FIELD OF THE INVENTION

The present disclosure discloses a temperature sensor assembly of a prime mover. More particularly, the present disclosure discloses an overmolded temperature sensor assembly of the prime mover.

BACKGROUND

In a two-wheeler, a prime mover is mounted or is installed on a frame assembly of the two-wheeler. Generally, due to generation of heat by friction of each moving part and combustion inside the prime mover, the prime mover of the two-wheeler is operated at a high temperature state. Hence to overcome the abovementioned problem, lubricating oil is used for lubricating the moving parts in the prime mover. This results in low friction characteristics at high temperature, which enables higher fuel efficiency. However, in some scenarios, the components of the prime mover are heated above a temperature resulting in overheating of the prime mover of the two-wheeler. Overheating increases risk of damaging of moving parts due to mechanical contact, surface wear and tear.

Conventionally, a temperature sensor assembly installed in the prime mover to measure temperature of the lubricating oil. The temperature sensor assembly includes a thermistor having terminals housed in a casing. However, the conventional temperature sensor assembly has disadvantages. For instance, the manufacturing of the conventional temperature sensors assembly requires complex and high precision machining operations such as the caulking process for sealing. Additionally, during molding of the components to form the temperature sensor assembly, terminals of the thermistor are exposed and comes in contact with the housing made up of brass due to vibration, that lead to insulation failure of the thermistor. Furthermore, the heat sink compound filling process has variation in quantity and thus enable air trap in heat sink compound after filling the housing, leads to degradation of response time performance of the sensor.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention. The aim of the present disclosure is to provide a temperature sensor assembly that can detect temperature of components at a cylinder head of a prime mover of a two-wheeler while eliminating requirement of additional components, requirement of caulking process and safeguarding a thermistor from the vibration.

In an embodiment, the temperature sensor assembly for the two-wheeler is disclosed. The temperature sensor assembly comprising a housing, and a thermistor. The housing comprising a top portion, a bottom portion, an opening, a plurality of crushing ribs. The opening is provided on the top portion adapted to provide access to a cavity in the housing. The plurality of crushing ribs is formed at a top edge of the opening. The thermistor is installed in the bottom portion and is adapted to detect temperature of a prime mover of the twowheeler. The thermistor comprising a pair of terminals, where the pair of terminals installed uprightly at the top portion by the plurality of crushing ribs.

In another embodiment, a prime mover in a two-wheeler is disclosed. The prime mover comprising a cylinder head, a temperature sensor assembly. The temperature sensor assembly is installed on the cylinder head to detect temperature of the prime mover. The temperature sensor assembly comprising a housing, a thermistor. The housing comprising a top portion, a bottom portion, an opening, a plurality of crushing ribs. The opening is provided on the top portion adapted to provide access to a cavity in the housing. The plurality of crushing ribs is formed at a top edge of the opening. The thermistor is installed in the bottom portion and is adapted to detect temperature of the prime mover of the two-wheeler. The thermistor comprising a pair of terminals, where the pair of terminals installed uprightly at the top portion by the plurality of crushing ribs.

In yet another embodiment, a two-wheeler is disclosed. The two-wheeler comprising a prime mover, a temperature sensor assembly. The temperature sensor assembly is installed at the prime mover to detect temperature of the prime mover. The temperature sensor assembly comprising a housing and a thermistor. The housing comprising a top portion, a bottom portion, an opening, a plurality of crushing ribs. The opening is provided on the top portion adapted to provide access to a cavity in the housing. The plurality of crushing ribs is formed at a top edge of the opening. The thermistor is installed in the bottom portion and is adapted to detect temperature of a prime mover of the two-wheeler. The thermistor comprising a pair of terminals, where the pair of terminals installed uprightly at the top portion by the plurality of crushing ribs. According to the present disclosure, the temperature sensor assembly has the crushing ribs, thermistor having the pair of terminals and other components where the pair of terminals are assembled with the crushing ribs ensuring ease of assembly with reduced number of components, thereby decreasing cycle time and process time. The present configuration decreases chances of potential failure at the time of assembly of the components.

To further clarify advantages and features of the present disclosure, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates a side view of a two-wheeler, in accordance with an embodiment of the present disclosure;

Figure 2A illustrates a perspective view of a cylinder head with a temperature sensor assembly, in accordance with an embodiment of the present disclosure;

Figure 2B illustrates an exploded view of the temperature sensor assembly, in accordance with an embodiment of the present disclosure;

Figure 2C illustrates a cut section of the housing with a pair of terminals on a molding table, in accordance with an embodiment of the present disclosure;

Figure 2D illustrates a sectional view of the temperature sensor assembly, in accordance with an embodiment of the present disclosure;

Figure 3A illustrates a top view of the housing with the pair of terminals, in accordance with an embodiment of the present disclosure;

Figure 3B illustrates a top view of the housing with the pair of terminals and a plurality of guide members, in accordance with an embodiment of the present disclosure;

Figure 3C illustrates perspective view of the housing with line DD, in accordance with an embodiment of the present invention; and

Figure 3D illustrates sectional view, taken along the line DD, of the housing with a plurality of crushing ribs, in accordance with an embodiment of the present disclosure. Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated assembly, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which invention belongs. The system and examples provided herein are illustrative only and not intended to be limiting.

