Exhaust Sensor Housing Segmentation for Moisture Protection
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Solution Overview
Problem
Existing pressure sensors in automotive applications, particularly in exhaust gas measurement, face challenges with moisture buildup leading to clogging, corrosion, and malfunction due to their design, which limits their reliability and efficiency.
Innovation Solution
A sensor system comprising a sensing element carrier, an electronics module carrier, and a main carrier supported by a housing assembly with features like sloping channels and barriers to prevent moisture accumulation, using efficient material usage and assembly techniques for robustness and cost-effectiveness, especially with differential pressure sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pressure sensor design is used, then manufacturing is simpler, but moisture buildup causes clogging and corrosion reducing reliability
Solution Approach 1:
The sensor housing is divided into multiple sealed compartments: a first housing space for the sensing element, a second housing space for electronics, and a third housing space for pressure reference. This segmentation prevents moisture from reaching critical components while maintaining manufacturing feasibility through modular assembly.
Solution Approach 2:
A protective gel is introduced as an intermediary substance between the sensing element and the exhaust gas environment. This gel barrier prevents moisture and corrosive substances from contacting the sensing element while allowing pressure transmission, thus improving reliability without requiring complete redesign of the sensor structure.
2Reliability
If sensing element is protected from environment, then reliability improves, but access to sensing element becomes difficult
Solution Approach 1:
The sensing element is nested within a protective gel inside the first housing space, which is itself nested within the main housing assembly. This nested structure provides multiple layers of protection while maintaining access through the housing's external ports and connections, allowing the sensing element to be protected yet accessible for installation and maintenance.
3Productivity
If separate carrier elements are used for sensing element and electronics, then manufacturing efficiency improves, but assembly complexity increases
Solution Approach 1:
The sensor system uses separate carrier elements: a first carrier for the sensing element and a second carrier for electronic components. These segmented carriers can be manufactured independently using optimized processes for each component type, then assembled together in a standardized sequence within the housing, improving manufacturing efficiency while controlling assembly complexity through modular design.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical support for separate carriers, creates sealed housing spaces, enables pressure transmission pathways, and facilitates thermal management. This multi-functional housing design accommodates separate carriers without proportionally increasing assembly complexity, as the same structural elements fulfill multiple roles.
Data Source
Figure 1
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Figure 4~5
AI summary
Sensor system for measuring pressure in an exhaust conduit of a combustion engine, the sensor system (1) comprising an electronics module assembly (5) and a housing assembly (2, 3, 4) for housing the electronics module assembly (5). The electronics module assembly (5) comprises - a sensing element carrier element (8) with a sensing element (10), - an electronics module carrier element (7) carrying electronic components, wherein electrical connections (7a) are provided between the electronic module carrier element (7) and the sensing element carrier element (8), and - a main carrier element (6) for supporting the sensing element carrier element (8) and the electronic module carrier element (7).