Sensor Housing Seal Integration via Integral Connecting Web

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Solution Overview

Problem

The existing methods for producing sensor housings with closed encircling seals are cumbersome, requiring multiple working steps and separate formation of seals, which complicates the production process.

Innovation Solution

The method involves connecting two seals with a unipartite connecting web formed integrally with the seals, allowing them to be formed in a single production step using a casting process where the housing shell and mold form seal-receiving channels connected by overflow channels, enabling simultaneous injection and hardening of the seals onto the housing shell.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If seals are injection-molded onto the housing shell in separate working steps, then each seal can be formed individually with good sealing integrity, but the production process becomes cumbersome and time-consuming

Engineering Contradiction:

Improvesealing integrityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines multiple seal formation operations into a single injection molding cycle. The housing shell includes multiple seal-receiving channels that are filled with sealing material in one continuous process, creating multiple seals simultaneously. This merging of operations maintains sealing integrity while dramatically improving production efficiency by eliminating repeated setup and processing steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing shell is segmented into multiple seal-receiving channels, each capable of receiving sealing material independently. This segmentation allows the injection molding process to distribute sealing material to multiple locations simultaneously through separate channels, enabling parallel formation of multiple seals in a single operation without compromising the integrity of individual seals.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If multiple seals are formed in separate working steps, then each seal can be precisely controlled, but the production time and complexity increase

Engineering Contradiction:

Improveseal formation precisionVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The injection molding process operates continuously to form multiple seals in one uninterrupted cycle. Sealing material is injected through multiple seal-receiving channels simultaneously, maintaining consistent material flow and pressure throughout the process. This continuous action ensures uniform sealing quality across all seals while eliminating the time losses associated with stopping and restarting the process between seal formations.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The housing shell is pre-configured with multiple seal-receiving channels positioned and dimensioned to receive sealing material. This preliminary preparation of the mold and housing shell ensures that when injection occurs, the sealing material flows precisely to the correct locations with the correct dimensions, maintaining manufacturing precision without requiring subsequent adjustment or rework.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If seals are produced separately from connecting structures, then each component can be optimized independently, but the overall device complexity and assembly steps increase

Engineering Contradiction:

Improvecomponent optimization flexibilityVSAvoidproduction process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the formation of seals and connecting structures into a single integrated component. The housing shell includes both seal-receiving channels and connecting structures (such as connecting webs) that are formed simultaneously in one injection molding operation. This integration reduces device complexity by eliminating separate components and assembly steps while maintaining the ability to optimize seal and connecting structure designs independently through mold design.

Inventive Principle:

Principle #5Merging (Combining)

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 approach simplifies and cost-reduces the production of sensor housings by integrating seals and connecting webs, allowing for efficient and reliable formation of multiple seals in a single step, enhancing the sealing integrity and assembly process.

Implementation Method 1

two of the seal-receiving channels are connected to one another in terms of flow by way of an overflow channel

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

introducing a casting material via a single one of the seal-receiving channels at an injection point, until all of the seal-receiving channels are filled with the casting material

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS9891081B2Method for producing a sensor housing and corresponding sensor housing

Publication Date: 2018.02.13 ROBERT BOSCH GMBH

AI summary

A method for producing a sensor housing comprises forming three seals including a first annular seal and a second annular seal connected to each other by a connecting web formed materially integral in a unipartite fashion with the first annular seal and the second annular seal, and positioning the first annular seal and the second annular seal on a housing shell of the sensor housing.