Coastal environment sensor housing with salt mist protection

Abstract

This utility model discloses a coastal environmental sensor housing with salt spray protection, belonging to the technical field of environmental sensor protection equipment. Key technical features include a mounting flange with a threaded connection at the top to the housing base. This application reduces gaps from the source by incorporating a mounting flange, a zinc-nickel alloy plating, a polytetrafluoroethylene (PTFE) salt spray protection coating, a bottom protection structure, and a top protection structure. The housing base, integrally cast from 316L stainless steel, provides double-layer protection, significantly enhancing the overall salt spray resistance of the housing base. In the bottom protection structure, a stepped sealing sleeve and a water-swellable sealing strip jointly strengthen the sealing at the connection between the mounting flange and the housing base. The water-swellable characteristic allows for flexible adaptation to gap changes, while the annular water channel and drainage hole promptly drain accumulated water, preventing chloride ions from accumulating at the joints.

Description

Technical Field

[0001] This utility model relates to the field of environmental sensor protection equipment technology, and in particular to a coastal environmental sensor housing with anti-salt spray treatment. Background Technology

[0002] In coastal environments, salt spray concentrations are extremely high, and the average annual relative humidity generally exceeds 85%. Coupled with the impact of sea spray, these factors cause continuous electrochemical corrosion and physical erosion on the sensor housing. As the "first line of defense" for the sensor, the salt spray resistance of the sensor housing directly determines the sensor's service life and monitoring accuracy.

[0003] Currently, existing solutions for preventing salt spray corrosion in coastal environmental sensor housings have significant problems: The two main approaches – relying on the inherent corrosion resistance of 304 stainless steel or applying an epoxy resin coating to ordinary carbon steel housings to isolate corrosive media – fail to effectively address corrosion issues at housing gaps and interfaces. These areas are prone to chloride ion accumulation due to water buildup and stress concentration, leading to crevice corrosion and pitting, which can result in rust and perforation within months. Even with the addition of ordinary rubber sealing rings, aging due to salt spray can cause them to fail, allowing corrosive media to seep in and damage the circuitry. Existing improvement methods involve multi-layered coatings, increasing weight and cost, and failing to address coating damage caused by repeated disassembly and reassembly. Applying anti-rust oil to the inside can cause volatile contamination of the sensor, affecting detection accuracy. Ultimately, this results in a significantly shorter average lifespan for coastal sensors compared to inland areas, drastically increasing maintenance costs.

[0004] To address this, a coastal environment sensor housing with salt spray protection is proposed. Utility Model Content

[0005] The purpose of this invention is to provide a coastal environmental sensor housing with salt spray protection, which can solve the prominent problems of existing salt spray protection solutions for coastal environmental sensor housings: the two main solutions, namely the mainstream 304 stainless steel material relying on its own corrosion resistance or ordinary carbon steel housing sprayed with epoxy resin coating to isolate corrosive media, have not effectively solved the corrosion problem at the gaps and interfaces of the housing. These areas are prone to chloride ion accumulation due to water accumulation and stress concentration, leading to crevice corrosion and pitting corrosion, and rust perforation can occur in as little as a few months. Even if ordinary rubber sealing rings are installed, they will fail due to salt spray aging, causing corrosive media to seep in and damage the circuit. In existing improvement methods, the superposition of multiple coatings increases weight and cost and cannot cope with the coating damage caused by repeated disassembly of the interface. Applying anti-rust oil to the inside will volatilize and pollute the sensor, affecting the detection accuracy. Ultimately, this results in the average service life of coastal sensors being much shorter than that of inland areas, significantly increasing the operation and maintenance costs.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a coastal environment sensor housing with anti-salt spray treatment, including a mounting flange, the top of which is threadedly connected to a housing base, the housing base being integrally cast from 316L stainless steel, the surface of the housing base being sequentially provided with a zinc-nickel alloy plating layer and a polytetrafluoroethylene anti-salt spray coating, the bottom of the mounting flange being provided with a bottom protection structure, the top of the housing base being provided with a top protection structure, and the outer side of the housing base being provided with a heat dissipation structure;

[0007] The bottom protective structure includes a stepped sealing sleeve fixedly connected to the top of the mounting flange. The inner wall of the stepped sealing sleeve contacts the outer side of the outer shell base. A water-swellable sealing strip is fixedly connected to the top of the stepped sealing sleeve. The water-swellable sealing strip is sleeved on the outer side of the outer shell base. An annular water guide groove is provided on the top of the mounting flange. A drain hole is provided on the bottom side inside the annular water guide groove.

