by eliminating the need for insert molding and allows for more efficient assembly and heat transfer, improving the accuracy of temperature detection.

Implementation Method 1

first and second retainers (2, 3) arranged to sandwich a wire (61 to 63)

Methodology Applied

Scientific EffectMechanical constraint: Mechanical Force

Implementation Method 2

physical quantity sensor (4) fixed to the wire (61 to 63) by the first and second retainers (2, 3)

Methodology Applied

Scientific EffectPhysical contact detection:

Data Source

PatentUS12301068B2Physical quantity detection device

Publication Date: 2025.05.13 PROTERIAL LTD

AI summary

A physical quantity detection device is provided with first and second retainers arranged to sandwich a wire, and a physical quantity sensor fixed to the wire by the first and second retainers. The physical quantity of the wire is detected by the physical quantity sensor, and the first and second retainers are fixed to the wire by being locked with each other.