Low Heat-Resistant Sensor Sealing via Fluorine Resin Thermal Bonding
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Solution Overview
Problem
Low heat-resistant sensors face damage and chemical ingress due to low heat resistance, leading to compromised precision and reliability, especially when coated with fluorine resin, resulting in gaps between the sensor body and cable connections.
Innovation Solution
A low heat-resistant sensor design featuring a housing and cable covered with fluorine resin, thermally bonded to prevent gaps and ensure complete sealing, using materials like polytetrafluoroethylene (PTFE) and tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) resins for enhanced chemical resistance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluorine resin coating is applied to the sensor body at high temperature (300 degrees or more), then chemical resistance is improved, but the sensor unit is damaged due to low heat resistance
Solution Approach 1:
The sensor body is divided into separate components (housing, cable, connection portion) that are coated with fluorine resin independently at low temperature, then assembled. This segmentation allows the coating process to be performed on individual parts rather than the complete assembled sensor, enabling low-temperature coating that does not damage the sensor unit while still achieving chemical resistance.
Solution Approach 2:
The fluorine resin coating is applied to the housing and cable before final assembly. By performing the coating action preliminarily on separate components at low temperature, the sensor unit is protected from heat exposure while still achieving the desired chemical resistance property in the final assembled product.
2Temperature
If only the cable or housing is coated with fluorine resin separately, then the sensor unit is protected from heat damage, but gaps appear between the sensor body and cable allowing chemical ingress
Solution Approach 1:
The housing, cable, and connection portion are merged into a single integrated structure through thermal bonding after all components are coated with fluorine resin. This merging eliminates gaps between components while maintaining the low-temperature coating process, achieving both heat protection and complete chemical resistance sealing.
Solution Approach 2:
The bonding method is changed from high-temperature processes to thermal bonding that occurs at lower temperatures after coating. This parameter change in the bonding process allows the fluorine resin coating to be applied first at low temperature, then the components are thermally bonded to merge them into a sealed structure without exposing the sensor unit to damaging high temperatures.
3Reliability
If high temperature processing is used to bond the housing and cable, then sealing is improved, but the sensor unit is damaged
Solution Approach 1:
The fluorine resin coating is applied preliminarily to all components before the thermal bonding process. By having the protective coating in place before bonding, the subsequent thermal bonding can be performed at controlled temperatures that achieve sealing without damaging the sensor unit, as the coating provides protection and the bonding is done on already-coated separate components.
Solution Approach 2:
The bonding temperature parameter is changed from high temperature to a lower temperature range suitable for thermal bonding of the coated components. This parameter change allows sealing to be achieved through thermal bonding at temperatures that do not damage the low heat-resistant sensor unit, while still providing adequate sealing quality.
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 high chemical resistance, excellent drip-proof, and dust-proof properties, ensuring the sensor unit is protected from damage and environmental contaminants, maintaining precision and reliability.
Implementation Method 1
A portion at which the housing and the tube are connected to each other is thermally bonded
Implementation Method 2
thermally bonded to each other with a connection member that is composed of fluorine resin interposed therebetween
Data Source
AI summary
To provide a method of manufacturing a low heat-resistant sensor that has high chemical resistance, excellent drip-proof properties, and excellent dust-proof properties. A method of manufacturing a low heat-resistant sensor includes a step of disposing a sensor unit in a recessed portion of a container composed of fluorine resin, inserting a cable into a through-hole in communication with the recessed portion, and electrically connecting the sensor unit that is disposed in the recessed portion and the cable to each other, a step of disposing a plate composed of fluorine resin such that the plate covers an opening of the recessed portion and capping the recessed portion, a step of covering the cable by using a tube composed of fluorine resin, a step of disposing a frame body composed of fluorine resin such that the frame body surrounds a perimeter of the plate, a step of thermally bonding the frame body, the container, and the plate to each other, and a step of thermally bonding the container and the tube to each other.