It should be appreciated by a person skilled in the art that the terminology and structure employed herein is for describing, teaching, and illuminating some embodiments and their specific features and elements and therefore, should not be construed to limit, restrict or reduce the spirit and scope of the present disclosure in any way.

For example, any terms used herein such as, “includes,” “comprises,” “has,” “consists,” and similar grammatical variants do not specify an exact limitation or restriction, and certainly do not exclude the possible addition of one or more features or elements, unless otherwise stated. Further, such terms must not be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated, for example, by using the limiting language including, but not limited to, “must comprise” or “needs to include.”

Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more...” or “one or more elements is required.”

Unless otherwise defined, all terms and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by a person ordinarily skilled in the art.

Reference is made herein to some “embodiments.” It should be understood that as per one embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.

Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.

For the sake of clarity, the first digit of a reference numeral of each component of the present disclosure is indicative of the Figure number, in which the corresponding component is shown. For example, reference numerals starting with digit “1” are shown at least in Figure 1. Similarly, reference numerals starting with digit “2” are shown at least in Figure 2.

Figure 1 illustrates a left-side view of an exemplary two-wheeler 100 in accordance with an embodiment of the present disclosure. The two-wheeler 100 disclosed in the present disclosure has a prime mover 120 having a cylinder head 201 where a temperature sensor assembly 202 (as shown in Figure 2A) is installed for detecting change temperature at the cylinder head 201.

Figure 2A illustrates a perspective view of the cylinder head 201 with the temperature sensor assembly 202, in accordance with an embodiment of the present disclosure. Figure 2B illustrates an exploded view of the temperature sensor assembly 202, in accordance with an embodiment of the present disclosure. Figure 2C illustrates a cut section of the housing 205 with a pair of terminals 207 on a molding table 212 in accordance with an embodiment of the present disclosure. Figure 2D illustrates a sectional view of the temperature sensor assembly 202, in accordance with an embodiment of the present disclosure.

In one example, referring to Figure 2A-2D, the cylinder head 201 has a hole 201a to install the temperature sensor assembly 202 with the cylinder head 201. In one implementation, the temperature sensor assembly 202 comprises a housing 205, a thermistor 206 having the pair of terminals 207, a coupler 208, a seal member 204, a cavity 210. The housing 205 includes a top portion 205a, a bottom portion 205b, an extended member 205d. The extended member 205d is extended from the bottom portion 205b to support the thermistor 206. The thermistor 206 is installed in the housing 205 through various mechanism, for example, press fit. More precisely, thermistor 206 is installed in the bottom portion 205b of the housing 205. The thermistor 206 is adapted to detect temperature at the cylinder head 201. The thermistor 206 is hold/supported by the extended member 205d in the housing 205. Further, the pair of terminals 207 is welded to the thermistor 202 through various means, for example, resistance welding. The pair of terminals 207 are installed uprightly at the top portion 205a of the housing 205.

In one example, specifically, referring to Figure 2B and 2C, the coupler 208 is formed by attaching the housing 205 with a mounting insert 209 by the overmolding assembly. More precisely, the housing 205 is supported invertedly with a plurality of legs 301 (as shown in Figure 3 A) over an over molded tool 212. The over molded tool 212 includes an insertion core 211. The insertion core 211 holds the pair of terminals 207 installed in the housing 205, where the thermistor 206 is installed in the housing 205 along with the pair of terminals 207. The over molded tool 212 is used for over molding the housing 205, and the mounting insert gate design is provided for the overmolding process. More precisely, the single gate design provides one gate or opening in the over molded tool 212, during over molding assembly, through which molten plastic resin is provided to form the coupler 208/ coupler overmold 208. This avoids formation of weld line at the mounting insert area 209 of the temperature sensor assembly 202

Further, the coupler 208 has an extended member 208a. The coupler 208 is adapted to be attached with the housing 205 where the extended member 208a is supported in the extended member 205d of the housing 205 along with the thermistor 206. Further, the pair of terminals 207 (207a, 207b) are supported in a slot 208b of the coupler 208. This configuration reduces interference of the pair of terminals with surrounding components, thus maintaining efficiency of the pair of terminals 207. The seal member 204 is attached with the coupler to form leak proof temperature sensor assembly 202.

In one example, referring to Figure 2A and 2D, the cavity 210 of the temperature sensor assembly 202 is coaxial with the hole 201a of the cylinder head 201 to attach the temperature sensor assembly 202 with the cylinder head 201 through different attachment elements, for example, fasteners 203. This configuration ensures requirement of reduce number of components, hence reduced cycle time and process time. Therefore, reduces overall potential failure.

