Reinforced flexible temperature sensor
A stator winding temperature sensor including at least one sensing wire for connecting to a stator. The sensor also includes a body, including a core material comprising a polyimide substrate having an acrylic adhesive surrounding at least a portion of the sensing wire, and a laminate material over the core material. The body has a thickness adapted to protect the sensing wire. The sensor includes a lead wire for connecting to an external monitoring device. The sensing wire is electrically connected to the lead wire at a lead step portion of the sensor. The sensor further includes a tab extending from the lead wire and encompassing the lead step, the tab including a flexible zone where the tab is surrounded by a polyimide and an adhesive but is not surrounded by fiberglass.
1. A temperature sensor for sensing temperature of a stator and communicating the sensed temperature to an external monitoring device, comprising:
at least one sensing wire, the sensing wire adapted to be fit to the stator and adapted to sense temperature of the stator;
a fiberglass body, including:
a core material comprising a polyimide substrate having an acrylic adhesive surrounding at least a portion of the sensing wire; and
an epoxy laminate material over the core material;
a lead wire for connecting to the external monitoring device;
a lead step where the sensing wire is electrically connected to the lead wire; and
a tab extending from the lead wire and encompassing at least a portion of the lead step, the tab comprising a flexible portion extending at least partially over a length thereof, the flexible portion of the tab comprising a flexible conductive circuit between and connecting the at least one sensing wire to the lead wire, wherein the tab protects the lead step and the sensing wire in a region where the sensor is adapted to extend over an end of the stator.
2. The sensor of claim 1 , wherein the at least one sensing wire includes a platinum sensing wire.
3. The sensor of claim 1 , wherein the sensing wire is adapted to be friction fit to a stator.
4. The sensor of claim 1 , wherein a thickness of the fiberglass body is approximately 0.04 inches.
5. The sensor of claim 1 , wherein a thickness of the fiberglass body is greater than approximately 0.04 inches.
6. The sensor of claim 1 , wherein the lead wire includes an 18 gage lead wire.
7. The sensor of claim 1 , wherein a length of the tab is approximately 2.375 inches.
8. The sensor of claim 1 , wherein the at least one sensing wire includes a copper sensing wire.
9. The sensor of claim 1 , wherein the lead step comprises a fiberglass body including an epoxy laminate material over at least a portion of the tab, and a polyimide and an adhesive over at least a portion of the fiberglass body.
10. The sensor of claim 9 , wherein the adhesive comprises an acrylic adhesive.
11. The sensor of claim 9 , wherein a portion of the tab between the lead step and the fiberglass body surrounding the core material and sensing wire is surrounded by a polyimide and an adhesive but is not surrounded by fiberglass.
12. The system of claim 11 , wherein the stator winding temperature sensor is adapted to measure operating temperature of the stator based on a sensed change in resistance in the at least one sensing wire.
13. The system of claim 1 , wherein the external monitoring device includes a personal computer.
14. A method for manufacturing a temperature sensor for sensing temperature of a stator, comprising:
fitting a sensing wire to the stator to sense temperature of the stator;
surrounding at least a portion of the sensing wire with a core material comprising a polyimide substrate having an acrylic adhesive;
surrounding the core material with an epoxy laminate material to form a fiberglass body;
electrically connecting a lead wire to an external monitoring device; and
electrically connecting the sensing wire to the lead wire at a lead step having a fiberglass body surrounding at least a portion of an elongated tab which is laminated with a polyimide substrate having an acrylic adhesive,
wherein the elongated tab extends from the lead wire and encompasses the lead step to protect the lead step and the sensing wire in a region where the sensor is adapted to extend over an end of the stator, and wherein at least a portion of the elongated tab comprises a flexible portion, the flexible portion comprising a flexible conductive circuit between the sensing wire and the lead wire for connecting the sensing wire to the lead wire.
15. The method of claim 14 , wherein fitting a sensing wire to the stator includes friction fitting the sensing wire to the stator.
16. The method of claim 14 , wherein fitting a sensing wire to the stator includes fitting a platinum sensing wire to the stator.
17. The method of claim 14 , wherein surrounding at least a portion of the sensing wire with a fiberglass body includes surrounding the sensing wire with a fiberglass body having a thickness of greater than approximately 0.04 inches.
18. The method of claim 14 , wherein electrically connecting a lead wire to an external monitoring device includes electrically connecting an 18 gage lead wire.
19. The method of claim 14 , wherein providing an elongated tab includes providing a tab having a length of at least approximately 2.375 inches.
20. The method of claim 14 , wherein electrically connecting the sensing wire to the lead wire at the lead step includes electrically connecting the sensing wire to a portion of the elongated tab which extends beyond the lead step and is surrounded by a polyimide substrate having an adhesive but not surrounded by fiberglass.