Magnetic Sensing Switch Air-Free Sealant Injection

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Solution Overview

Problem

Conventional magnetic sensing switches face issues with air entrapment and bubble formation during sealant injection, leading to inaccurate positioning of magnetic reed switches and wires, reduced production efficiency, and increased costs due to prolonged curing times and yield loss.

Innovation Solution

A magnetic sensing switch design featuring a plug with a sealant injection portion and retaining portion made of elastic material, providing an interference fit and expelling air, ensuring the sealant completely wraps the magnetic reed switch and wires, preventing displacement and ensuring accurate positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If sealant is injected into the hollow tube to position the magnetic reed switch, then the magnetic reed switch can be secured, but air is brought into the tube causing positioning inaccuracies and requiring multiple injection steps

Engineering Contradiction:

Improvepositioning accuracy of magnetic reed switchVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The plug is pre-installed in the tube before sealant injection, creating a sealed environment that prevents air entrapment during the subsequent sealant injection process. This preliminary action eliminates the need for multiple injection steps to correct air bubbles, thereby improving both positioning accuracy and production efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plug acts as an intermediary component that facilitates controlled sealant injection through its injection hole while preventing air from entering the tube. The plug mediates between the external sealant source and the internal tube environment, ensuring air-free sealant application and accurate component positioning

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If sealant is injected to fix the magnetic reed switch, then positioning is achieved, but air bubbles form and float upward causing insulation failure and requiring production interruption

Engineering Contradiction:

Improveinsulation reliability of magnetic reed switchVSAvoidcuring time and production interruption

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The plug is installed beforehand to establish a sealed injection system that prevents air bubble formation from the start. This preliminary sealing action eliminates the need for subsequent bubble-piercing and re-injection steps, maintaining insulation reliability while avoiding production time loss

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plug with its controlled injection hole extracts the harmful air bubbles from the sealant injection process by providing a narrow passage that allows sealant to enter while preventing air from being trapped. This extraction of air prevention mechanism ensures continuous production without interruptions for insulation repairs

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If conventional sealant injection is used, then the magnetic reed switch can be positioned, but air entrapment causes bubbles to form and float up exposing copper wires

Engineering Contradiction:

Improvepositioning accuracy of magnetic reed switch and wiresVSAvoiddifficulty of securing components

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The plug serves as an intermediary device that controls sealant flow through its injection hole, preventing air entrapment while ensuring complete wire and component encapsulation. This intermediary mechanism simplifies the manufacturing process by eliminating the need for complex multi-step injection procedures to achieve accurate positioning and secure component fixation

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution achieves accurate component positioning, enhances production efficiency, and improves yield by eliminating air pockets and ensuring the magnetic reed switch remains immovable after sealant curing.

Implementation Method 1

The plug is made of an elastic material to provide an elastic clamping force

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the plug is interference fit in the hollow tube, thereby preventing a relative displacement between the magnetic reed switch and the wire

Methodology Applied

Scientific EffectInterference fit: Mechanical Force

Data Source

PatentUS9773629B1Magnetic sensing switch

Publication Date: 2017.09.26 FINETEK CO LTD

AI summary

A magnetic sensing switch includes switch body having a hollow tube and an opening. A magnetic reed switch is disposed in the tube and includes two conductive points. The plug having an elastic clamping force is fixed in the opening by interference fit. The plug including a sealant injection portion and a retaining portion communicating with the tube. The two wires are inserted in the tube, one end of each wire is connected to one conductive point, and the other end passes through the retaining portion to protrude out of the tube. A sealant is injected into the tube via the sealant injection portion to entirely wrap the magnetic reed switch and the wires inside the tube, and the sealant partially protrudes out of the sealant injection portion.