Engine Temperature Sensor Terminal Flange Sealing and Fast Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing temperature sensors for vehicle engines, particularly thermocouple sensors, face issues with insufficient sealing and complex manufacturing processes, leading to assembly challenges and high production time.
Innovation Solution
A temperature sensor design featuring a housing with a flange for holding terminals, where the flange is fixed via plastic deformation of a holding pin, and a connector with a metal insert for electrical connection, along with a fiber-loaded material for enhanced mechanical strength and sealing, and a method of manufacturing where lugs are folded inside the housing using a folding tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing uses conventional sealing methods with ribs remelted during plastic injection, then the sealing structure is simple, but the sealing quality is insufficient due to imperfect fusion
Solution Approach 1:
The patent changes the sealing mechanism from thermal fusion of ribs to mechanical deformation of a metal flange. The flange is crimped onto the housing and deformed to engage with grooves, providing reliable sealing through mechanical interlocking rather than imperfect plastic fusion. This parameter change from thermal to mechanical sealing resolves the contradiction between sealing quality and structural simplicity.
Solution Approach 2:
The patent introduces a composite sealing structure combining metal flange with plastic housing. The metal flange provides superior sealing and mechanical strength, while the plastic housing maintains simplicity. This composite approach achieves high reliability sealing without requiring complex modified sealing structures in the housing itself.
2Reliability
If the sensor assembly uses multiple components including terminals brazed to PCB with crimped connections, then the electrical connection is robust, but the manufacturing complexity increases and assembly time increases
Solution Approach 1:
The patent merges the terminal connection functions into an integrated flange structure that simultaneously provides mechanical retention and electrical connection. The flange is crimped onto the wire conductor and also engages with the housing grooves, combining multiple functions into a single component and operation, thereby reducing assembly steps while maintaining connection reliability.
Solution Approach 2:
The flange structure is designed to be self-retaining through its deformation characteristics. When crimped, the flange automatically engages with the housing grooves and secures the terminal without requiring additional fastening operations or complex assembly steps. This self-service mechanism reduces assembly time while ensuring reliable electrical and mechanical connections.
3Strength
If the flange holding pin has small diameter, then the housing structure remains simple, but the mechanical strength and retention force are insufficient
Solution Approach 1:
The patent changes the holding pin diameter parameter to be greater than or equal to 1.5mm, which significantly increases the mechanical strength and retention capability of the flange connection. This parameter change ensures that the flange can withstand the forces applied during crimping and operation without deformation or failure, resolving the contradiction between strength and structural simplicity.
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 provides improved sealing and reduced complexity in assembly, resulting in a more robust and precise temperature sensor with enhanced mechanical strength and reduced assembly time.
Implementation Method 1
the flange being fixed to the housing via the plastic deformation of at least one holding pin arranged in the housing
Implementation Method 2
The thermocouple measurement principle is based on the Seebeck effect which results in a potential difference between two different metal wires when they are subjected to a temperature difference
Implementation Method 3
the terminal consisting of a portion crimped on a conductor placed in the box
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The present invention relates to a temperature sensor (1) for a motor vehicle, comprising: - a casing (1) containing circuit board (14) and traversed by at least one pair (2) of wires (3) provided with terminals (8), the terminal (8) being made up of a portion (804) crimped onto a conductor (5) arranged in the casing (1), - a connector (101) comprising at least one metal insert (10) providing an electrical connection with the circuit board (14) characterized in that the casing comprises at least one flange (9) for holding the terminals (8), the terminals (8) being folded.