Gasket-Free Sensor Sealing via Integral Segments
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Solution Overview
Problem
Existing sensor packaging solutions require additional sealing parts, such as gaskets, which increase costs and risk of loss during maintenance, and do not provide a reliable watertight seal in humid or wet environments, posing safety risks due to moisture ingress and potential short circuits.
Innovation Solution
A sensor assembly design featuring a gasket-free sealing region between two segments with sloped surfaces that form a tight fit when assembled, eliminating the need for extra sealing parts and ensuring a watertight seal without visible external components, using integral polymer plastic parts and a bayonet mounting mechanism for secure locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gaskets or sealing rings are used to ensure watertightness, then sealing reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent removes the gasket component entirely from the sealing system. Instead of using a separate gasket or sealing ring, the invention creates a gasket-free sealing region where the cover member and first member directly contact each other through precisely engineered complementary surfaces, eliminating the need for extra sealing parts
Solution Approach 2:
The sealing function is merged into the structural design of the first member and cover member themselves. The encircling wall and contact surfaces are designed to provide both structural support and sealing functionality simultaneously, combining what were previously separate sealing components into the main housing structure
2Reliability
If gaskets are used for sealing, then watertightness is improved, but risk of part loss during maintenance increases
Solution Approach 1:
By removing the gasket component entirely, the patent eliminates the risk associated with gasket loss during battery replacement or maintenance operations. The gasket-free design ensures that no separate sealing parts can be misplaced or lost when the device is opened for maintenance
3Reliability
If multiple sealing parts are used, then sealing reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the need to purchase, inventory, and install separate gasket components. The sealing functionality is achieved through the molded-in design of the first member and cover member, reducing bill of materials costs and simplifying manufacturing processes
Solution Approach 2:
The sealing function is integrated into the housing components themselves, which are likely molded as single pieces using polymer plastics. This consolidation reduces the total number of parts that need to be manufactured, assembled, and quality-checked, thereby reducing overall manufacturing cost
4Reliability
If threaded casings are used for watertight sealing, then sealing reliability is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent removes threaded coupling mechanisms from the sealing system. Instead of using threads to achieve watertightness, the invention employs a gasket-free sealing region with complementary contact surfaces that provide sealing through direct contact and geometric interference, eliminating the need for threaded assemblies
Data Source
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AI summary
A watertight sensor assembly (100, 500) is disclosed. The assembly (100, 500) comprises a first member (102, 502), at least one sensor positioned in or on the first member (102, 502), and a cover member (101, 501) for covering the at least one sensor. The first member (102, 502) comprises at least a base portion (103, 503) and a first segment (104, 504) forming a encircling wall for the at least one sensor and the cover member (101, 501) comprises at least a top portion and a second segment (107, 507). The first segment (104, 504) and the second segment (107, 507) are adapted in shape and/or position so that, when the cover member (101, 501) is mounted to the first member (102, 502), the first segment (104, 504) and the second segment (107, 507) are positioned adjacent and in contact with each other to form a sealing region between the first member (102, 502) and the cover member (101, 501) based on a tight fit in a contact area (314) between the first segment (104, 504) and the second segment (107, 507).