Flow Sensor Module Coupling With Fluid-Resistant Electrical Sealing

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Solution Overview

Problem

Existing devices for delivering flowing media face challenges in maintaining electrical connections between sensor modules and the device while preventing contamination during cleaning, as traditional connections can allow cleaning solutions to enter the device, potentially damaging internal components.

Innovation Solution

A device with a fluid-resistant seal and twist-lock mechanism allows for secure mechanical and electrical connection of sensor modules, using spring-loaded pins and a compression-type conductive seal to ensure electrical contact without fluid ingress, enabling easy attachment and detachment for cleaning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If sensor modules are selectively attachable to the device, then ease of operation is improved, but reliability deteriorates due to potential contamination and cleaning solution ingress

Engineering Contradiction:

Improveease of attachment and detachmentVSAvoidprotection against contamination

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A fluid-resistant seal acts as an intermediary between the sensor module and device housing, providing a protective barrier that prevents cleaning solutions and contaminants from entering the device while allowing the sensor module to be selectively attached and detached. The seal includes spring-loaded electrical connector pins that maintain electrical contact while preserving fluid resistance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The fluid-resistant seal utilizes a flexible compression-type electrically conductive membrane that can deform to accommodate the attachment and detachment of the sensor module while maintaining its fluid-resistant barrier function. The flexible nature of the seal allows it to compress and seal around the connection interface.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If a fluid-resistant seal is used, then protection against cleaning solution ingress is improved, but device complexity increases

Engineering Contradiction:

Improveprotection against cleaning solution ingressVSAvoidcomplexity of seal mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The seal integrates multiple functions into a single component: fluid resistance, electrical connection, and mechanical coupling. By combining the sealing barrier with spring-loaded electrical connector pins in one integrated seal assembly, the design reduces overall complexity compared to having separate sealing and electrical connection mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If spring-loaded electrical connector pins are used, then electrical connection reliability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidalignment precision of contact pads

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The spring-loaded electrical connector pins incorporate a spring mechanism that provides beforehand cushioning, allowing for tolerance compensation in the alignment between contact pads and connector pins. The spring force ensures reliable electrical contact while accommodating minor misalignments that occur during assembly.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 reliable electrical connection that prevents contamination during cleaning, ensuring the device's integrity and functionality by keeping cleaning solutions out of the internal components.

Implementation Method 1

a plurality of spring-loaded electrical connector pins are disposed in the fluid-resistant seal

Methodology Applied

Scientific EffectSpring (elasticity): Spring

Implementation Method 2

a plurality of spring-loaded electrical connector pins

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

the fluid-resistant seal comprises a compression-type electrically conductive membrane

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 4

compression-type electrically conductive seal

Methodology Applied

Scientific EffectConduction (electrical): Conduction (electrical)

Data Source

PatentUS12629464B2Devices for delivering at least one flowing media, associated sensor modules, and associated methods of mechanically and electrically coupling a sensor module to a device for delivering at least one flowing media

Publication Date: 2026.05.19 HONEYWELL INTERNATIONAL INC

AI summary

A device for delivering a flowing media is provided. For example, a device for delivering a flowing media may include a housing defining an opening, a first printed circuit board assembly (PCBA), a fluid-resistant seal occluding the opening, and a sensor module. The sensor module comprises a second PCBA having a plurality of electrical contact pads; a sensing element in electrical communication with one or more of the electrical contact pads; and a flow tube at least partially defining a flow path for conveying a flowing media therethrough. The flow tube comprises an elongated main body disposed proximate the first major surface of the second PCBA such that the flow path is disposed proximate the sensing element such that at least a portion of the flowing media makes direct contact with the sensing element. The sensor module is selectively mechanically and electrically attachable to the device.