Integrated Gas Cell Housing Mold for Optical Path Robustness

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Solution Overview

Problem

Conventional gas sensors face challenges in achieving high robustness of multiple reflection optical paths due to separate housing and mirror sections, which complicates assembly tolerance adjustments and limits accurate detection of gas concentrations.

Innovation Solution

A gas cell housing molding mold that integrates reflectors on the inner surface of the housing using an oblique mold release configuration, eliminating the need for separate mirror sections and simplifying assembly tolerance adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the housing section and mirror sections are prepared as separate components, then the manufacturing flexibility is improved, but the robustness of the multiple reflection optical path deteriorates due to assembly tolerance issues

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidrobustness of optical path

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent combines the housing section and mirror sections into a single integrated component molded from resin. The mirror surfaces are formed directly on the inner wall of the housing through mold design, eliminating the need for separate mirror components and their associated assembly tolerances. This integration resolves the contradiction by maintaining manufacturing simplicity while achieving high optical path robustness.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If the housing section and mirror sections are prepared as separate components, then the ease of assembly is improved, but the adjustment of assembly tolerance for optical components becomes more difficult

Engineering Contradiction:

Improveease of assemblyVSAvoidassembly tolerance adjustment

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

By integrating the mirror sections into the housing as a single molded component, the patent eliminates the need for separate assembly steps and tolerance adjustments. The mirror surfaces are precisely formed during the molding process itself, achieving both ease of assembly (single-component integration) and high manufacturing precision (mold-defined geometry).

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mirror surfaces are pre-formed on the housing inner wall during the molding process, before any assembly operations. This preliminary formation of precise optical surfaces eliminates the need for subsequent tolerance adjustments, resolving the contradiction between ease of assembly and manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If 3D printing technology is used to form mirror surfaces on the housing section, then the integration of components is improved, but the accuracy of surface roughness for mirror surfaces deteriorates

Engineering Contradiction:

Improvecomponent integrationVSAvoidsurface roughness accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces 3D printing technology with traditional injection molding to form the housing and mirror surfaces. Injection molding provides superior surface finish control and dimensional precision compared to 3D printing, while still achieving full integration of the housing and mirror sections as a single component. This substitution resolves the contradiction between integration and surface accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhances the robustness of the multiple reflection optical path, allowing for more accurate and stable gas concentration detection by eliminating assembly misalignment and material expansion issues.

Implementation Method 1

a mirror section including a plurality of reflectors arranged to multiple reflect light emitted from a light emitter and cause the light to enter a light receiver

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS11808609B2Gas cell housing molding mold, method for manufacturing gas cell housing, gas cell housing for gas sensor, and gas sensor including same

Publication Date: 2023.11.07 ASAHI KASEI MICRODEVICES CORP

AI summary

A gas sensor includes, in a single housing section, a substrate mounting surface 31 mounted with a substrate including a light emitter and a light receiver and a mirror section including plural reflectors. Then, in the housing section, all of the plural reflectors are integrally molded on an inner surface of the housing section to multiple reflect light emitted from the light emitter and cause the light to enter the light receiver in an opposing direction of one side and the other side in an extension direction of the substrate mounting surface.