Sensor Clamp Rib Geometry for Sealing Resin Leakage Control
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Solution Overview
Problem
Existing sensors face leakage issues due to sealing resin exuding from between the housing and the clamp, particularly when the rib height is insufficient, leading to resin leakage outside the sensor.
Innovation Solution
A sensor design featuring a cylindrical housing with a clamp having ribs with an apex and sloped surfaces that intersect the outer wall, utilizing surface tension to prevent resin flow and leakage, with the ribs continuously formed along the clamp's outer circumference and multiple ribs aligned axially, and a sealing resin viscosity of 96 mPa·s or higher and sloped angles of 140° or more to enhance sealing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rib is formed on the clamp to prevent sealing resin leakage, then sealing reliability is improved, but manufacturing precision deteriorates due to difficulty in controlling rib height within tight tolerances
Solution Approach 1:
The invention changes the geometric parameters of the rib structure by introducing a sloped surface with a specific angle range (120° to 150°) instead of a simple protrusion. This parameter change allows the rib to effectively block sealing resin leakage while reducing sensitivity to height tolerance variations, thus improving manufacturing precision without compromising sealing reliability
Solution Approach 2:
The invention applies a curved sloped surface to the rib structure, transitioning from a flat or simple protruding shape to a surface with controlled curvature. This curved geometry creates an optimal angle for preventing resin leakage while being more tolerant to manufacturing variations, resolving the contradiction between reliability and manufacturing precision
2Reliability
If the rib height is increased to ensure sealing, then sealing reliability is improved, but device complexity increases due to additional structural requirements
Solution Approach 1:
The invention applies local quality by creating a rib with a sloped surface only at the specific location where sealing is needed, rather than increasing the overall complexity of the entire clamp structure. The sloped surface is localized to the rib portion that contacts the housing inner wall, providing enhanced sealing reliability without making the entire device more complex
3Reliability
If multiple ribs are formed to improve sealing precision, then sealing reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The invention applies segmentation by dividing the sealing function into multiple ribs distributed along the clamp's axial direction. Each rib with its sloped surface independently contributes to sealing precision, and the segmented structure is easier to manufacture than a single complex rib, as it can be formed through standard molding processes and allows for better resin distribution
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 design effectively prevents sealing resin leakage from the housing to the outside, ensuring reliable sealing and precise prevention of resin flow over the entire periphery, even with varying resin viscosities and angles, maintaining sensor functionality and accuracy.
Implementation Method 1
the sealing resin, which exudes from between the inner wall of the housing and the apex and which is positioned on the sloped surface, having a recess resulting from surface tension
Data Source
AI summary
A sensor is provided with a cylindrical-shaped housing which has an opening formed at one end, an electronic component which is housed in the housing, a cylindrical-shaped clamp of which one end is inserted into the housing from the opening, and a sealing resin which seals the gap between the inner wall of the housing and the outer wall of the clamp. On the outer wall, the clamp has a rib which rises towards the inner wall of the housing. The rib includes an apex and a sloped surface which extends from the apex towards another end of the clamp and which intersects the outer wall of the clamp. The sealing resin, which exudes from between the inner wall of the housing and the apex and which is positioned on the sloped surface, has a recess resulting from surface tension.