Plug-in Sensor Thread Segmentation for Corrosion Protection
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Solution Overview
Problem
Conventional pressure and temperature sensors in air conditioning systems, particularly in CO2 systems, face challenges with high operating pressures and temperatures, and are susceptible to corrosion from corrosive media due to design flaws like blow-out grooves that allow impurities to reach the sealing surfaces, compromising hermeticity and reliability.
Innovation Solution
A plug-in sensor with an external thread subdivided into continuous and interrupted sections, where the continuous section protects the sealing surface from corrosive media and the interrupted section allows easy insertion by providing blow-out grooves, manufactured using powder metallurgical methods like metal injection molding to enhance durability and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flattenings (blow-out grooves) are provided on the threads to facilitate threading, then ease of operation is improved, but corrosive media can reach the sealing surface causing reliability to deteriorate
Solution Approach 1:
The external thread is divided into two distinct sections: a first threaded section with continuous threads for protection, and a second threaded section with interrupted threads (blow-out grooves) for ease of installation. This segmentation allows each section to fulfill its specific function without compromising the other.
Solution Approach 2:
Different parts of the external thread are given different structural qualities - the first section has continuous threads for corrosion protection, while the second section has interrupted threads for installation ease. Each local region is optimized for its specific purpose.
2Ease of manufacture
If conventional threading with blow-out grooves is used, then ease of manufacture is improved, but protection against corrosive media is insufficient causing durability to deteriorate
Solution Approach 1:
The thread structure is segmented into protective and installable sections, allowing the sensor to maintain threading capability while extending service life through corrosion protection.
Solution Approach 2:
The first threaded section with continuous threads is designed to prevent corrosive media from reaching the sealing surface before damage can occur, providing preliminary protection that extends the sensor's operational life.
3Adaptability or versatility
If separate pressure and temperature sensors are used, then measurement capability is improved, but device complexity increases
Solution Approach 1:
Multiple sensing functions (pressure and temperature measurement) are merged into a single integrated sensor body, eliminating the need for separate sensors and reducing overall system complexity while maintaining full measurement capability.
Data Source
AI summary
A plug-in sensor for measuring at least one property of a fluid medium, in particular for use in the coolant circuit of an air conditioning system of a motor vehicle. The plug-in sensor has at least one sensor for detecting the at least one property. Furthermore, the plug-in sensor has at least one sensor body having an external thread for threading the plug-in sensor into a threaded bore hole of a housing. Furthermore, the plug-in sensor includes a sealing surface for sealing an inner space of the housing against an outer space. The external thread has at least two threaded sections: a first threaded section including at least one continuous thread, and a second threaded section including at least one interrupted thread, at least one interruption of the at least one interrupted thread forming at least one blow-out groove.