Gas Sensor Module Thermal Isolation via Housing Gaps

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Solution Overview

Problem

Existing gas sensors, particularly those detecting hydrogen, face instability due to condensation issues caused by temperature drops, leading to inaccurate readings and misoperations.

Innovation Solution

The sensor module is designed with a housing separated from the inner wall and a first member by gaps, incorporating a battery to supply electrical power and maintain the temperature of the sensor circuit, preventing condensation and ensuring thermal isolation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the sensor module is placed directly against the inner wall without gaps, then the structural stability is improved, but condensation occurs due to temperature drops causing unstable operation

Engineering Contradiction:

Improvesensor operation stabilityVSAvoidcondensation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces gaps as an intermediary space between the sensor module housing and the inner wall, filled with insulating material or air, to mediate thermal transfer and prevent condensation while maintaining structural stability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent uses a simple plastic bag or insulating material as a temporary or replaceable thermal barrier between the sensor module and the inner wall, providing effective thermal insulation without complex permanent structures

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Strength

If the housing is in direct contact with the inner wall, then the mechanical support is improved, but thermal isolation is reduced leading to condensation

Engineering Contradiction:

Improvemechanical supportVSAvoidthermal isolation

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The patent divides the contact interface between the housing and inner wall into discrete contact points through feet or support structures, rather than continuous contact, allowing thermal isolation in the gaps while maintaining mechanical support at specific locations

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different properties to different parts of the housing: the feet or support areas provide mechanical contact and support, while the gaps between these localized contact points provide thermal isolation and prevent condensation

Inventive Principle:

Principle #3Local quality

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 design stabilizes the sensor operations by preventing condensation, ensuring accurate readings and maintaining sensor functionality even in low temperatures.

Implementation Method 1

a battery configured to supply electrical power to the sensor circuit

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

A gap is between the inner wall and the housing and between the housing and a first member under the housing

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11879753B2Sensor and sensor module

Publication Date: 2024.01.23 KK TOSHIBA

AI summary

A sensor includes a handhole part and a sensor module. The handhole part includes an inner wall and a holder. The holder is located at the inner wall. The sensor module is provided in the handhole part. The sensor module includes a held part held by the holder, a housing connected with the held part, a sensor circuit provided in the housing and including a gas sensor element, and a battery configured to supply electrical power to the sensor circuit. A gap is between the inner wall and the housing and between the housing and a first member under the housing.