Inductive Sensor Sleeve Welding for Sealing
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Solution Overview
Problem
Current methods for manufacturing inductive sensors are cumbersome and prone to high preparation and assembly efforts, with risks of rejects due to sensitivity to pressure and temperature, and require complex bonding processes that are time-consuming and vulnerable to thermal expansion issues.
Innovation Solution
A method involving welding the sleeve directly to the housing without an intermediate layer, using a collar for precise positioning and ultrasonic welding to create a material-bonded connection, simplifying the manufacturing process and eliminating the need for subsequent finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coils are inserted into a separate coil housing and injection molded around with synthetic material, then the coils are protected during processing, but the preparation and assembly effort increases and the risk of rejects increases due to coil sensitivity to pressure and temperature
Solution Approach 1:
The invention extracts the coils from the housing structure entirely. Instead of inserting coils into a separate coil housing and injection molding, the coils are mounted directly on the support plate which is then inserted into the housing. This eliminates the intermediate coil housing and injection molding process, reducing complexity while maintaining coil protection through the housing's inherent structure.
Solution Approach 2:
The invention segments the manufacturing process by mounting coils on a separate support plate before insertion into the housing. This allows coil assembly and housing assembly to be prepared independently, reducing the risk of rejects during injection molding while maintaining protection through the final integrated structure.
2Strength
If the coils are premounted in a coil housing with soldering and welding, then the coils are secured, but the preparation and assembly effort increases and subsequent finishing of weld seams is necessary
Solution Approach 1:
The invention replaces mechanical connection methods (soldering, welding, threading) with a simplified mounting system where coils are directly fixed on the support plate using adhesive or mechanical fasteners. The support plate itself provides structural support, eliminating the need for additional welding or threading operations and subsequent finishing work.
Solution Approach 2:
The coils are preliminarily mounted on the support plate in a simplified manner before the support plate is inserted into the housing. This preliminary mounting does not require complex welding or soldering, and the final securing is achieved through the housing's structure, eliminating subsequent finishing operations.
3Reliability
If the housing is closed with a sleeve inserted through a wall and adhered with adhesive, then the housing is sealed, but the bonding process requires complex treatment and time consumption, and the bond gap has different thermal expansion properties
Solution Approach 1:
The invention extracts the sealing function from the adhesive bonding process. Instead of using adhesive to seal the sleeve to the housing, the sleeve is designed with a collar that is pressed into a cavity of the housing, creating a mechanical interference fit that provides both sealing and positioning functions, eliminating the need for adhesive bonding and subsequent finishing.
Solution Approach 2:
The sleeve and housing are designed as complementary components where the collar material and housing cavity material work together to create a sealed connection. The collar is pressed into the cavity to form an interference fit that provides both mechanical strength and sealing, combining the functions of positioning and sealing in a single integrated solution.
4Strength
If adhesive is used to bond the sleeve to the housing, then the sleeve is secured, but the adhesive has lesser chemical resistance than plastic and requires complex treatment
Solution Approach 1:
The invention extracts the adhesive intermediate layer from the connection system. The sleeve is directly mechanically connected to the housing through the collar-cavity interference fit, eliminating the adhesive layer and its associated chemical resistance limitations. The plastic-on-plastic mechanical connection provides superior chemical resistance compared to adhesive bonding.
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 results in a stable, sealed, and efficient manufacturing process with reduced preparatory work, ensuring the integrity of the coils and electronics while preventing damage from external influences, and facilitating smoother flow of measured media through the sensor.
Implementation Method 1
the collar of the sleeve is pressed into the first cavity during the welding. Via application of pressure onto the collar of the sleeve, the collar melts together with the cavity of the housing
Implementation Method 2
the collar melts together with the cavity of the housing
Implementation Method 3
using a collar for precise positioning and ultrasonic welding to create a material-bonded connection
Data Source
AI summary
A method for manufacture of an inductive sensor, wherein coils are placed on both sides of a support plate surrounding an opening of the support plate, and the support plate with the coils is inserted into a housing. A sleeve is inserted through a first cavity of the housing through the opening of the support plate into the housing. In order to achieve a secure and temperature independent joint between the sleeve and the housing, the sleeve (5) is welded with the housing (2).