The invention relates to a heater for a sensor, to a heated sensor and to a radiation sensing method according to the preamble of the independent claims.
Radiation sensors are sensors that convert radiation into an electrical signal. The conversion is in many cases not direct, but indirect in that incident radiation is converted by absorption into a rising temperature, and this temperature—or the resulting temperature change—leads to an electrical signal. Naturally, then, the signal is relatively weak because also the temperature change is relatively weak because the incident radiation has relatively low power. The incident radiation (radiation to be detected) may be predominantly infrared radiation of a wavelength larger than 800 nm.
For such sensors, significant efforts were spent so far for minimizing the effects of thermal noise superimposed on the intermediate thermal signal generated by the incident radiation. A first step of minimizing thermal noise is separating the radiation sensitive portions from the environment as far as possible for avoiding the intermediate thermal signal being short-circuited to thermal ground. Accordingly, sensitive portions of a radiation sensor are usually held on a thin membrane with almost no thermal mass that itself is supported by a frame-like substrate. The substrate has a relatively high thermal mass and may be considered to be thermal ground. Sensitive portions may then be situated on the membrane distant from the substrate.
Thermopiles have cold and hot contacts, and the incident radiation is detected by a temperature difference generated between the hot and the cold contacts by the incident radiation. The incident radiation is guided towards the hot contacts so that they are heated by it above ambient temperature, whereas the,cold contacts are kept at ambient temperature and do not receive the incident radiation so that the temperature difference necessary for detection can develop. In thermopile sensors, the cold contacts are often thermally connected to the substrate as thermal ground for keeping their temperature at ambient temperature. The hot contacts, however, are usually held by the membrane only distant from the substrate/frame. Since the membrane is thin, its mass is almost zero and its thermal capacity may be neglected. Then, except the ambient gas/air, the sensitive portions are disconnected from immediate contact to the environment with high heat capacity. This gives a first success in thermally stabilizing radiation sensors, particularly in situations where the sensor is in thermal equilibrium (constant, equal ambient temperature).
But thermal equilibrium is not always given because the ambient temperature of the sensor may change. In use, the ambient temperature of radiation sensors often changes rapidly. For example, in air conditioning applications, the air flow passing by a sensor may more or less immediately change its temperature from say 17° C. to 27° C., for example upon changed command values. When the ambient temperature changes, the internal temperature of the sensor element itself will also change until thermal equilibrium has been reached again. A changing ambient temperature will cause a temperature change going through the sensor from outside to inside. Then, heat conduction by circulating ambient air/gas and also through the membrane still constitutes recognizable sources of thermal noise, particularly when in thermopile sensors the temperature change reaches the hot and cold contacts at different points of time so that a temperature difference is generated that is not caused by the radiation to be detected, but by the time differences of a temperature change reaching hot and cold contacts. Until the thermal equilibrium is reached, measurement results may again be uncertain to some extent.
For minimizing this effect, placing also the cold contacts of thermopiles on the membrane distant from the support/substrate serves to equalize thermal coupling of hot and cold contacts to some extent to the ambience so that time differences of changes of ambient temperature changes reaching the hot and cold contacts become smaller.
For further minimizing the effect of changing ambient temperature it has shown that actively heating (pre-heating) the sensor in a certain manner reduces the effects of changing ambient temperature on the sensor output signal.
a shows Figures from U.S. Pat. No. 6,626,835 B1. FIG. 1 thereof shows a sensor element 71 accommodated in a casing 72 and immediately attached to a radiation-permeable window 79. At the connecting portion between window 79 and casing 72 a heating element 73 is provided. FIG. 5 of the same publication shows a sensor element 20 provided on the one surface of a casing bottom 72, wherein on the other surface thereof a heating element 73 is provided.
b shows Figures from PCT/US 2009/061842. FIG. 3 thereof shows heating resistors 73 attached to a thermal shield 75, wherein the thermal shield accommodates a sensor. FIG. 7 of the same publication shows a radiation sensor accommodated in a thermal shield 75, wherein a heating element 73 is thermally coupled with the sensor 72.
