Metal Sensor Housing with Integral Eyelets for Deformation Resistance
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Solution Overview
Problem
Sensors with microchip sensor elements face deformation and subsequent measurement distortion when bolted to uneven surfaces due to inadequate stability of their housings, which are often made of plastic or metal, leading to mechanical stress and sensitivity issues.
Innovation Solution
The sensor housing is designed with integral attachment eyelets that limit cross-sectional pass-through openings to prevent deformation, using a metal material for increased stability, and featuring a recess with a non-circular contour for secure electronic circuit board placement and elastic encasement to distribute forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the housing is made from plastic material, then the manufacturing cost is reduced and ease of manufacture is improved, but the stability and resistance to deformation under bolting forces deteriorates
Solution Approach 1:
The patent changes the material parameter from plastic to metal (specifically aluminum alloy), which fundamentally alters the mechanical properties including strength, stiffness, and resistance to deformation. This material substitution resolves the contradiction by providing sufficient stability under bolting forces while maintaining manufacturing feasibility through standard metal forming processes
Solution Approach 2:
The housing employs a composite structure combining metal material with an encasement compound (epoxy resin or similar). The metal provides structural strength and stability, while the encasement compound provides damping and protection. This composite approach maintains ease of manufacture through conventional processes while achieving superior stability and deformation resistance
2Stability of the object's composition
If the housing dimensions are increased to prevent deformation, then the stability is improved, but the compactness and portability deteriorate
Solution Approach 1:
By changing the material parameter to metal with higher strength-to-weight ratio, the housing achieves sufficient stability and deformation resistance at reduced dimensions. The metal material's superior mechanical properties allow the same structural performance in a more compact form factor, resolving the contradiction between stability and volume
Solution Approach 2:
The patent optimizes the dimensional parameters of the housing, particularly the wall thickness and overall size, to achieve the minimum dimensions required for structural stability. By carefully selecting dimensional parameters in conjunction with the metal material, the housing achieves compactness without sacrificing stability under bolting forces
3Strength
If the wall thickness is increased to prevent deformation, then the strength and stability are improved, but the weight and volume increase
Solution Approach 1:
The patent changes the material parameter to metal, which has a higher strength-to-weight ratio than plastic. This allows the housing to achieve sufficient strength and deformation resistance with thinner walls, thereby reducing both weight and volume while maintaining structural integrity under bolting forces
Solution Approach 2:
The patent optimizes the wall thickness parameter to the minimum value required for structural stability. By selecting the optimal wall thickness in conjunction with the metal material, the housing achieves the necessary strength with minimal weight and volume, resolving the contradiction between strength and weight
4Strength
If bolts are tightened to secure the sensor to uneven surfaces, then the attachment strength is improved, but the mechanical stress and deformation of the housing increase
Solution Approach 1:
The patent changes the material parameter to metal, which has superior strength and stiffness properties. This allows the housing to withstand high bolting forces and mechanical stress without deforming, resolving the contradiction between attachment strength and stress resistance
Solution Approach 2:
The composite structure of metal housing with encasement compound provides both strength for attachment and damping for stress distribution. The metal framework handles the bolting forces while the encasement compound distributes and dampens the mechanical stress, protecting the sensor elements from deformation
5Stability of the object's composition
If the housing is made more rigid to prevent deformation, then the stability is improved, but the ability to absorb mechanical shocks deteriorates
Solution Approach 1:
The patent employs a composite structure where the metal housing provides rigid structural stability and shock resistance, while the encasement compound (epoxy resin or similar) provides additional damping and cushioning. This combination maintains stability under normal conditions while absorbing mechanical shocks and protecting the sensor elements from damage
Data Source
AI summary
In order to configure a housing (3) for a sensor received in the housing as deformation stable as possible the housing is made integrally in one piece from metal instead of being made from plastic and furthermore the pass through openings (6a, b) for attaching the sensor by bolting to another component are sized and positioned so that impartible forces are not able to deform the housing (3) which has a defined stability.