Duct Sensor Cover With Resilient Seal And Guide Runners
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Solution Overview
Problem
Existing duct sensor covers require threaded connections and specialized tools for mounting, which can be costly and prone to leakage, and do not effectively prevent uncured potting compound from leaking.
Innovation Solution
A cover design for a tubular housing of a duct sensor that uses a single-piece, resiliently yieldable seal with a tapered tip to create a fluid-tight connection without threaded connections, featuring guide runners and latching members to secure the circuit board and prevent play, allowing for easy assembly and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded connections are used to mount the cover to the tubular housing, then the connection strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the cover and seal into a single integrated component, eliminating the need for separate sealing elements and threaded fasteners. This merging reduces the number of parts and assembly steps while maintaining both structural strength and sealing effectiveness through the integrated design.
Solution Approach 2:
The patent replaces complex threaded mechanical connections with a simpler snap-fit or friction-fit mechanism. The cover is retained on the tubular housing through dimensional interference and geometric locking features rather than threaded fasteners, reducing assembly complexity while maintaining connection strength.
2Reliability
If threaded connections and specialized tools are used for mounting, then the mounting security is improved, but the ease of manufacture and assembly are worsened
Solution Approach 1:
The cover design incorporates self-aligning and self-retaining features that allow it to automatically secure to the tubular housing without requiring specialized tools or complex assembly procedures. The geometric locking features and dimensional interference enable the cover to self-retain once positioned.
Solution Approach 2:
The patent divides the mounting function into distinct geometric features on the cover and corresponding features on the housing, such as locking ribs, snap-fit elements, or friction-fit surfaces. This segmentation allows each feature to perform a specific function (alignment, retention, sealing) independently, simplifying the overall assembly process.
3Adaptability or versatility
If the duct is designed to allow circuit board passage, then the functionality is improved, but the sealing effectiveness against moisture ingress is worsened
Solution Approach 1:
The patent uses a flexible or elastomeric seal material that can deform to accommodate the circuit board passing through the duct while maintaining the sealing barrier. The seal material flexes around the circuit board edges and returns to its original shape, preventing moisture ingress while allowing electrical component passage.
Solution Approach 2:
The duct design incorporates localized sealing features such as gaskets, sealing rings, or coated surfaces at specific locations where the circuit board passes through. These localized sealing elements provide moisture protection at the critical penetration points while leaving the rest of the duct structure optimized for circuit board accommodation.
4Ease of manufacture
If a single-piece seal design is used, then the manufacturing cost is reduced, but the adaptability to different housing sizes is worsened
Solution Approach 1:
The patent employs a single-piece seal design with variable geometric parameters such as thickness, diameter, or length that can be adjusted during manufacturing to accommodate different housing sizes. The seal incorporates tapered sections, stepped features, or graduated thickness that allow it to adapt to various dimensions while remaining a single integrated component.
Solution Approach 2:
The single-piece seal is made from composite materials or material blends that provide both structural integrity and flexibility. This allows the seal to maintain its shape and sealing force across different housing sizes while remaining manufacturable as a single piece through processes like injection molding or compression molding.
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
The solution provides a cost-effective, durable, and leak-proof cover that can be mass-produced, suitable for a wide range of moisture conditions, and meets high IP protection standards, ensuring the sensor's reliability in HVAC systems.
Implementation Method 1
the at least one seal is resiliently yieldable so as to adapt to a groove on an inner wall of a tubular housing
Data Source
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AI summary
Cover for a duct sensor. A cover (1) for a duct sensor comprising an outer envelope (3) circumferentially surrounding the cover (1) and connecting to a seal (4), the seal (4) standing proud of the outer envelope (3) and circumferentially surrounding the outer envelope (3), a duct (2) with walls (8, 9) and with side walls, the duct (2) extending through the cover (1), a front surface connecting to the outer envelope (3) and to the walls (8, 9) of the duct (2), wherein the duct (2) comprises a guide runner (17) laterally arranged along a side wall of the duct (2), wherein the cover (1) comprises an opening (12) in the front surface, wherein the opening (12) provides an entry for a circuit board into the duct (2), wherein the guide runner (17) is configured to support a circuit board (20) extending through the duct (2).