Connection Head Return Cavity Air Bubble Reduction
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Solution Overview
Problem
Conventional connection heads for fluid sensors in SCR systems face issues with reliable electrical connections between conductive tubes and ground potential, leading to potential wire breakage and cumbersome designs that are not suitable for challenging environments, and the presence of air bubbles impairs sensor functionality.
Innovation Solution
A connection head with a return cavity integrated into the base, eliminating the need for return tubes and incorporating electrically insulated grounding elements and leads, which are over-molded with insulating material for robustness and ease of assembly, and a simplified geometry for tube anchoring without threads, using a metal plate for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection heads use separate grounding wires for each tube, then electrical connection to ground potential is achieved, but the wires can break and the design becomes cumbersome
Solution Approach 1:
The patent combines multiple grounding connections into a single integrated grounding element that contacts multiple tubes simultaneously. Instead of using separate grounding wires for each tube, the invention employs one grounding element with multiple contact points, thereby reducing the number of separate grounding components and eliminating wire breakage issues while maintaining reliable electrical connection to ground potential for all tubes.
Solution Approach 2:
The grounding element serves multiple functions: it provides grounding for multiple tubes, acts as a structural support component, and facilitates assembly through its integrated design. This multi-functional approach eliminates the need for separate grounding wires and simplifies the overall connection head structure.
2Strength
If conventional connection heads use threaded tube anchoring, then secure fixation is achieved, but the design becomes cumbersome and unsuitable for challenging environments
Solution Approach 1:
The patent removes the threaded anchoring mechanism from the connection head design and replaces it with a simplified press-fit or snap-fit system. By extracting the complex threading requirement, the invention achieves secure tube fixation through geometric interlocking and elastic deformation of the base material, thereby reducing structural complexity while maintaining fixation strength.
Solution Approach 2:
The base material is designed with elastic properties that allow it to deform during assembly and retain the tube securely. The flexible base structure provides mechanical retention through elastic deformation rather than rigid threading, simplifying the anchoring mechanism while ensuring secure fixation in challenging environments.
3Reliability
If conventional designs use separate grounding elements for each tube, then electrical connection is achieved, but assembly becomes time-consuming
Solution Approach 1:
The patent merges multiple grounding operations into a single assembly action. By integrating multiple grounding contacts into one grounding element that is installed simultaneously for all tubes, the invention eliminates the need to separately ground each tube, thereby maintaining reliable electrical grounding while significantly reducing assembly time and improving productivity.
Data Source
AI summary
A connection head for being arranged in an orifice of a fluid tank with a return cavity in the form of a radial duct is provided. The return cavity overcomes the problems of the formation of air bubbles in the tank and enhances the functioning of the sensor in the tank.