Exhaust Gas Sensor Strain Relief and Anti-Vibration Sleeve
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Solution Overview
Problem
Temperature sensors in internal combustion engines face harsh conditions such as vibration, debris, moisture, corrosive chemicals, and extreme temperature ranges, leading to performance degradation and reduced suitability for their intended purpose.
Innovation Solution
The use of an epoxy within the sensor tip for thermal conductivity and strain relief, combined with an anti-vibration sleeve to stabilize the sensor system, enhances the sensor's ability to withstand thermal stresses and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the temperature sensor is exposed to harsh operating conditions (vibration, extreme temperatures, moisture, corrosive chemicals), then the sensor can function in the exhaust gas environment, but the sensor performance degrades and reliability decreases
Solution Approach 1:
The patent applies beforehand cushioning by incorporating an elastomeric strain relief sleeve and anti-vibration sleeve into the sensor construction before deployment. These sleeves are positioned to absorb and dampen vibrational stresses and thermal expansion forces before they can damage the temperature sensing element, thereby maintaining reliability while adapting to the harsh exhaust gas environment
Solution Approach 2:
The patent employs composite materials by combining the temperature sensing element with an elastomeric strain relief sleeve and an anti-vibration sleeve made of vibration-dampening material. This composite structure integrates multiple material properties (thermal conductivity, vibration damping, strain relief) into a single protective assembly that maintains sensor reliability in harsh conditions
2Temperature
If the sensor operates in large temperature ranges with high continuous use temperatures, then the sensor can measure exhaust gas temperature, but thermal stress degrades the sensor and reduces its lifespan
Solution Approach 1:
The patent addresses thermal expansion by incorporating an elastomeric strain relief sleeve that accommodates differential thermal expansion between the temperature sensing element and the sensor housing. The elastomeric material flexes to absorb expansion forces during high-temperature operation, preventing stress-induced failure and extending the sensor's operational lifespan in hot exhaust environments
Solution Approach 2:
The patent applies beforehand cushioning by positioning the anti-vibration sleeve and strain relief components in advance to absorb thermal and mechanical stresses before they can damage the sensing element. This preventive approach maintains the sensor's temperature measurement capability while protecting it from thermal degradation over extended operation
3Reliability
If vibration damping components are added to the sensor system, then vibrational stresses are reduced and reliability improves, but device complexity increases
Solution Approach 1:
The patent merges multiple protective functions into integrated components: the elastomeric strain relief sleeve simultaneously provides strain relief, vibration damping, and thermal expansion accommodation. The anti-vibration sleeve combines vibration isolation with mechanical support functions. This merging approach improves vibration resistance without proportionally increasing device complexity, as each component performs multiple protective roles
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 improves the thermal response and longevity of the temperature sensors by providing effective strain relief and reducing vibrational stresses, ensuring accurate temperature measurement and extended system life.
Implementation Method 1
The epoxy provides a thermal pathway between the sensing element and the housing
Implementation Method 2
being flexible to accommodate different rates of thermal expansion between the sensing element and electrical connections
Implementation Method 3
being flexible to accommodate different rates of thermal expansion
Implementation Method 4
an anti-vibration sleeve positioned against a bottom surface of the stop flange and between the stop flange and the temperature sensor
Data Source
AI summary
A temperature sensor includes a housing and a temperature sensing element disposed in the housing. Electrical connections may extend from the temperature sensing element through the housing and an epoxy may be disposed in the housing, wherein the epoxy may at least partially around the temperature sensing element. The epoxy may provide a thermal pathway between the sensing element and the housing and may be being flexible to accommodate different rates of thermal expansion between the temperature sensing element and the electrical connections without requiring a separate mechanical strain relief. A temperature sensor system includes a temperature sensor and a mineral insulated cable coupled to the temperature sensor. The temperature sensor may be configured to be removably coupled to the mineral insulated cable via a stop flange and a sleeve coupled to the mineral insulated cable. The sleeve may be configured to provide stability and reduce vibrational stress to the temperature sensor system.