[0008] Preferably, the top protection structure includes a sensor head mounting port opened on the top of the outer shell base, and an annular sealing groove is provided on the bottom side inside the sensor head mounting port.

[0009] Preferably, the annular sealing groove is provided with a fluororubber sealing ring inside, and the top of the sensor head mounting port is provided with a protective sleeve.

[0010] Preferably, the interior of both the protective sleeve and the sensor head mounting port is coated with salt spray resistant silicone sealant.

[0011] Preferably, the heat dissipation structure includes a plurality of heat dissipation through holes circumferentially opened on the outer wall of the outer shell substrate, and the interior of the heat dissipation through holes is embedded with a waterproof and breathable membrane.

[0012] Preferably, an inclined baffle plate is fixedly connected to the outer side of the heat dissipation through hole, the outer surface of the inclined baffle plate is coated with polytetrafluoroethylene, and the inner wall of the outer shell substrate is bonded with a graphene anti-corrosion lining.

[0013] Preferably, a sealing elastic gasket is provided on the top of the mounting flange, and the sealing elastic gasket is located on the bottom side inside the housing substrate.

[0014] Preferably, a mesh waterproof cover is provided on the top of the sensor head mounting port, and the mesh waterproof cover is bolted to the top of the outer shell base.

[0015] Compared with the prior art, the beneficial effects of this utility model are:

[0016] 1. This application reduces gaps from the source by setting up an installation flange, a housing base, a zinc-nickel alloy plating, a polytetrafluoroethylene (PTFE) anti-salt spray coating, a bottom protection structure, and a top protection structure. The housing base is integrally cast from 316L stainless steel, and the double protection formed by the zinc-nickel alloy plating and the PTFE anti-salt spray coating significantly improves the overall salt spray resistance of the housing base. In the bottom protection structure, the stepped sealing sleeve and the water-swellable sealing strip together enhance the sealing performance of the connection between the installation flange and the housing base. The water-swellable characteristics can flexibly adapt to changes in gaps. The annular water guide groove and drainage hole can drain accumulated water in time and prevent chloride ions from accumulating at the joints. The top protection structure on the top of the housing base not only meets the usage requirements of the environmental sensor being installed inside the housing base and the sensor head protruding from the housing base through it, but also provides installation sealing and anti-aging treatment for the sensor head area, effectively overcoming the pain points of easy corrosion of gaps and interfaces and easy failure of sealing rings in existing solutions.

[0017] 2. By setting up a heat dissipation structure, this application can not only achieve effective heat dissipation to ensure the normal operation of the sensor inside the housing substrate, but also block the intrusion of salt spray and moisture with its specific design, reduce the direct impact of sea spray and droplets, enhance corrosion resistance and improve the internal protection performance. While ensuring the heat dissipation function, it avoids the heat dissipation-related parts from becoming the entry point for corrosive media, and takes into account both heat dissipation and anti-salt spray performance, thus solving the problem that the heat dissipation structure in the existing solution is prone to corrosion. Attached Figure Description

[0018] Figure 1 This is an overall structural diagram of the coastal environment sensor housing with anti-salt spray treatment according to this utility model;

[0019] Figure 2 This is a structural diagram of the outer shell substrate of this utility model;

[0020] Figure 3 This is a structural diagram of the bottom protective structure of this utility model;

[0021] Figure 4 This is a structural diagram of the top protection structure of this utility model;

[0022] Figure 5 This is a structural diagram of the heat dissipation structure of this utility model;

[0023] Figure 6 This is a structural diagram of the mesh waterproof cover of this utility model.

