FIELD

[0001] The present disclosure relates to a temperature sensor, and particularly to a temperature sensor for measuring an average air temperature.

BACKGROUND

[0002] This section provides background information related to the present disclosure which is not necessarily prior art.

[0003] Temperature sensors may be used to measure an average temperature of air in an ambient environment. Some temperature sensors have a probe body that can include an air mixing location enclosed by a cover and an air guide slot through which ambient air can pass. The probe body gathers thermal energy from the ambient air and conducts the energy to a temperature response element, such as a negative temperature coefficient (NTC) thermistor. Thus, these devices provide indirect air temperature measurements. . However, in known devices air can escape from the air guide slot prior to proper mixing and temperature sensing, resulting in decreased accuracy. Furthermore, use of the enclosed probe body may result in slow response times.

[0004] Some other devices, e.g., point sensors, can include a single temperature response element, such as an NTC thermistor, exposed to the ambient air. These devices sense temperature at a distinct location rather than in a wider area, resulting in decreased accuracy in determining an average air temperature.

[0005] Thus, there is a need for average air temperature sensors that accurately measure an average air temperature. There is a further need for temperature sensors that have an improved response time.

SUMMARY

[0006] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0007] In one aspect, the present disclosure provides a temperature sensor. The temperature sensor includes a base, a cover, an interior compartment, and a temperature responsive element. The base includes a first base portion. The first base portion includes a front surface, a first interior surface, a second interior surface, a baffle plane, and a plurality of baffles. The first interior surface is disposed at a first angle with respect to the front surface. The second interior surface is adjacent to the first interior surface. The second interior surface forms a second angle with respect to the first interior surface. The baffle plane is substantially parallel to the front surface of the base and is disposed between the front surface and the second interior surface. Each baffle of the plurality extends from a front plane defined by the front surface to the baffle plane. Each baffle of the plurality is substantially parallel to the first interior surface. The cover is fixed to the base. The interior compartment is at least partially defined by the cover and the base. The interior compartment has a first interior compartment portion. The first interior compartment portion includes a mixing chamber and a first sensing region. The mixing chamber is at least partially defined by the first interior surface, the second interior surface, and the baffle plane. The first sensing region is adjacent to the mixing chamber. The temperature responsive element is at least partially disposed in the first sensing region.

[0008] The first angle can be greater than or equal to 40° and less than or equal to 50°. The first angle can be 45°.

[0009] The second angle can be greater than or equal to 135° and less than or equal to 145°. The second angle can be 140°.

[0010] The temperature sensor can also include a second base portion and a second interior compartment portion. The second base portion can be adjacent to and integrally formed with the first base portion. The second base portion can be a mirror image of the first base portion about an intermediate plane parallel to the baffle plane and opposite the front plane. The second interior compartment portion can be adjacent to the first interior compartment portion. The second interior compartment portion can be a mirror image of the first interior compartment portion about the intermediate plane.

[0011] The second interior compartment can include a second sensing region. The first interior compartment portion can be fluidly connected to the second interior compartment portion at respective first and second sensing regions.

[0012] The temperature responsive element can be a negative temperature coefficient (NTC) thermistor.

[0013] In certain other aspects, the present disclosure provides a temperature sensor. The temperature sensor includes a housing and a temperature responsive element. The housing includes a plurality of channels, a mixing chamber, an interior surface, and an outlet passage. The plurality of channels is configured to receive a fluid at an inlet. The mixing chamber is fluidly connected to the plurality of channels. The mixing chamber is configured to receive the fluid from the plurality of channels. The interior surface is adjacent to the mixing chamber. The interior surface is configured to direct air toward a sensing region. The outlet passage is fluidly connected to the mixing chamber and disposed downstream of the sensing region. The outlet passage is configured to receive the fluid from the mixing chamber and discharge the fluid from the housing. The temperature responsive element is disposed in the sensing region.

[0014] The temperature responsive element can be a negative temperature coefficient (NTC) thermistor.

