Sealed Grommet for Exhaust Sensor Using Fluoropolymer Fill
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Solution Overview
Problem
Existing exhaust gas sensors face manufacturing complexity due to the need for multiple discrete components for sealing, particularly in high-temperature and aggressive environments, where a reliable and durable seal is required between the protective sleeve and connection cables.
Innovation Solution
A cable bushing system using a metallic protective sleeve with thermoplastically processable fluoropolymer materials, such as PFA or FEP, is introduced to fill the space between the sleeve and connection cables, eliminating the need for prefabricated plugs and simplifying the manufacturing process by using a single, homogeneous material for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple discrete pre-formed components are used for sealing the cable exit, then the sealing reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple discrete sealing components (prefabricated plug, hose, insulating sheaths) into a single integrated cable gland made of fluorinated plastic. This single component performs multiple sealing functions simultaneously, eliminating the need for separate assembly steps and reducing manufacturing complexity while maintaining sealing reliability.
Solution Approach 2:
The cable gland according to the invention serves multiple functions within a single component: it seals the cable penetration, provides mechanical support for the cables, and offers electrical insulation. This multi-functional design replaces the need for multiple specialized components, simplifying the overall structure and manufacturing process.
2Reliability
If numerous discrete components are assembled for cable sealing, then the seal tightness is improved, but the manufacturing time increases
Solution Approach 1:
The cable gland is designed as a pre-formed single piece with all necessary sealing features integrated into its structure. The cable passages and sealing surfaces are built-in during manufacturing of the single component, eliminating the need for subsequent assembly operations and reducing manufacturing time.
Solution Approach 2:
By merging multiple sealing components into one integrated cable gland, the patent eliminates multiple assembly steps including inserting the plug, fitting the hose, and welding insulating sheaths. This single-component approach maintains seal tightness while significantly reducing manufacturing time and increasing productivity.
3Object-affected harmful factors
If a prefabricated plug system is used for sealing, then the corrosion protection is improved, but the number of components increases
Solution Approach 1:
The cable gland is made from fluorinated plastic, a composite material that combines the corrosion resistance of PTFE with the elastomeric properties of fluoroelastomers. This single composite material provides superior corrosion protection while eliminating the need for multiple discrete components made of different materials.
Solution Approach 2:
The single cable gland component provides both corrosion protection and sealing functionality simultaneously. The fluorinated plastic material inherently resists corrosion from exhaust gases and liquids while its elastomeric properties enable effective sealing, replacing multiple specialized components.
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 solution provides a high-tightness seal, ensuring helium tightness of less than 10^-5 mbar*l/s, and reduces manufacturing complexity by eliminating the need for multiple components, while maintaining mechanical stability and durability at high temperatures.
Implementation Method 1
at least one cross-section of the space located between the protective sleeve and the at least one connecting cable is filled with a thermoplastically processable fluoropolymer-containing material
Implementation Method 2
filled with a thermoplastically processable fluoropolymer-containing material, in particular in a material-bonded manner
Implementation Method 3
The cable exit and its interaction with the housing of the exhaust gas sensor are subject to a high degree of sealing. This high level of sealing effectively and permanently prevents the ingress of harmful liquids and gases
Implementation Method 4
which seals the housing body and electrically contacts the sensor element
Data Source
Figure 1a~1b
Figure 1c
Figure 2a
AI summary
The invention relates to a cable bushing for sealing and for electrically contacting an exhaust sensor (1), comprising a protective sleeve (15) and comprising at least one connection cable (21) which is led out of the protective sleeve (15) on at least one end face (32) of the protective sleeve (15), characterized in that at least one cross-section of the chamber located between the protective sleeve (15) and the at least one connection cable (21) is filled with a material comprising fluoropolymers (31), which can be processed in a thermoplastic manner.