Sensor Assembly Sealing Without Filling Materials
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Solution Overview
Problem
Existing sensors, such as inductive distance sensors, require environmentally hazardous filling materials like polyurethane foam or casting resin to prevent moisture penetration and solder connection breakdown, which complicates assembly and is not cost-effective.
Innovation Solution
A sensor assembly featuring a hollow cylindrical lid with a coil and a spring-loaded insert with latching hooks, allowing for adhesive sealing and electrical connection without the need for filling materials, enabling fast and flexible assembly of different sensor types by determining the sensor type based on the circuit board inserted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filling material (foam or resin) is used to prevent moisture penetration and secure circuit board, then protection against moisture and component stability is improved, but environmental hazard and assembly complexity increase
Solution Approach 1:
The invention extracts and eliminates the filling material (foam or resin) from the sensor housing, replacing it with a sealing lid that has an integrated sealing flange. The sealing flange creates a moisture barrier without requiring hazardous filling materials, thus removing the environmental hazard while maintaining protection against moisture penetration.
Solution Approach 2:
The lid is segmented into a functional body and an integrated sealing flange, where the sealing flange acts as a separate sealing element. This segmentation allows the sealing function to be achieved through the lid structure itself rather than through filling material, eliminating the need for hazardous substances while maintaining reliability.
2Stability of the object's composition
If filling material is used to prevent circuit board movement, then positional stability is improved, but assembly complexity and cost increase
Solution Approach 1:
The invention removes the filling material that was previously used to secure the circuit board, replacing it with dedicated positioning elements integrated into the lid structure. These positioning elements provide mechanical retention for the circuit board without requiring foam or resin filling, thus simplifying the assembly process while maintaining positional stability.
Solution Approach 2:
The positioning elements act as intermediaries between the lid and the circuit board, providing a mechanical interface that secures the circuit board in the correct position. This intermediary structure replaces the need for filling material to achieve positional stability, reducing assembly complexity.
3Reliability
If traditional sealing methods with filling material are used, then moisture protection is achieved, but manufacturing cost and environmental impact increase
Solution Approach 1:
The sealing flange is merged with the lid structure, integrating the sealing function directly into the lid rather than requiring separate filling materials. This merging of functions reduces the number of components and materials needed, lowering manufacturing costs while maintaining moisture protection through the sealed enclosure.
Solution Approach 2:
The invention extracts and eliminates the filling material from the sealing process, replacing it with a sealable enclosure created by the lid and sealing flange. This removal of hazardous filling material reduces both environmental impact and manufacturing costs associated with handling and disposing of such materials.
4Strength
If a fixed sensor design with integrated coil and housing is used, then structural integrity is improved, but adaptability to different sensor types decreases
Solution Approach 1:
The sensor assembly is segmented into modular components: the lid with integrated coil and sealing flange forms one module, while the circuit board forms another. This segmentation allows different circuit board configurations to be used with the same lid module, maintaining structural integrity through the standardized lid design while enabling adaptability to different sensor types through circuit board variation.
Solution Approach 2:
The lid with integrated coil and sealing flange serves as a universal module that can accommodate different sensor configurations. The standardized interface and mounting structure allow the same lid assembly to work with various circuit board designs, providing multi-functionality and adaptability across different sensor types while maintaining structural integrity.
Data Source
AI summary
An assembly for a sensor has a lid (30) which is substantially designed in the shape of a hollow cylinder and is closed at a first end. A coil (20) is arranged at the first end in the lid (30). An insert (10), substantially in the shape of a hollow cylinder, is inserted into the lid (30) so that its first end is facing the coil (20) and its second end protrudes from the lid (30). The insert (10) has at least one latching hook (11) in its interior, which is designed to be spring-loaded orthogonal to the longitudinal axis of the insert (10). The sensor has the assembly and a circuit board (50). The circuit board (50) extends through the second end of the insert (10) into the assembly and is latched with the latching hook (11).