[0015] The housing can further include a plurality of baffles. Each baffle can include a pair of opposing side walls. Each side wall can at least partially define one channel of the plurality of channels.

[0016] Each baffle can extend from a side of the housing to a baffle plane parallel to the side and disposed between the side and the interior surface so that the plurality of baffles is spaced apart from the interior surface to define the mixing chamber.

[0017] Each baffle can form a first angle with a side of the housing. As one example, the first angle can be greater than or equal to 40° and less than or equal to 50°.

[0018] Each baffle can form a second angle with respect to the interior surface. As one example, the second angle can be greater than or equal to 135° and less than or equal to 145°.

[0019] The temperature responsive element can be configured to sense an average temperature of the fluid.

[0020] In still other aspects, the present disclosure provides a temperature sensor. The temperature sensor includes a body, a metal plate, and a temperature responsive element. The metal plate extends from the body. The plate comprises a material having a high thermal conductivity. The temperature responsive element is disposed against a surface of the plate. The temperature responsive element is configured to sense an average temperature of a fluid.

[0021] As one example, the metal plate can have a high thermal conductivity of greater than or equal to 150 W/m -K at 0°C. As another example, the metal plate can have a high thermal conductivity of greater than or equal to 200 W/m -K at 0°C.

[0022] As one example, the metal plate can comprise aluminum (Al).

[0023] The metal plate can include a plurality of apertures configured to enable airflow around the temperature responsive element.

[0024] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0025] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0026] FIG. 1A is a front perspective view of an average air temperature sensor according to certain aspects of the present disclosure;

[0027] FIG. 1 B is a back perspective view of the average air temperature sensor of FIG. 1A;

[0028] FIG. 1 C is a bottom view of the average air temperature sensor of FIG 1A;

[0029] FIG. 2A is a perspective view of a base of the average air temperature sensor of FIG. 1A;

[0030] FIG. 2B is a top view of the base of FIG. 2A;

[0031] FIG. 3 is a perspective view of a cover of the average air temperature sensor of FIG. 1A;

[0032] FIG. 4 is a perspective view of another average air temperature sensor according to certain aspects of the present disclosure;

[0033] FIG 5A is a perspective view of a base of the average air temperature sensor of FIG. 4;

[0034] FIG. 5B is a top view of the base of FIG. 5A;

[0035] FIG. 6 is a perspective view of a cover of the average air temperature sensor of FIG. 4;

[0036] FIG. 7A is a perspective view of another average air temperature sensor according to certain aspects of the present disclosure; and [0037] FIG. 7B is a top view of the average air temperature sensor of FIG.

7A.

[0038] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0039] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0040] As generally shown in FIGs. 1A-3, an average temperature sensor 10 includes a housing 12, which may be made from a dielectric material. The housing 12 may be a two-piece housing comprising a base 14, a cover 16, and an interior compartment 18 that can be at least partially defined or enclosed by the base 14 and the cover 16. The base 14 includes a first end 20 and a second end 22. A connector block portion 24 extends from the second end 22.

[0041] The base 14 may include a front surface 26, a first interior surface 28 disposed at a first angle 30 with respect to the front surface 26, and a second interior surface 32 disposed at a second angle 34 with respect to the first interior surface 28. The interior compartment 18 may include a baffle plane 36 that is parallel to the front surface 26. As one non-limiting example, the first angle 30 can be greater than or equal to about 40° to less than or equal to about 50°, optionally about 45°. As one non-limiting example, the second angle 34 can be greater than or equal to about 135° to less than or equal to about 145°, optionally about 140°.

[0042] The base 14 may include a plurality of baffles 38. Each baffle 38 may extend from a front plane 40 defined by the front surface 26 to the baffle plane 36. One or more of the baffles 38 may be substantially parallel to the first interior surface 28. Some baffles 38 may not be parallel to the first interior surface 28. For example, some baffles 38 may be substantially perpendicular to the front plane 40. In other examples, each of the baffles 38 may be disposed at a distinct angle based on the desired fluid flow path.

