Pressure Switch Spatter Trapping via Communication Passage
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Solution Overview
Problem
Conventional pressure switches connected to fluid circuits face issues with deformation due to trapped fluid expansion, as spatters generated during projection-welding are not effectively contained, leading to pressure buildup and potential damage to the connection member and case part.
Innovation Solution
A fluid-related function device with a metal connection member and case part bonded by annular projection-welding, featuring a communication passage that allows fluid flow while trapping spatters, preventing them from passing through and releasing pressure to prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If projection-welding is performed to bond the joint and cap member, then the connection strength is improved, but spatters are generated and trapped in the space between the components causing pressure buildup
Solution Approach 1:
The harmful spatters are extracted from the fluid circuit system by providing a dedicated trapping space between the joint and cap member. The spatters are separated from the fluid flow path and contained in a specific region, preventing them from entering the fluid circuit while maintaining the welding connection.
Solution Approach 2:
A communication passage with a filter structure acts as an intermediary between the spatter-trapping space and the fluid circuit. This intermediary structure allows fluid to pass through while blocking spatters, enabling selective transmission based on size and properties.
2Object-generated harmful factors
If the peripheral edge of the inner hole is crimped to seal the space, then spatters are trapped effectively, but fluid cannot escape and pressure builds up causing deformation
Solution Approach 1:
The communication passage structure provides locally different properties: it allows fluid molecules to pass through while blocking larger spatter particles. This local quality differentiation enables selective permeability, allowing pressure equalization for fluid while maintaining containment for spatters.
Solution Approach 2:
The communication passage serves as an intermediary structure that mediates between the need to trap spatters and the need to release pressure. It selectively transmits fluid while retaining spatters, balancing the conflicting requirements of containment and pressure relief.
3Stress or pressure
If a communication passage is provided to release pressure, then deformation is prevented, but spatters may flow out into the fluid circuit
Solution Approach 1:
The communication passage structure has specific local properties (dimensions, shape, material characteristics) that create a size-based filtration effect. These local qualities enable the passage to differentiate between fluid molecules and spatter particles, allowing selective transmission.
Solution Approach 2:
The communication passage functions as a porous structure that allows fluid to pass through while blocking larger spatter particles. The pore size and structure are designed to provide filtration capability, enabling pressure relief without spatter leakage.
4Object-generated harmful factors
If the gap between inner projection and lid member is made small to prevent spatter leakage, then spatter containment is improved, but the inner projection may weld to the lid member and spatters still flow out
Solution Approach 1:
The welding structure is segmented into multiple independent welding locations around the periphery. This segmentation allows the welding process to be distributed, preventing concentrated heat buildup that could cause the inner projection to weld to the lid member while still maintaining effective spatter containment.
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 effectively contains spatters and allows fluid to flow through communication passages, preventing pressure buildup and thus suppressing deformation of the connection member and case part, even when fluid expands due to temperature changes.
Implementation Method 1
the connection member and the case part being bonded to each other by projection-welding which is carried out annularly to surround the respective inner holes
Implementation Method 2
the communication passage is formed such that it permits the fluid to pass through the communication passage and restrains spatters generated by the projection-welding from passing through the communication passage
Data Source
AI summary
The present invention provides a fluid-related function device capable of suppressing deformation of a connection member and a case part which may adversely be generated by expansion of fluid stored in a space in which spatters at the time of resistance-welding are trapped. A pressure switch includes a space in which spatters generated at the time of projection-welding are trapped. The space is provided between a joint and a cap member. A communication passage brings inside and outside of the space into communication with each other. The communication passages is formed such that it permits fluid to pass through the communication passages and restrains spatters from passing through the communication passages.