Movable Wall Sensor Housing Tool for Moisture Protection
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Solution Overview
Problem
The existing methods for housing sensor measuring elements using injection molding or casting leave the measuring element exposed, leading to moisture penetration and reduced sensor lifespan, as it cannot be securely embedded within the molding cavity.
Innovation Solution
A tool with a movable wall within the molding cavity allows the measuring element to be positioned on the wall, which then moves away during the molding process, ensuring the element is secured by the hardening material, and additional material is injected to fill the gap, preventing moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the measuring element is placed on the wall that delimits the molding cavity, then the measuring element can be positioned and supported during injection molding or casting, but the measuring element remains exposed and uncovered at this site, allowing moisture to penetrate
Solution Approach 1:
The wall that delimits the molding cavity is made dynamically movable rather than fixed. The wall can be displaced relative to the measuring element during the molding process, allowing it to initially support the measuring element and then move away to enable complete encapsulation with housing material, eliminating exposed sites where moisture could penetrate.
Solution Approach 2:
The measuring element is preliminarily positioned on the movable wall before the injection molding or casting process begins. This preliminary placement allows the measuring element to be securely supported during the initial stage of material injection, and then the wall moves away to allow the material to fully encapsulate the measuring element.
2Stability of the object's composition
If the measuring element is embedded in the molding cavity wall, then the element is secured in place, but the element remains exposed and uncovered, reducing serviceable life
Solution Approach 1:
The molding cavity wall is designed with a movable portion that can be displaced relative to the measuring element. This dynamic structure allows the wall to initially hold the measuring element in a stable position during material injection, then move away to enable complete encapsulation, thereby protecting the measuring element and extending the sensor's serviceable life by preventing moisture penetration.
3Device complexity
If a fixed molding cavity wall is used, then the structure is simple, but the measuring element cannot be fully encapsulated with housing material, leaving exposed sites
Solution Approach 1:
The molding cavity incorporates a movable wall portion that can be displaced during the injection molding or casting process. This dynamic feature enables the measuring element to be completely encapsulated by the housing material without leaving exposed sites, while adding only minimal complexity to the overall molding cavity structure.
Solution Approach 2:
The molding cavity wall is segmented into fixed and movable portions. The movable portion can be displaced relative to the fixed portions, allowing the measuring element to be completely encapsulated by housing material. This segmentation resolves the contradiction between structural simplicity and complete encapsulation by isolating the complexity to only the necessary movable portion.
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 significantly extends the sensor's service life by preventing moisture penetration and ensuring a sealed housing around the measuring element.
Implementation Method 1
the material that is to be injected or cast in the molding cavity holds the measuring element in place, said material being hardened or even already cured
Implementation Method 2
at least one part of the wall that delimits the molding cavity is mounted in such a manner that it can be displaced
Data Source
AI summary
A tool for the primary shaping of a housing for a sensor which is designed to capture, via a sensing element, a physical area that is dependent on a variable to be measured, and to emit an electrical output signal on the basis of the captured physical area, including: —a mold cavity for receiving a material that molds the housing, and the sensing element, and —a box having a wall that bounds the mold cavity, wherein at least a part of the wall that bounds the mold cavity is mounted in a displaceable manner.