The disadvantage of known sensor heating constructions are difficulties in the mechanical and/or electrical and/or thermal coupling of the heater with the remaining structures of the sensor. Besides, known ways of using heated sensors have a relatively high consumption of energy, this being particularly disadvantageous in devices with battery power supply.
Preferably, the invention provides a heater which can mechanically, electrically and thermally easily be connected to the sensor to be heated. Further, preferably the invention provides a sensor having an easily attachable heater, and optionally to provide a sensing method with a heated sensor exhibiting reduced power consumption.
Preferably, these aims are accomplished by the features of the independent claims. Dependent claims are directed on preferred embodiments of the inventions.
In a first aspect, the invention provides a heater comprising a resistive electric heating structure held in shape by some kind of carrier or substrate, the heater having a connecting portion for electrically connecting the heating structure to an outside terminal of the sensor. In such an arrangement, a heater can easily be coupled with the sensor to be heated, both electrically, mechanically and thermally.
The heater may comprise a rigid substrate that may be plate-shaped and on which the heating structure is formed. The heater may be an independent device that is separately attachable to the sensor either before the final assembly of the sensor or after its otherwise final assembly. The heater substrate may show on at least one of its surfaces a form fit to a surface of the sensor to be equipped with the heater.
The heater substrate may comprise through-holes or recesses allowing external sensor terminals to pass through or pass by the heater so that an immediate electrical contact to at least one of the terminals can be established.
The outer shape (plan view contour) of the heater substrate may be the same as that of a plan view contour of the sensor to be equipped with the heater.
The heating structure may be a printed conductive pattern or line which may constitute an elongated conductor of an overall desired resistance. It may be formed from a conductive paste. The conductor may be meandering on the substrate surface according to a desired pattern for covering, and thus heating, the desired surface portions. One end or both ends of the meandering conductor may be directly connected to outside terminals of the sensor.
The heater may comprise circuitry, particularly control circuitry. It may comprise a temperature sensor or a terminal for receiving a temperature signal from an otherwise provided temperature sensor, particularly from a temperature sensor inside the radiation sensor. The control may be a forward control or a feedback control.
The material of the conductive heating structure may be of practically constant resistance over temperature (change of less than 5% in a nominal operating temperature range) or may rise with rising temperature (PCT—positive temperature coefficient).
The sensor may be formed as a housing with solderable wires extending out of one of the housing surfaces, or it may be a surface mounted device (SMD) with soldering bumps or contact pads on one or more surfaces thereof.
In a further aspect, the invention provides a method of sensing radiation from an object, comprising the step of pre-heating a sensor, wherein the pre-heating target temperature is a temperature or temperature range below an expected temperature of the object and/or a temperature or a defined temperature range that is a defined temperature above the ambient temperature of the sensor.
In the following, embodiments of the invention will be described with reference to the attached drawings in which
a and 2b are schematic views of embodiments of the heater,
The sensor may have several contact wires or terminals 14 for connecting the sensor with external circuitry for supplying energy to the sensor and for supplying signals to the sensor and away therefrom. Signal input and output may be analogue or digital, and if digital parallel or serial. The inside construction of the sensor in certain embodiments is shown
15 is a heater for the sensor. In the shown embodiment, it is separately manufacturable from the sensor and can, as a unit, be attached thereto. In the shown embodiment, it is attachable to the underside of sensor 10 and may mechanically be fixed at sensor 10 by glue or resin, which is preferably of relative good heat conductivity for establishing not only the mechanical contact but also good thermal contact. Generally, the heater 15 shows for at least a portion of its surface a form fit to a surface or a surface portion of the sensor 10 so that an intimate contact for establishing good thermal connection amongst heater 15 and sensor 10 is given.