[0024] In the diagram: 1. Mounting flange; 2. Housing base; 3. Bottom shield structure; 31. Stepped sealing sleeve; 32. Water-swellable sealing strip; 33. Annular water guide groove; 34. Drain hole; 4. Top shield structure; 41. Sensor head mounting port; 42. Annular sealing groove; 43. Fluororubber sealing ring; 44. Protective sleeve; 45. Salt spray resistant silicone sealant; 5. Heat dissipation structure; 51. Heat dissipation through hole; 52. Waterproof and breathable membrane; 53. Inclined water baffle; 54. Graphene anti-corrosion lining; 6. Sealing elastic gasket; 7. Mesh waterproof cover; 8. Zinc-nickel alloy plating; 9. Polytetrafluoroethylene anti-salt spray coating. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] Please see Figure 1-6 The present invention provides the following technical solution:

[0027] A coastal environment sensor housing with salt spray protection includes a mounting flange 1, a housing base 2 threadedly connected to the top of the mounting flange 1, the housing base 2 being integrally cast from 316L stainless steel, a zinc-nickel alloy plating layer 8 and a polytetrafluoroethylene salt spray protection coating 9 sequentially disposed on the surface of the housing base 2, a bottom protection structure 3 disposed at the bottom of the mounting flange 1, a top protection structure 4 disposed at the top of the housing base 2, and a heat dissipation structure 5 disposed on the outer side of the housing base 2.

[0028] The bottom protective structure 3 includes a stepped sealing sleeve 31 fixedly connected to the top of the mounting flange 1. The inner wall of the stepped sealing sleeve 31 contacts the outer side of the outer shell base 2. A water-swellable sealing strip 32 is fixedly connected to the top of the stepped sealing sleeve 31. The water-swellable sealing strip 32 is sleeved on the outer side of the outer shell base 2. An annular water guide groove 33 is opened on the top of the mounting flange 1. A drain hole 34 is opened on the bottom side inside the annular water guide groove 33.

[0029] In this embodiment: by setting up an installation flange 1, an outer shell base 2, a zinc-nickel alloy plating 8, a polytetrafluoroethylene anti-salt spray coating 9, a bottom anti-corrosion structure 3, a top anti-corrosion structure 4, and a heat dissipation structure 5, during use, the installation flange 1 is first fixed to the coastal observation bracket, and then the bottom of the outer shell base 2 is threadedly connected to the top of the installation flange 1. During this process, the inner wall of the stepped sealing sleeve 31 at the top of the installation flange 1 is in close contact with the outer side of the outer shell base 2, initially blocking the gaps. The water-swellable sealing strip 32 at its top is simultaneously fitted onto the outer side of the outer shell base 2. After encountering salt spray and water vapor, it will automatically expand to further fill any possible tiny gaps, preventing corrosive media from seeping in from the connection seam between the installation flange 1 and the outer shell base 2. At the same time, the annular water guide groove 33 at the top of the installation flange 1 can collect the dripping salt spray water. The water is quickly discharged through the drain hole 34 at the bottom of the water guide groove, preventing water from staying at the joint and causing chloride ion accumulation, thus reducing the risk of crevice corrosion from the source. The outer shell base 2 is integrally cast from 316L stainless steel, which itself reduces The seam is formed by a zinc-nickel alloy plating layer 8 and a polytetrafluoroethylene (PTFE) anti-salt spray coating 9, creating a double-layer anti-salt spray barrier. The zinc-nickel alloy plating layer 8 acts as a sacrificial anode, preferentially resisting corrosion. The outer PTFE anti-salt spray coating 9, with its excellent hydrophobicity and corrosion resistance, prevents most salt spray and sea spray droplets from directly contacting the housing substrate 2, significantly improving the overall salt spray resistance. When the environmental sensor is installed inside the housing substrate 2, the top protective structure 4 on the top of the housing substrate 2 can meet the usage requirements of the sensor head. At the same time, the interface between the sensor head and the housing substrate 2 is sealed and treated with anti-aging to prevent the interface from becoming a corrosion breakthrough. The heat dissipation structure 5 on the outside of the housing substrate 2 can ensure the heat dissipation requirements of the sensor operation while blocking the intrusion of salt spray and moisture through its own design, reducing the impact of sea spray droplets. This maintains the normal operating temperature of the sensor and prevents corrosion of heat dissipation-related parts, ultimately achieving long-term protection of the housing and stable operation of the sensor in the high salt spray environment of the coast.

