Reflective Thermal Sleeve Assembly for Secure Serviceable Sensor Mounting
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Solution Overview
Problem
Existing thermal sleeve assemblies for protecting sensors in harsh automotive environments face challenges in secure and reliable attachment, as adhesives and interference fits are unreliable and complicate servicing, while additional fastening devices increase complexity and cost.
Innovation Solution
A thermal sleeve with a tubular member and a separate positioning member featuring radially extending tangs that are fixedly disposed to inhibit movement, allowing for secure attachment without secondary fasteners, enabling easy removal and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive attachment is used to secure the sleeve about the sensor, then the sleeve is initially securely attached, but the sleeve cannot be easily removed for sensor servicing and the adhesive can breakdown over time causing the sleeve to become dislodged
Solution Approach 1:
The attachment mechanism is segmented into two distinct components: the positioning member with tangs that engage with the sensor, and the sleeve that provides thermal protection. This segmentation allows the positioning member to remain attached to the sensor while the sleeve can be independently removed for sensor servicing, resolving the contradiction between secure attachment and ease of repair.
Solution Approach 2:
The positioning member acts as an intermediary component between the sensor and the sleeve. It provides the secure attachment function through tangs that engage with the sensor, while allowing the sleeve to be easily removed when servicing is needed, thus mediating between the conflicting requirements of reliable attachment and ease of repair.
2Ease of repair
If tape or interference fit is used to attach the sleeve, then the sleeve can be removed, but the attachment is unreliable under heat and vibration conditions
Solution Approach 1:
The attachment function is segmented from the protective function. The positioning member with engagement tangs handles the reliable attachment under heat and vibration, while the sleeve maintains its removability for servicing. This segmentation resolves the contradiction by assigning different functions to different components.
Solution Approach 2:
The mechanical attachment system replaces adhesive or tape-based systems. The positioning member uses mechanical engagement features (tangs) that provide reliable attachment under harsh conditions while still allowing for easy removal when needed, substituting the unreliable adhesive/tape mechanical systems.
3Reliability
If a separate end cap with secondary fastening devices is used, then the sleeve can be secured, but the complexity and cost of manufacture and assembly increases
Solution Approach 1:
The positioning and attachment functions are merged into a single integrated positioning member. The tangs on the positioning member provide both the positioning function and the attachment security, eliminating the need for separate end caps and secondary fastening devices, thus reducing complexity while maintaining reliability.
Solution Approach 2:
The positioning member serves multiple functions: it positions the sleeve, secures the sleeve through tang engagement, and provides attachment security without requiring additional components. This multi-functionality eliminates the need for separate fastening devices, reducing assembly complexity while maintaining reliable attachment.
4Ease of manufacture
If interference fit is used to attach the sleeve, then the sleeve can be assembled without adhesives, but assembly becomes difficult if the interference is too great or the sleeve must traverse obstacles
Solution Approach 1:
The attachment mechanism is segmented into the positioning member with tangs and the sleeve. The positioning member can be assembled separately onto the sensor, and then the sleeve is attached to the positioning member rather than directly to the sensor. This segmentation eliminates the need for difficult interference fits or adhesives, simplifying both manufacture and assembly operations.
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 provides a secure, reliable, and cost-effective means of attaching the thermal sleeve to sensors, eliminating the need for adhesives and additional fastening devices, thus simplifying assembly and maintenance while maintaining effective thermal protection.
Implementation Method 1
a reflective outer layer comprising, for example, an aluminum foil layer laminated to an outer surface of the inner layer
Implementation Method 2
at least one resilient flange extending radially inwardly from the tubular portion for abutment with the wiring harness
Data Source
AI summary
A thermal sleeve for protecting an electronic member connected to a wiring harness against exposure to heat is provided. The thermal sleeve has a tubular member including a circumferentially continuous wall with an inner surface bounding an inner cavity extending along a central axis between open opposite ends and a reflective outer surface. The thermal sleeve includes a positioning member constructed of a separate piece of material from the tubular member. The positioning member has a circumferentially continuous, tubular portion and at least one resilient flange extending radially inwardly from the tubular portion for abutment with the wiring harness. The tubular portion has a plurality of tangs extending radially therefrom. The tangs are fixedly disposed in the wall of the tubular member to inhibit relative rotational and/or axial movement between the tubular member and the positioning device.