Sealed Sensor Package With Hydrophobic Vent for Moisture Ingress

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Solution Overview

Problem

Existing sensor packages face challenges in underwater applications due to water and moisture ingress, which can cause malfunction and affect electrical connections, leading to performance degradation.

Innovation Solution

The sensor package includes a mounting adaptor with a housing, a sensor assembly, potting material, a locking mechanism, and a hydrophobic filter to encapsulate and seal the sensor assembly, preventing moisture ingress and enhancing protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the sensor assembly is exposed to the ambient environment for sensing, then the sensor can detect environmental parameters, but water and moisture can ingress into the sensor housing causing malfunction

Engineering Contradiction:

Improvesensor performanceVSAvoidmoisture ingress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sensor assembly is nested within multiple protective layers: the housing, potting material, and sealing structures. The sensor assembly is positioned in the housing and encapsulated with potting material, creating a nested configuration that protects the sensing element while allowing environmental interaction through controlled ports

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

A hydrophobic filter serves as an intermediary element that allows gas exchange while blocking liquid water and moisture ingress. The filter is positioned in the port channel to enable sensing functionality while preventing harmful moisture from reaching the sensor assembly

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the sensor assembly is sealed to prevent moisture ingress, then protection is improved, but water vapor and gas exchange may be restricted affecting sensor operation

Engineering Contradiction:

Improvewater ingress preventionVSAvoidgas exchange capability

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The sealing structure employs local quality by using a hydrophobic filter specifically at the port channel where gas exchange is needed. The filter allows vapor and gas transmission while blocking liquid water, creating different permeability properties in different locations of the sealing system

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The sealing system uses composite materials including the hydrophobic filter combined with the potting material and housing seal. This composite approach allows the system to simultaneously achieve moisture blocking and gas exchange functionalities through the combined properties of different materials

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If connection cables are secured with a locking mechanism, then cable stability is improved, but the encapsulation integrity may be compromised

Engineering Contradiction:

Improvecable connection stabilityVSAvoidencapsulation integrity

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The locking mechanism is segmented into separate functional elements: the cable clamp structure and the sealing structure. The connection cables are secured through a locking mechanism with crush ribs that clamp around the cables, while the sealing integrity is maintained through the potting material and separate sealing elements in the port channel

Inventive Principle:

Principle #1Segmentation

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 reduces water ingress, improving sensor performance and reliability in underwater environments by encapsulating the sensor assembly and securing electrical connections, achieving IP68 and IP69 protection for submersible applications.

Implementation Method 1

a hydrophobic filter configured to prevent fluid to pass through the hydrophobic filter to the sensing element of the sensor assembly and reduce moisture ingress to the sensing element

Methodology Applied

Scientific EffectHydrophobic effect: Hydrophobe

Implementation Method 2

a potting material deposited within the housing to encapsulate the sensor assembly

Methodology Applied

Scientific EffectEncapsulation:

Implementation Method 3

a locking mechanism positioned in the port channel and configured to clip with the mounting adaptor to prevent seepage of the potting material

Methodology Applied

Scientific EffectMechanical fastening: Mechanical Fastener

Implementation Method 4

the at least one crush rib is crushing radially against the connection wire to prevent the seepage of the potting material and the moisture ingress to the sensor assembly

Methodology Applied

Scientific EffectRadial compression:

Data Source

PatentEP4517274B1Sensor package

Publication Date: 2026.04.22 HONEYWELL INTERNATIONAL INC

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AI summary

A sensor package is provided. The sensor package includes, but not limited to: a mounting adaptor defining a housing and a port channel connecting with the housing; a sensor assembly positioned in the housing and including a sensing element to sense an ambient environment; a potting material deposited within the housing to encapsulate the sensor assembly; and a locking mechanism positioned in the port channel and configured to clip with the mounting adaptor to prevent seepage of the potting material.