[0030] Specifically, such as Figure 4 As shown, the top protection structure 4 includes a sensor head mounting port 41 opened on the top of the outer shell base 2, and an annular sealing groove 42 is opened on the bottom side inside the sensor head mounting port 41.

[0031] Specifically, such as Figure 4 As shown, a fluororubber sealing ring 43 is provided inside the annular sealing groove 42, and a protective sleeve 44 is provided on the top of the sensor head mounting port 41.

[0032] Specifically, such as Figure 4 As shown, the interior of both the protective sleeve 44 and the sensor head mounting port 41 is coated with salt spray resistant silicone sealant 45.

[0033] In this embodiment: by setting the top protection structure 4, when the environmental sensor is installed inside the housing base 2, the sensor head can extend through the sensor head mounting port 41 at the top of the housing base 2. At this time, the annular sealing groove 42 on the bottom side inside the sensor head mounting port 41 will limit the fluororubber sealing ring 43. After being squeezed by the sensor head, the fluororubber sealing ring 43 tightly fits the outer wall of the sensor head and the groove wall, initially blocking salt spray from seeping in from the interface. Then, the protective sleeve 44 is installed on the top of the sensor head mounting port 41. It and the salt spray resistant silicone sealant 45 pre-coated inside the mounting port will further fill the gap, forming a secondary seal. Both the salt spray resistant silicone sealant 45 and the fluororubber sealing ring 43 have excellent anti-salt spray aging performance and can maintain the sealing effect for a long time. This not only meets the use requirements of normal extension of the sensor head, but also completely solves the problem of easy corrosion of the sensor head mounting interface.

[0034] Specifically, such as Figure 5 As shown, the heat dissipation structure 5 includes several heat dissipation through holes 51 circumferentially opened on the outer wall of the outer shell base 2, and a waterproof and breathable membrane 52 is embedded inside the heat dissipation through holes 51.

[0035] Specifically, such as Figure 5 As shown, an inclined baffle plate 53 is fixedly connected to the outer side of the heat dissipation hole 51. The outer surface of the inclined baffle plate 53 is coated with polytetrafluoroethylene. The inner wall of the outer shell substrate 2 is bonded with a graphene anti-corrosion lining layer 54.

[0036] In this embodiment: by setting up a heat dissipation structure 5, the heat generated by the sensor inside the outer shell substrate 2 can be dissipated by exchanging with the outside air through the circumferentially opened heat dissipation holes 51. The waterproof and breathable membrane 52 embedded in the heat dissipation holes 51 allows air circulation while blocking the entry of salt spray and moisture, preventing corrosive media from intruding with the airflow. The inclined water baffles 53 on the inner and outer sides of the heat dissipation holes 51 can physically block sea spray droplets from directly impacting the waterproof and breathable membrane 52, reducing the risk of damage and blockage of the waterproof and breathable membrane 52. The polytetrafluoroethylene coating sprayed on its outer surface further enhances the resistance to salt spray corrosion. The graphene anti-corrosion lining 54 bonded to the inner wall of the outer shell substrate 2 can isolate trace amounts of corrosive media that may penetrate from the inside, forming a synergy with the outer protection. While ensuring heat dissipation performance, it can prevent corrosion of heat dissipation-related parts in all aspects.

[0037] Specifically, such as Figure 6 As shown, a sealing elastic gasket 6 is provided on the top of the mounting flange 1, and the sealing elastic gasket 6 is located on the bottom side inside the housing base 2.

[0038] Specifically, such as Figure 6 As shown, a mesh waterproof cover 7 is provided on the top of the sensor head mounting port 41, and the mesh waterproof cover 7 is bolted to the top of the housing base 2.

[0039] In this embodiment: by setting a sealing elastic gasket 6 and a mesh waterproof cover 7, when the outer shell base 2 is threadedly connected to the mounting flange 1, the outer wall of the sealing elastic gasket 6 will contact the inner wall of the outer shell base 2, thereby further tightly filling the gap between the two. The mesh waterproof cover 7 on the top of the sensor head mounting port 41 can, on the one hand, prevent rainwater, fallen leaves and other debris from directly impacting the sensor head and the protective sleeve 44, reducing physical damage. On the other hand, its mesh structure does not affect air circulation and will not interfere with the sensor head's acquisition of environmental parameters. It can also reduce the impact of sea waves and droplets on the interface. Together with the top protection structure 4, it further improves the protection effect and ensures the long-term stable operation of the sensor.

