Fuel Filter Water Level Sensor Using Conductive Plastic
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Solution Overview
Problem
Existing fuel filter designs with metal pins for water level sensors are complex and costly due to the need for oxidation protection and sealing, which increases manufacturing expenses.
Innovation Solution
Replacing metal pins with electrically conductive plastic for the water level sensor poles and using electrically conductive plastic for the filter housing to form the second pole, eliminating the need for metal pins and their complex coatings, and using a two-component plastic injection molded design for insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal pins are used for water level sensor poles, then reliable electrical contact is achieved, but manufacturing complexity and cost increase due to oxidation protection and sealing requirements
Solution Approach 1:
The patent replaces expensive metal pins with inexpensive plastic components that serve as water level sensor poles. The plastic material, while less conductive than metal, provides sufficient electrical contact for the sensor's function and eliminates the need for costly oxidation protection and sealing measures, directly addressing the contradiction between reliability and manufacturing complexity
Solution Approach 2:
The patent changes the material parameter from metal to plastic for the sensor poles. This material substitution fundamentally alters the electrical and mechanical properties, allowing the use of simpler manufacturing processes while maintaining adequate sensor functionality, thus resolving the contradiction between reliable electrical contact and manufacturing simplicity
2Reliability
If metal pins with oxide coating are used, then oxidation resistance is improved, but manufacturing cost increases due to additional coating processes
Solution Approach 1:
The patent substitutes metal pins requiring expensive oxide coatings with inexpensive plastic components. The plastic material inherently resists oxidation without requiring additional protective layers, eliminating the need for costly coating processes while maintaining adequate durability for the sensor application
Solution Approach 2:
The patent uses plastic as a composite alternative to metal, combining electrical conductivity (through carbon black or other additives) with oxidation resistance. This composite approach provides both required properties in a single material, eliminating the need for separate metal substrate and protective coating layers
3Measurement precision
If metal pins are used for water level detection, then effective water level sensing is achieved, but production expenses increase due to sealing and coating requirements
Solution Approach 1:
The patent replaces expensive metal pins with inexpensive plastic components for water level detection. The plastic poles maintain sufficient electrical conductivity (through carbon black or conductive fillers) to detect water levels accurately while eliminating the need for costly sealing and coating operations
Solution Approach 2:
The patent changes the material parameter from metal to plastic for the sensor poles, fundamentally altering the manufacturing approach. This substitution maintains adequate electrical conductivity for water level detection while eliminating the need for expensive protective treatments, directly resolving the contradiction between measurement precision and production cost
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
This approach results in a more cost-effective and simpler manufacturing process for the fuel filter, reducing production costs while maintaining effective water level detection without the risk of short circuits.
Implementation Method 1
a first pole (6) which is formed of an electrically conductive plastic
Data Source
Figure 1~3
AI summary
The invention relates to a fuel filter (1) comprising a housing (2), a filter element (3) in the housing, a water collection chamber (4) for collecting water that separates from the fuel, and a water level sensor (5) for sensing a water level in the water collection chamber (4). The invention is characterized in that a first terminal (6) made of an electroconductive plastic material is formed on the water level sensor (5). This makes it possible to dispense with at least one of the expensive metal electrodes.