Fuel-Resistant Spacer Element for Level Sensor Housing
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Solution Overview
Problem
Existing filling level sensors in fuel tanks are not resistant to the aggressive chemical properties of fuel, requiring complex and expensive fluid-tight housings to prevent fuel ingress, which can lead to functional restrictions or failure.
Innovation Solution
A filling level sensor with a spacer element made of plastic, connected to the contact element and resistance network via hot caulking, which is resistant to corrosive fuel properties, eliminating the need for a sealed housing and allowing for a direct measurement of the fuel level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fluid-tight housing is used to protect the level sensor from fuel, then the sensor is protected from corrosive fuel properties, but the housing complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent removes the fluid-tight housing from the level sensor design, extracting the protective function and replacing it with fuel-resistant plastic materials used directly in the sensor components. This eliminates the complex sealed housing structure while maintaining fuel resistance through material selection.
Solution Approach 2:
The patent employs plastic materials with specific fuel resistance properties in the sensor construction, using material composition to achieve chemical resistance rather than relying on a sealed housing structure. This material-based approach simplifies the overall device while maintaining reliability.
2Reliability
If a sealed housing with protective gas is used to prevent fuel ingress, then the sensor reliability is improved, but the production cost and manufacturing complexity increase
Solution Approach 1:
The patent eliminates the sealed housing and protective gas filling from the design, removing these complex manufacturing steps while maintaining sensor reliability through the use of fuel-resistant plastic materials in the sensor construction.
Solution Approach 2:
The patent uses inexpensive plastic materials that are inherently resistant to fuel corrosion, replacing the need for expensive sealed housings and protective gas systems. This material-based solution reduces both manufacturing cost and complexity.
3Reliability
If the contact element is arranged at a distance from the resistance network, then the electrical connection reliability is improved, but the spacer element material must resist fuel corrosion
Solution Approach 1:
The patent uses plastic material for the spacer element that possesses both the mechanical properties needed for spacing and electrical insulation, and chemical resistance to fuel corrosion. This material selection addresses both the electrical connection reliability and fuel resistance requirements simultaneously.
Solution Approach 2:
The patent employs a simple plastic spacer element that is inexpensive to manufacture and inherently resistant to fuel, replacing complex sealed structures. This approach maintains electrical connection reliability while eliminating corrosion concerns through material selection.
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 and reliable method for determining the fuel level without the need for a sealed housing, reducing production complexity and avoiding errors associated with fuel ingress, while ensuring long-term resistance to corrosive fuels.
Implementation Method 1
an electrically conductive connection between the contact element and the resistance network can be established by deflecting the contact element
Implementation Method 2
the spacer element is connected to the resistance network and/or the contact element by means of hot crimping
Data Source
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AI summary
The invention relates to a filling level indicator for determining a filling level in a tank, comprising a resistor network (13), a contact element (14) and a magnetic element, wherein the contact element (14) is arranged at a distance from the resistor network (13) and the magnetic element can be moved relative to the resistor network (13) and the contact element (14), wherein an electrically conductive connection can be established between the contact element (14) and the resistor network (13) by means of a deflection of the contact element (14), wherein a spacer element (12) made of plastic is arranged between the resistor network (13) and the contact element (14), and wherein the spacer element (12) is heat-staked with the resistor network (13) and/or the contact element (14).