[0040] Working Principle: In the actual use of the coastal environmental sensor housing, the basic installation and protection deployment must first be completed: the mounting flange 1 is firmly fixed on the coastal observation bracket, and then the environmental sensor is installed inside the housing base 2: the sensor head extends through the sensor head mounting port 41 at the top of the housing base 2. At this time, the annular sealing groove 42 on the bottom side inside the sensor head mounting port 41 limits the fluororubber sealing ring 43. After being squeezed by the sensor head, the fluororubber sealing ring 43 tightly fits the outer wall of the sensor head and the groove wall, initially blocking salt spray from seeping in from the sensor head interface. Then, the protective sleeve 44 is installed on the top of the sensor head mounting port 41, and it and the salt spray resistant silicone sealant 45 pre-coated inside the mounting port further fill the gap, forming a secondary seal and salt resistance. Both the silicone sealant 45 and the fluororubber sealing ring 43 possess excellent resistance to salt spray aging and can maintain a long-term sealing effect. Next, the bottom of the outer shell base 2 and the top of the mounting flange 1 are connected by threads. During connection, the inner wall of the stepped sealing sleeve 31 on the top of the mounting flange 1 fits tightly against the outer side of the outer shell base 2, initially blocking the gap between them. Simultaneously, the water-swellable sealing strip 32 on the top of the stepped sealing sleeve 31 is simultaneously fitted onto the outer side of the outer shell base 2. Upon subsequent contact with salt spray and moisture in the coastal environment, it will automatically expand, further filling any tiny gaps that may arise from the threaded connection. This double protection prevents corrosive media from seeping into the connection between the mounting flange 1 and the outer shell base 2. During this process, the sealing elastic gasket 6 on the top of the mounting flange 1 (located inside the outer shell base 2)... The bottom side of the casing 2 is squeezed by the bottom of the casing 2 and the top of the mounting flange 1, and its outer wall is in close contact with the inner wall of the casing 2, further filling the gap between the two to form a third seal, completely cutting off the path of salt spray intrusion from the bottom joint. The annular water guide groove 33 at the top of the mounting flange 1 can collect the salt spray water dripping from the top of the casing 2 in real time. The water is quickly discharged through the drain hole 34 at the bottom of the water guide groove, avoiding water from staying at the joint and causing chloride ion accumulation, thus reducing the risk of crevice corrosion from the source. The casing 2 itself is made of 316L stainless steel in one piece, which reduces the generation of splicing gaps in the structure. The zinc-nickel alloy plating layer 8 and the polytetrafluoroethylene anti-salt spray coating 9 arranged sequentially on its surface form a double-layer anti-salt spray barrier: the zinc-nickel alloy plating layer 8 through Through a sacrificial anode protection mechanism, it preferentially reacts with the corrosive medium in the salt spray, preventing corrosion of the outer casing substrate 2. The outer polytetrafluoroethylene anti-salt spray coating 9, with its excellent hydrophobicity and corrosion resistance, blocks most of the salt spray and sea spray droplets from directly contacting the outer casing substrate 2, significantly improving the overall salt spray resistance of the outer casing. After completing the installation of the outer casing substrate 2, the mesh waterproof cover 7 is fixed to the top of the outer casing substrate 2 (covering the sensor head mounting port 41) by bolting. On the one hand, it can prevent rainwater, fallen leaves and other debris from directly impacting the sensor head and the protective sleeve 44, reducing physical damage. On the other hand, its mesh structure does not affect air circulation and will not interfere with the sensor head's acquisition of environmental parameters such as temperature, humidity and wind speed. At the same time, it can also reduce the impact of sea spray droplets on the interface.In conjunction with the top protective structure 4, the protective effect is further enhanced. When the sensor is started, the heat dissipation structure 5 on the outside of the housing substrate 2 begins to function: the heat generated by the sensor is conducted through the housing substrate 2 to the circumferentially opened heat dissipation holes 51, exchanging with the outside air to achieve heat dissipation. The waterproof and breathable membrane 52 embedded in the heat dissipation holes 51 allows air circulation while blocking the entry of salt spray and moisture, preventing corrosive media from intruding with the airflow. The inclined water baffles 53 inside and outside the holes can physically block sea spray droplets from directly impacting the waterproof and breathable membrane 52, reducing the risk of damage and blockage of the waterproof and breathable membrane 52. The polytetrafluoroethylene coating sprayed on its outer surface further enhances its resistance to salt spray corrosion. The graphene anti-corrosion lining 54 bonded to the inner wall of the housing substrate 2 can isolate trace amounts of corrosive media that may penetrate from the inside, forming a synergy with the outer protection. While ensuring heat dissipation efficiency, it can prevent corrosion of heat dissipation-related parts in all directions. In summary, through the synergistic cooperation of various structures, the housing substrate 2 meets the requirements of sensor installation, heat dissipation and environmental parameter acquisition, while achieving all-round protection against the high salt spray environment of the coast, ensuring the long-term stable operation of the sensor. ,