[0043] The interior compartment 18 includes a plurality of channels 42, a mixing chamber 44, and a sensing region 46. The plurality of channels 42 is at least partially defined by the plurality of baffles 38 of the base 14. For example, the baffles 38 and the channels 42 may be alternately disposed and parallel to one another within the interior compartment 18 so that side walls 47 of the baffles 38 at least partially define the channels 42. Each channel 42 includes a respective inlet 48. The mixing chamber 44 is at least partially defined by the first interior surface 28 and the baffle plane 36. The mixing chamber 44 is fluidly connected to and downstream of the plurality of channels 42. The sensing region 46 is disposed adjacent to the mixing chamber 44, downstream of the mixing chamber 44, and fluidly connected to the mixing chamber 44.

[0044] A temperature responsive element 50 is disposed within the sensing region 46 of the interior compartment 18. The temperature responsive element 50 may be a negative temperature coefficient thermistor (NTC thermistor), by way of non- limiting example. The temperature responsive element 50 may part of a circuit subassembly (not shown). The circuit subassembly may include the temperature responsive element 50, a pair of leads, a pair of terminals respectively connected to the pair of leads, and one or more coatings or insulators.

[0045] The connector block portion 24 is configured to accommodate a plug- in type electrical connector to connect the average temperature sensor 10 to a circuit for monitoring an output, such as a voltage or current, for example, that can be correlated to average air temperature value. The connector block portion 24, therefore, houses the pair of terminals of the circuit subassembly (not shown), which is electrically connected to the temperature responsive element 50. The connector block portion 24 includes a connector receptacle 52 (as best shown in FIG. 1 C) that is configured to accommodate any of a variety of standard plug-in-type connectors that are well-known in the art.

[0046] The cover 16 may be fixed to the base 14 to form the housing 12. The cover 16 may include a first end 54 and a second end 56 that are aligned with the respective first and second ends 20, 22 of the base 14. The cover may include a bottom surface 58 that engages a top surface 60 of the base 14.

[0047] The average temperature sensor 10 is configured to measure an average temperature of a fluid, such as air in an ambient environment. More specifically, the plurality of channels 42 is configured to receive the fluid at the respective inlets 48. The mixing chamber 44 is configured to receive the fluid from the plurality of channels 42. The second interior surface 32 facilitates mixing of the fluid in the mixing chamber 44. That is, the fluid molecules flow into the mixing chamber 44 from the plurality of channels 42, collide with the second interior surface 32, and are directed back into the mixing chamber 44. The second angle 34 of the second interior surface 32 also facilitates flow of the fluid from the mixing chamber 44 toward the sensing region 46. The second angle 34 opens toward the sensing region 46 so that it forms a ramp from the first interior surface 28 to the sensing region 46. The temperature responsive element 50 is disposed in the sensing region 46 and is configured to sense an average fluid temperature. The fluid exits the housing 12 through an outlet passage 62. The outlet passage is fluidly connected to the sensing region 46. The outlet passage 62 is configured to receive fluid from the sensing region 46 and discharge the fluid from the housing 12.

[0048] Referring now to FIGs. 4-6, another average temperature sensor 70 according to certain aspects of the present disclosure is provided. The average temperature sensor 70 may include a housing 72. The housing 72 may generally include a base 74 and a cover 76. The base 74 may include a first base portion 78 and a second base portion 80. The first and second base portions 78, 80 may be adjacent and integrally formed. The housing 72 may further comprise first and second interior compartments 82, 84. The first interior compartment 82 may be at least partially defined or enclosed by the first base portion 78 and the cover 76. The second interior compartment 84 may be at least partially defined or enclosed by the second base portion 80 and the cover 76. The base 74 may further include first and second ends 86, 88. The second end 88 may include a connector block portion 90 extending from the second end 88.