The heater 15 may, but needs not, comprise a circuit 22 thereon, suitable for controlling current flow through the heating structure 21.
The outer contour of the heater substrate 20 may be such that it matches, or is smaller than, the outer contour of the mounting surface of the sensor 10. In the shown examples, the sensor base plate 12 may be of round/circular shape, and the heater substrate 20 may have a matching shape, and particularly a diameter D same as, or smaller than, that of sensor base plate 12.
Power supply to the heating structure 21 may be made such that at least one terminal of the heating structure 21 is directly connected to an external connection terminal 14 of sensor 10.
b shows an alternate design. Substrate 20 is formed such that it gets close to some or all of the external terminal wires 14 of sensor 10. “Close” in this context may mean a distance smaller than 1 mm, preferably smaller than 0.5 mm, or less than a cross-sectional dimension (e.g. diameter) of wire 14, or less than 50% thereof. Then, also the heating structure 21 can contact at least one external terminal wire 14 of sensor 10.
The dashed line in
The heating structure 21 may be a printed conductive line, e.g. formed from a conductive paste, which may constitute an elongated conductor of an overall desired resistance. It may be formed by known processes. The heating structure may comprise one or more calibration portions for adjusting its characteristics, particularly its resistance, after its first manufacturing. Adjustment may, for example, be made by laser trimming by burning away conductive portions for increasing resistance of the heating structure.
Electrical signals from the sensor elements 33 are led via bond contacts 36 to external terminals 14 of the sensor and/or to internal circuitry 35 of the sensor, which in turn may be connected to external terminal wires. The sensor 10 may further comprise a temperature sensor 34 for sensing the internal temperature of the sensor and providing a related signal either to an external terminal 14 and/or to internal circuitry 35 for further use there.
In
Optionally, in addition to the base-plate 12, the sensor may comprise an internal substrate 37 such as a circuit board carrying several or all of the installations (31-36) inside the sensor. For improving heat flow from the heater 15 towards the inside of the sensor 10 a construction may however be preferred that does not have an additional internal substrate 37 in addition to the sensor base plate 12. Then, particularly the sensing portion 31-33 is directly mounted on the sensor base-plate 12. Internal connections of the components in the sensor housing may be made by bond wiring and/or by printed wiring on the housing base plate 12 or the internal substrate 37.
But instead of being attached to an outside surface of sensor 10, the heater 15 may also be attached to an inside surface of the sensor 10, for example to the upper surface of base plate 12 or to the lower surface or upper surface of an internal substrate 37. It is pointed out that in these cases the heater 15 needs not necessarily to have an own substrate 20. Rather, the sensor base plate 12 or the internal substrate 37 of sensor 10 may serve as heater substrate 20. Such embodiments are particularly suited for SMD sensors where the lower surface is designed to immediately contact external structures such as a printed circuit board so that it is not accessible for mounting the heater 15 to the outside surface. But just as in the earlier embodiments, the plate/substrate serving as the heater substrate 20 may have through-holes 29 and/or notches 28 permitting external contacts to pass through or pass by. And as mentioned above, the heating structure 21 may directly be connected to at least one of the external terminals 14 which may be terminal wires as shown in
The external terminals 14 are therefore exchanging energy and signals with the sensor inside. At least one of them may also directly be connected to the sensor element 33. Box 20 in
Further provided is a control circuit 22 that may control current flow through the heating structure 21. Control may be made for maintaining a target temperature or a target temperature range. Control may be made in accordance with a temperature sensor 42 that may also be provided on the heater substrate 20. The sensor may be connected with one terminal thereof with an external terminal 14 of the sensor. Another terminal of sensor 42 may be connected with the control circuit 22 of heater 15. This renders a feedback structure in that temperature information of the temperature generated by the heating structure 21 is fed back via sensor 42 to the control circuit 22. But instead of a feedback structure, control may also be made without feedback.