[0041] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A coastal environment sensor housing with salt spray protection, comprising a mounting flange (1), characterized in that: The mounting flange (1) is threadedly connected to the top of the outer shell base (2). The outer shell base (2) is integrally cast from 316L stainless steel. The surface of the outer shell base (2) is sequentially provided with a zinc-nickel alloy plating layer (8) and a polytetrafluoroethylene anti-salt spray coating (9). The bottom of the mounting flange (1) is provided with a bottom protection structure (3). The top of the outer shell base (2) is provided with a top protection structure (4). The outer side of the outer shell base (2) is provided with a heat dissipation structure (5). The bottom protective structure (3) includes a stepped sealing sleeve (31) fixedly connected to the top of the mounting flange (1). The inner wall of the stepped sealing sleeve (31) is in contact with the outer side of the outer shell base (2). A water-swellable sealing strip (32) is fixedly connected to the top of the stepped sealing sleeve (31). The water-swellable sealing strip (32) is sleeved on the outer side of the outer shell base (2). An annular water guide groove (33) is provided on the top of the mounting flange (1). A drain hole (34) is provided on the bottom side inside the annular water guide groove (33).

2. The coastal environment sensor housing with salt spray protection according to claim 1, characterized in that: The top protection structure (4) includes a sensor head mounting port (41) opened on the top of the outer shell base (2), and an annular sealing groove (42) is opened on the bottom side inside the sensor head mounting port (41).

3. The coastal environment sensor housing with salt spray protection according to claim 2, characterized in that: The annular sealing groove (42) is provided with a fluororubber sealing ring (43), and the top of the sensor head mounting port (41) is provided with a protective sleeve (44).

4. A coastal environment sensor housing with salt spray protection according to claim 3, characterized in that: The interior of both the protective sleeve (44) and the sensor head mounting port (41) is coated with salt spray resistant silicone sealant (45).

5. A coastal environment sensor housing with salt spray protection according to claim 1, characterized in that: The heat dissipation structure (5) includes a plurality of heat dissipation through holes (51) circumferentially opened on the outer wall of the outer shell base (2), and the interior of the heat dissipation through holes (51) is embedded with a waterproof and breathable membrane (52).

6. A coastal environment sensor housing with salt spray protection according to claim 5, characterized in that: An inclined baffle plate (53) is fixedly connected to the outside of the heat dissipation through hole (51). The outer surface of the inclined baffle plate (53) is coated with polytetrafluoroethylene. A graphene anti-corrosion lining (54) is bonded to the inner wall of the outer shell substrate (2).

7. A coastal environment sensor housing with salt spray protection according to claim 1, characterized in that: A sealing elastic gasket (6) is provided on the top of the mounting flange (1), and the sealing elastic gasket (6) is located on the bottom side inside the housing base (2).

8. A coastal environment sensor housing with salt spray protection according to claim 2, characterized in that: The top of the sensor head mounting port (41) is provided with a mesh waterproof cover (7), which is bolted to the top of the outer shell base (2).

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