[0049] The base 72 may include opposing first and second inlet surfaces 92, 94. Each inlet surface 92, 94 is similar to the front surface 40 of the average air temperature sensor 10 of FIGs. 1A-3. The base may further include an intermediate plane 95. The intermediate plane 95 may be substantially parallel to both the first inlet plane 96 defined by the first inlet surface 92 and a second inlet plane 97 defined by the second inlet surface 94. The intermediate plane 95 may be disposed between the first inlet plane 96 and the second inlet plane 97. The intermediate plane 95 may be equidistant between the first and second inlet planes 96, 97.

[0050] The first base portion 78 and the first interior compartment 82 may be similar or identical to the base 14 and the interior compartment 18 of the average temperature sensor 10 of FIGs. 1A-3. The second base portion 80 and the second interior compartment 84 may be a mirror image of the first base portion 78 and the first interior compartment 82, respectively, about the intermediate plane 95. The first and second interior compartments 82, 84 may be fluidly connected at a first sensing region interior compartment. 84. A temperature responsive element 102, such as an NTC thermistor may be disposed at least partially in the first and second sensing regions 98, 100.

[0051] The average temperature sensor 70 is configured to sense an average temperature of a fluid, such as air, in an ambient environment. The fluid may enter near the first and second inlet surfaces 92, 94. Thus, the average temperature sensor 70 is bidirectional. Fluid may exit adjacent the first and second sensing regions 98, 100.

[0052] The connector block portion 90 and the cover 76 may be similar or identical to the connector block portion 24 and cover 16 of the average temperature sensor of FIGs. 1A-3. The cover may include first and second ends 104, 106 that are aligned with respective first and second ends 86, 88 of the base 74. The cover 76 may include a bottom surface 108 and the base 74 may include a top surface 1 10. The bottom surface 108 of the cover 76 may engage the top surface 1 10 of the base 74 to form the housing 72.

[0053] With reference to FIGs. 7A-7B, yet another average temperature sensor 120 is provided. The temperature sensor includes a body 122 having a connector block portion 124. The body 122 may comprise a dielectric material. A plate 126 extends from the body 122. The plate 126 may have a base portion 128 and opposing side walls 130. The opposing side walls 128 may include a plurality of apertures 132.

[0054] A temperature responsive element 134 may be disposed on or against the plate 126, for example, on the base portion 128. The temperature responsive element 134 may be an NTC thermistor, by way of non-limiting example. The plate 126 may comprise a material having high thermal conductivity. The plate 126 may comprise a material having a thermal conductivity of greater than or equal to about 150 W/m -K at 0°C, optionally greater than or equal to about 200 W/m -K at 0°C. The plate 126 may comprise a metal, such as aluminum (Al), by way of non-limiting example.

[0055] The temperature responsive element 134 may be in contact with the plate 126 so that the temperature responsive element is configured to sense a temperature of the plate 126. The high thermal conductivity of the plate 126 enables it to quickly reach a temperature of the surrounding fluid or air. The relatively large surface area of the plate 126 compared to the temperature responsive element 134 enables the plate to gather thermal energy over a wide area rather than a discrete location so that an average temperature can be measured over the area rather than a specific temperature at a discrete location of the temperature responsive element 134. The plate 126, however, is not enclosed inside a casing. Instead, it is exposed to maximize fluid flow and mixing over its surface area. The plurality of apertures 132 in the plate 126 facilitates fluid flow through and around the plate 126 and near the temperature responsive element 134.

[0056] The connector block portion 124 of the body 122 is configured to accommodate a plug-in type electrical connector to connect the average temperature sensor 120 to a circuit for monitoring an output, such as a voltage or current, for example, that can be correlated to an average air temperature value. The connector block portion 124, therefore, houses the pair of terminals of the circuit subassembly (not shown), which is electrically connected to the temperature responsive element 134. The connector block portion 124 includes a connector receptacle (not shown) that is configured to accommodate any of a variety of standard plug-in-type connectors that are well-known in the art.

[0057] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.