Gas Sensor Seal Protrusion for Wire Protection
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Solution Overview
Problem
Existing gas sensors with protection members having small openings in the ventilation unit are prone to clogging and can damage lead wires during installation due to protrusions that may hook onto them, and are vulnerable to external impacts that can break the filter member.
Innovation Solution
A gas sensor design featuring a seal member with a protrusion that extends beyond the rear end surface of the seal member, preventing lead wire damage and ensuring good air ventilation while protecting the filter member from external impacts by having a smaller opening than the atmosphere communication hole, and optionally incorporating arms and grooves for additional protection and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a protection member with small openings is provided to cover the filter member, then the filter member is protected from external impacts, but the openings may be clogged and air ventilation is restricted
Solution Approach 1:
The protection member is divided into multiple ventilation portions with openings arranged in a radial direction, allowing air to flow through multiple paths while maintaining protection. This segmentation prevents clogging by distributing the ventilation load across multiple smaller openings rather than a single large opening.
Solution Approach 2:
The openings in the ventilation portions are arranged in a radial direction rather than axially, creating a three-dimensional ventilation pattern. This radial arrangement allows air to enter from multiple directions simultaneously, improving ventilation efficiency while maintaining small opening sizes for protection.
2Reliability
If a protrusion is provided on the protection member to improve air ventilation, then good air ventilation is ensured, but the protrusion may hook and damage lead wires during installation
Solution Approach 1:
The lead wire is inserted into the lead wire insert hole of the seal member before the protection member is assembled onto the outer tube. This preliminary insertion ensures the lead wire is positioned safely within the seal member, preventing it from being hooked or damaged by the protrusion during subsequent assembly operations.
Solution Approach 2:
The seal member acts as an intermediary structure that provides a dedicated lead wire insert hole, guiding and protecting the lead wire during assembly. This intermediary component separates the lead wire routing function from the protection member, eliminating the risk of the protrusion damaging the lead wire.
3Object-affected harmful factors
If multiple small openings are provided in the protection member, then protection from impacts is improved, but the openings are prone to clogging
Solution Approach 1:
The protection member is designed with elastic properties, allowing it to deform elastically under external impact forces. This dynamic response enables the structure to absorb impact energy while maintaining open ventilation passages, preventing permanent blockage that would occur with rigid small openings.
Solution Approach 2:
The opening area of the ventilation portions is specifically optimized to balance protection and ventilation requirements. The openings are sized to be small enough to resist clogging from debris yet large enough to maintain adequate air flow, achieving an optimal parameter range that satisfies both contradictory requirements.
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 design effectively prevents lead wire damage and maintains air ventilation while protecting the filter member from external impacts, reducing the risk of clogging and breakage due to its specific protrusion and arm configurations.
Implementation Method 1
a filter member for introducing the atmosphere into the outer tube (air ventilation) and preventing the entry of water droplets (waterproofing properties)
Data Source
AI summary
A gas sensor, including a cylindrical outer tube; and a seal member disposed in the outer tube, the seal member including: a lead wire insert hole and an atmosphere communication hole extending in an axial direction thereof. The gas sensor further includes: a protection portion which covers the atmosphere communication hole from the rear end of the gas sensor in the axial direction, the protection portion having a protrusion which protrudes toward a rear side of the gas sensor, and has an opening smaller than an opening of the atmosphere communication hole, wherein the protrusion is disposed at a further front end side of the rear end surface of the seal member.