Integrated Sensor Casting with Jacket Recess for Media Access
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Solution Overview
Problem
Existing devices for detecting physical state variables of a medium, such as pressure or temperature, require extensive prepackaging and media-tight sealing, which complicates production and increases costs.
Innovation Solution
A device design where the measuring sensor and electronic components are embedded in a casting core with a conductor section, which is then enclosed by a casting jacket with a recess for media access, eliminating the need for extensive prepackaging and inner seals, and allowing for a simple and accurate pressure measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extensive prepackaging of sensor and electronic components is used to ensure media-tight sealing, then reliability is improved, but device complexity and production difficulty increase
Solution Approach 1:
The patent merges the sensor, electronic components, and sealing structures into a single integrated module where the sensor housing and electronic component housing are combined with sealing elements that form a unified media-tight structure, eliminating the need for separate prepackaging layers
Solution Approach 2:
The integrated module serves multiple functions simultaneously: the housing provides structural support, the sealing elements ensure media-tightness, and the conductor sections provide both electrical connection and structural integration, reducing the number of separate components needed
2Reliability
If extensive prepackaging and inner seals are used to ensure media-tight sealing, then reliability is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The sealing structures and conductor sections are pre-integrated into the sensor and electronic component housings during manufacturing, so that when the modules are assembled together, media-tightness is achieved without requiring additional sealing steps or components
Solution Approach 2:
Multiple sealing functions are combined into integrated sealing elements that form part of the housing structure, allowing media-tight sealing to be achieved in a single assembly operation rather than through multiple separate prepackaging steps
3Measurement precision
If the sensor contact surface is directly exposed to the medium, then measurement accuracy is improved, but media-tight sealing becomes more difficult to maintain
Solution Approach 1:
The patent introduces a conductor section as an intermediary element that serves dual purposes: it provides electrical connection to the sensor while also acting as a structural component that maintains media-tight sealing, allowing the sensor contact surface to remain exposed to the medium without compromising sealing
Solution Approach 2:
The conductor section is designed to perform multiple functions simultaneously: electrical signal transmission, structural support, and sealing maintenance, allowing the sensor to have direct medium access while preserving media-tightness through the multi-functional conductor structure
Data Source
AI summary
In the case of a device for detecting physical state variables of a medium, such as pressure or temperature, for example, of a liquid, comprising at least one measuring sensor, which is connected to at least one electrical conductor so as to transmit signals, wherein at least one section of the conductor, which encompasses the sensor, is embedded in a casting compound, the casting compound is embodied, according to the invention, from at least one casting core and a casting jacket, which encloses the casting core, and provision is made in the casting compound for at least one recess for a media-conducting access to a contact surface of the sensor.