Figure 3A illustrates a top view of the housing 205 with the pair of terminals 207, in accordance with an embodiment of the present disclosure, Figure 3B illustrates a top view of the housing 205 with the pair of terminals 207 and a plurality of guide members 305 in accordance with an embodiment of the present disclosure. Figure 3C is a perspective view of the housing 205 with line DD, in accordance with an embodiment of the present invention. Figure 3D illustrates sectional view, taken along the line DD, of the housing 205 with a plurality of crushing ribs 306, in accordance with an embodiment of the present disclosure.

Referring to Figure 3A to 3D, the extended member 205d having a diameter D2 is tapered from the bottom portion 205b having a diameter DI and a top portion 205a having a diameter D3. The diameter D2 is smaller than a diameter D3 of the top portion 205a and a diameter DI of the bottom portion 205b. This implies that area of the top portion 205a is larger than area of the bottom portion 205b and the extended member 205d. In this regard, the top portion 205a of the housing 205 comprises an opening 307 and a plurality of vertically extended members 302 provided on the top portion 205a of the housing 205. The plurality of vertically extended members 302 is disposed between the plurality of legs 301. The plurality of vertically extended members 302 is disposed diametrically opposite along a top edge 310 of the opening 307 to form a plurality of slots 308.

In one example, referring 3C and 3D, the plurality of slots 308 includes a plurality of crushing ribs 306 for installing the thermistor 206 with the pair of terminals 207 in the housing 205, where at the time of assembly, the pair of terminals 207 crushes the crushing ribs 306 and disposed uprightly at top portion 205a of the housing 205.

Further, referring to Figure 3B, the plurality of slots 308 also includes a resting joint 304 for supporting the pair of terminals 207 in the housing 205. The plurality of crushing ribs 306 (as shown in Figure 3D) and the resting joint 304 is formed at the top edge 310 of the opening 307. Further, the plurality of the crushing ribs 306 and the resting joint 304 are provided to install the thermistor 206 with the pair of terminals 207 in the housing 205.

More precisely, the plurality of crushing ribs 306 install the pair of terminals 207 uprightly at the top portion 205a of the housing 205 such that a lead member 207a, 207b of the pair of terminals 207 is supported in the coupler 208. Further, the resting joint 204 supports the pair of terminals 207 on the top portion 205a of the housing 205. More precisely, a base member 207c, 207d of the pair of terminals 207 crushes the plurality of crushing ribs 306 and is supported by the resting joint 304 in the housing 205 such that the thermistor 206 is supported in the extended member 205d of the housing 205.

In one example, the extended member 205d has a cavity, where the opening 307 provides access to the cavity in the housing 205. The cavity has a plurality of guide members 305. The plurality of guide members 305 is provided at a bottom portion of the extended member 205d in the cavity. The plurality of guide members 305 hold the thermistor 206 in the extended member 205d of the housing 205. This ensures rigid and stable configuration of the thermistor 206 in the housing 205 and restrict entry of air which can affect the performance of thermistor 206, thus maintains the efficiency of the thermistor 206. Hence, also eliminates interference caused due to vibration, in the thermistor 206.

In one example, the housing 205 includes a plurality of side edges 305. The plurality of side edges 305 includes a plurality of melting ribs 303. The plurality of melting ribs 303 melts and act as an adhesive member to attach the coupler 208 with the housing 205 during the overmolding process. Further, the coupler 208 is attached with the housing 205 in such a way that the lead 207a, 207b of the pair of terminals 207 is supported in the slot 208a of the coupler 208. Further, the extended member 208a of the coupler 208 is supported in the cavity of the extended member 205d of the housing 205 along with the thermistor 206. This configuration ensures rigid attachment of the coupler 208 with the housing 205, restrict entry of foreign materials, and ensures a closed, compact light weighted structure of the temperature sensor assembly 202.

As would be gathered, the temperature sensor assembly 202 of the present disclosure offer a comprehensive approach for detecting temperature change at the cylinder head 201 in the prime mover 120 with reduced number of components while maintaining the efficiency of the temperature sensor assembly 202. This also reduces a cycle time and the manufacturing time, thereby reducing number of potential failures. The configuration as disclosed involves the overmolding process which reduces manufacturing cost of the temperature sensor assembly 202. In the present configuration, attachment of the coupler 208 with the housing 205 ensures a leakage proof configuration of the temperature sensor assembly 202. Further, in the present configuration, as the thermistor 202 is disposed in the housing 205 and is hold by the plurality of guide member 305, this ensures that the thermistor 206 is protected from any damages and also, eliminates insulation loss. Further, this configuration eliminates entry of foreign material in the temperature sensor assembly 202, thus maintaining efficiency of the temperature sensor assembly 202.

While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.