Gm Global Technolgoy Operations, Inc.

Delphi Technologies, Inc.

Michael James Boehm

Timothy M Betzner

Peter John Straub

Richard Darrell Kirkwood

Peter J Straub

David P O'Connell

A temperature sensor incorporating flexible circuit technology. A flexible circuit sensor subassembly is composed of a flexible printed circuit substrate on which is printed a sensor circuit. In a preferred example the flexible circuit sensor subassembly, the sensor circuit has a sensor at a distal end, as for example a surface mount device (SMD) thermistor, a plurality of trace pads at a proximate end, and an interconnecting conductive trace between each trace pad and the sensor. A crimp terminal is respectively crimped onto each trace pad to provide a flexible circuit sensor assembly, wherein the crimp terminals are configured as needed for interfacing with an external circuit. The location of the sensor may be selectively located anywhere on the conductive traces to thereby easily size the probe length of the flexible circuit sensor subassembly to suit a any particular application and fit into any housing. A housing id molded over the flexible circuit sensor assembly. The housing either alone or located in an external shell provides a temperature sensor for a particular purpose. In a variation of the flexible circuit sensor assembly, electronic components can be integrated with the sensor circuit to provide a smart sensor circuit, which may include multiple sensing devices.

Temperature sensor with flexible circuit substrate

The present invention generally includes a thermal sensor assembly for a vehicle application including an insert molded part having a thermistor/wire sub-assembly and terminal that are assembled with a 'F' crimp and resistance welded that are insert molded to a pre-mold or connector that has a shut-off plate seal on the terminal's insulation crimp. The invention provides a more robust package that is resistant to vibration, insulates the terminals from shorting and permits further handling of the sub-assembly without damage to the terminals. Further, the thermistor can be very small and a very small wire can be used to connect the terminal to the thermistor element. Because a smaller thermistor can be utilized, a much smaller probe tip can be design into the thermal sensor assembly. The insert molded part can either be a preform for press-fit applications or a male sensor connector for applications requiring a metal housing. The pre-molded plastic protects the terminals from short circuiting to the sensor shell or other terminal.

Thermal probe assembly with mold-over crimp sensor packaging

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Warren, OH, United States of America

Michael James Boehm