Instead of having an own sensor 42, the heater 15 may also receive a signal from a temperature sensor 34 inside sensor 10, as indicated by dashed line 41. It is pointed out in this context that one or more of the external terminals 14 of the sensor 10 may be provided for the sole purpose of contacting an outside heater 15. This option is indicated by terminal 14a in
The maximum operating voltage of the heater may be below 20 V and may be a usual battery voltage such as 9V or a multiple of 1.5 V. A controller may control the effective voltage applied across the terminals of the heater to be same as, or lower than, the maximum operating voltage. The control may comprise or be a pulse width modulation.
The substrate 20 of heater 15 may be a rigid substrate. It may be made of ceramics, particularly alumina ceramics. It may have a thickness t of less than 1 mm, preferably less then 0.5 mm. In an alternative embodiment, the substrate may be or comprise a flexible material, such as a plastic sheet or film or a resin sheet or film, e.g. Mylar, of appropriate shape and stiffness.
The wiring pattern of the heating structure 21 in the
As said above, the sensor element 33 may be a pyro-electric element, a bolometer or a thermopile. It may comprise “hot” contacts 33a held above orifice 38 on membrane 32 and may comprise cold contacts 33b that may be situated above the substrate 31 to be in close thermal contact therewith (as shown in
A sensing method may comprise controlling the temperature at a portion inside sensor 10 by a sensor heater 15 to a certain target temperature or to fall into a target temperature range preferably before the actual measurement values are taken. The target temperature or target temperature range may be chosen to coincide with, or include, an expected temperature of a measurement object emitting infrared radiation. In thermometer applications for humans, for example, the expected temperature may be around 35° C. in the case of ear thermometers. The target temperature may then be 35° C. or a temperature range (+/−0.5° C., +/−1° C.) around it. This would minimize temperature distortions because the changing ambient temperature would not be experienced by the sensor because it (or its relevant portions at least) are already at the temperature of the new environment (the human ear channel, for example).
In another embodiment it may be desirable to keep the temperature at a lower value or value range than the expected temperature, for example by a certain amount (first difference temperature) below it (for example at least a value of 3° C. to 7° C. below the expected temperature). This decreases heating power and decreases the time required for heating up the sensor 10 by heater 15 upon switch-on and increases sensitivity. A further control goal may then be to keep the temperature by a certain amount (second difference temperature, e.g. 3° C. to 7° C.) above the present ambient temperature (i.e. in thermometer applications usually room temperature). For example, a control goal may be to bring the temperature at the relevant sensor portions to a temperature of 7° C. above a present equilibrium temperature. When then the thermometer is inserted into the ear channel, it will take a certain time for the temperature rise to exceed the already established distance. In this time span measurement can be completed so that a changing temperature will not be experienced by the sensing portion although it was not completely heated up to the expected temperature of the measurement object (ear channel in the chosen example).
For minimizing heating effects in the sensor from unwanted external sources, the sensor may on its outside and/or on its inside be provided with thermal insulation means (not shown in any of the Figures). It may be a kind of jacket of thermally insulating material, preferably form-fitting, surrounding or covering significant portions of the sensor surface, for example a cylindrical jacket covering the outer periphery and possibly also parts of the top surface of sensor 10 as shown in
Also part of the invention is a thermometer comprising the described sensor and/or using the mentioned method. It may be an ear thermometer comprising an outer housing, the sensor, control circuitry, preferably user input means such as one or more switches, and a display and/or another appropriate analogue or digital signal output.
In this specification and the appended claims, same reference numerals shall denote same components. Features described herein shall be deemed combinable with each other also if this is not explicitly said, as far as a combination is not excluded by technical reason. Apparatus features shall be considered as disclosure also of features of methods implemented by the mentioned apparatus features, and vice versa.
Number | Date | Country | Kind |
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10 2011 009 128.9 | Jan 2011 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2012/050886 | 1/20/2012 | WO | 00 | 8/22/2013 |