Diesel Exhaust Fluid Cover Sealing with Sonic Weld
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Solution Overview
Problem
Existing diesel exhaust fluid (DEF) modules face challenges in reliable sealing due to the corrosive nature of urea and the need for temperature maintenance, which can lead to leaks and inefficiencies in component integration.
Innovation Solution
A DEF module cover assembly with a reliable sealing system using a combination of tapered plugs and sonic welding for secure component passage, along with an improved sensor assembly for temperature and level monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components pass through the cover into the DEF holding tank, then the functionality of the DEF module is improved, but the sealing reliability deteriorates due to multiple potential leak points
Solution Approach 1:
The cover is divided into multiple separate openings, each with its own dedicated sealing device (gland or plug). This segmentation allows each opening to be sealed independently, maintaining sealing reliability while accommodating multiple different components (sensors, heating elements, tubing) passing through the cover.
Solution Approach 2:
Sealing glands and plugs act as intermediary components between the cover and the passing components. These intermediaries provide the sealing function, allowing components to pass through while maintaining the seal integrity of the DEF tank.
2Reliability
If sealing devices are used to seal openings for component passage, then the sealing reliability is improved, but the device complexity increases due to additional sealing components
Solution Approach 1:
The cover design uses universal sealing mechanisms (glands and plugs) that can accommodate multiple different component types (sensors, heating elements, tubing) through standardized opening configurations. This reduces overall system complexity by using repeated, standardized sealing solutions rather than custom seals for each component.
Solution Approach 2:
Instead of making the cover itself complex with integrated sealing features, the invention inverts the approach by keeping the cover simple with basic openings and placing the sealing functionality in separate, removable glands and plugs. This simplifies the cover design while maintaining reliable sealing.
3Manufacturing precision
If sonic welding is used to fix sealing devices to the cover, then the manufacturing precision and sealing reliability are improved, but the manufacturing complexity increases
Solution Approach 1:
The invention replaces traditional mechanical attachment methods (screws, clips, or adhesive bonding) with sonic welding to attach sealing glands and plugs to the cover. Sonic welding provides precise, consistent attachment without the complexity of mechanical fasteners or surface preparation required for adhesives, improving both precision and ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances sealing reliability and integration of components within the DEF module, ensuring effective temperature control and level detection, thereby maintaining the integrity of the DEF system.
Implementation Method 1
DEF has a freezing point around 12° F. and therefore must be heated in order to ensure that DEF remains liquid
Implementation Method 2
Each sealing device is fixed to the cover portion by a sonic weld
Data Source
AI summary
A cover for a DEF assembly with openings dimensioned to receive various components that are positioned in the DEF holding tank and associated seals for closing the openings and retaining the components is disclosed. The seals are fixed to the cover by a sonic weld.