Insert-Molded Steam Generator Level Sensor for Leak-Free Detection
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Solution Overview
Problem
Conventional water level sensors in steam generators for clothes washing machines are complex, leading to reduced productivity, erroneous level detection due to water undulation, and potential electrical leakage, with limited installation positions and simple structures.
Innovation Solution
A water level sensor integrated by insert molding, featuring a conductor and housing as a single body, preventing gaps and allowing for easy assembly and curved designs to adjust depth, with a covering part extending to the end of the conductor to prevent droplet-induced errors and undulation restrictions to enhance precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional water level sensors are used with separate housing and electrodes, then the sensor can be assembled, but the assembly process becomes complex and productivity decreases
Solution Approach 1:
The patent merges the housing and electrodes into a single integrated component through insert molding. The conductor (electrode) is inserted into the housing cavity, and molten resin is injected to form the housing around the conductor, creating a unified water level sensor assembly. This eliminates separate assembly steps and reduces manufacturing complexity.
2Reliability
If conventional water level sensors are used with gaps between electrodes and housing, then assembly is simpler, but water leakage and electrical leakage occur
Solution Approach 1:
The insert molding process creates a seamless integration where the resin housing completely encapsulates the conductor, eliminating gaps between the electrode and housing. This unified structure prevents both water leakage and electrical leakage without requiring additional sealing components or complex sealing procedures.
3Measurement precision
If conventional water level sensors are used with limited covering, then the structure is simpler, but erroneous level detection occurs due to water undulation
Solution Approach 1:
The integrated housing structure extends to completely cover the conductor, creating a unified encapsulation that prevents water undulation from affecting the electrode. The resin housing acts as a protective barrier that stabilizes the conductor position and prevents false level detection caused by water movement, while maintaining structural simplicity.
4Adaptability or versatility
If conventional water level sensors are used with straight conductor design, then manufacturing is easier, but installation position is limited
Solution Approach 1:
The conductor design transitions from a fixed straight shape to a flexible configuration that can be bent into curved shapes. The insert molding process accommodates pre-bent conductors, allowing the electrode to follow curved paths and reach various installation positions within the steam generator while maintaining the simplicity of the molding process.
Data Source
AI summary
A steam generator is used in a machine such as a clothes washing machine, a clothes drying machine, a clothes washing and drying machine, and the like and a level sensor is used in the same. More particularly, a level sensor is integrally formed by molding and conveniently assembled in the steam generator. The steam generator includes a case having a space for storing water, and formed with a level sensor insertion hole and a level sensor. The level sensor includes a conductor having a detector positioned in the space for storing the water and a connector electrically connected to the exterior, and a level sensor housing is inserted into the level sensor insertion hole and is integrally formed with the conductor by insert molding.