Inverted Cone Probe Transition for Sensor Sealing Integrity
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Solution Overview
Problem
Conventional probe transitions in sensors for determining process variables in containers face challenges such as leakage, mechanical damage, and complex metalworking requirements, which affect sealing integrity and durability, especially in dynamic and hygienic applications.
Innovation Solution
The proposed solution involves an inverted cone element with a conical design, where the cone's base is oriented downwards, creating a sealing interface with sloping bearing surfaces and a ring welded to the probe for additional support, enhancing sealing and stability with minimal additional effort, and using PEEK for the cone element and metal for the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cutting edge is used to seal the probe to the cone, then sealing is achieved, but the probe diameter is significantly reduced creating a weak point prone to fatigue fracture
Solution Approach 1:
The patent inverts the conventional sealing approach by placing the cutting edge on the cone element instead of on the probe. This reversal allows the probe to maintain its full diameter and structural integrity while the cone element absorbs the sealing function through its cutting edge that penetrates the PEEK material.
Solution Approach 2:
The cone element acts as an intermediary component between the probe and the housing. It provides a sealing interface through its cutting edge without requiring the probe itself to be modified with a cutting edge, thus preserving the probe's strength while achieving reliable sealing.
2Reliability
If disc springs are used to seal the cone to the housing, then sealing is achieved, but process pressure acts against the spring force reducing the sealing effect
Solution Approach 1:
The patent inverts the sealing mechanism by using a cutting edge on the cone element that actively penetrates the PEEK housing material, rather than relying on spring force to push the cone against the housing. This inversion makes the sealing effective even under high process pressure.
Solution Approach 2:
The patent converts the harmful effect of process pressure into a beneficial sealing mechanism. The cutting edge design allows process pressure to force the cone element's cutting edge deeper into the PEEK housing, enhancing the sealing effect rather than reducing it.
3Reliability
If a conventional probe transition design is used, then connection is achieved, but complex metalworking and precise manufacturing are required
Solution Approach 1:
The patent changes the material parameter of the cone element to PEEK, a thermoplastic that can be manufactured using molding processes rather than complex metalworking. This parameter change from metal to plastic simplifies manufacturing while maintaining connection stability.
Solution Approach 2:
The patent uses a composite design where the cone element is made of PEEK and the housing is made of metal. This combination allows the PEEK cone to be manufactured with simpler processes while the metal housing provides structural strength, reducing overall manufacturing complexity.
Data Source
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AI summary
A sensor (10) for determining a process variable in a container (12) is described, comprising an elongated probe (16) for immersion in a medium (14) in the container (12), a control and evaluation unit (24) for measuring the process variable by means of the probe (16), and a housing (22) with a connection area for connecting an upper end of the probe (16) to the housing (22), wherein the connection area rests with an inclined bearing surface (32) on a conical element (26) arranged in the connection area. The base of the conical element (26) is oriented downwards towards the lower end of the probe (16).